Metso Neles SwitchGuard SG9200H Operating and maintenance manual

Neles SwitchGuard™
SG9200H
Rev. 1.1
Installation, Maintenance and
Operating Instructions
7 SG92H 70 en • 2/2009

27 SG92H 70 en
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about the safe handling and operation of the intelligent on/off controller.
If you require additional assistance, please contact the manufacturer or manufacturer's representative.
Addresses and phone numbers are printed on the back cover.
SAVE THESE INSTRUCTIONS!
Subject to change without notice.
All trademarks are property of their respective owners.
Table of Contents
1 SG9200H SWITCHGUARD INTELLIGENT
ON/OFF CONTROLLER WITH
HART COMMUNICATION............................... 3
1.1 General.................................................. 3
1.2 Technical description............................. 3
1.3 Markings ................................................ 3
1.4 Technical specifications......................... 4
1.5 Recycling and disposal.......................... 5
1.6 Safety precautions................................. 5
2 TRANSPORTATION, RECEPTION AND
STORAGE ....................................................... 6
3 MOUNTING...................................................... 6
3.1 General.................................................. 6
3.2 Mounting on Metso actuators
with VDI/VDE mounting face.................. 6
3.3 Mounting on linear actuator with IEC 60534
mounting face ........................................ 7
3.4 Piping..................................................... 7
3.5 Electrical connections.......................... 10
4 LOCAL USER INTERFACE (LUI) ................. 11
4.1 Measurement monitoring..................... 11
4.2 Guided start-up.................................... 11
4.3 Configuration menu.............................. 12
4.4 MODE menu........................................ 12
4.5 Configuration parameters .................... 13
4.6 Valve travel calibration......................... 15
4.7 Special displays................................... 15
4.8 HART write protection.......................... 16
5 MAINTENANCE............................................. 16
5.1 Prestage .............................................. 17
5.2 Spool valve .......................................... 17
5.3 Restrictor.............................................. 17
5.4 Communication circuit board ............... 18
6 ERROR MESSAGES..................................... 18
6.1 Failsafe errors...................................... 18
6.2 Alarms.................................................. 18
6.3 Errors................................................... 19
6.4 Warnings.............................................. 19
6.5 Notifications ......................................... 19
7 TROUBLE SHOOTING.................................. 20
8 SG92_/K_, SG92_/I__, SG92_/D__
(WITH LIMIT SWITCHES) ............................. 21
8.1 Introduction .......................................... 21
8.2 Installing SG92_/K_, SG92_/I_ or
SG92_/D_ on a valve controller ........... 22
8.3 Electrical connections .......................... 22
8.4 Adjustment........................................... 23
8.5 Removal of the limit switches SG92_/K_,
SG92_/I_ or SG92_/D for accessing
the valve controller............................... 23
8.6 Circuit diagrams................................... 23
8.7 Maintenance ........................................ 23
9 TOOLS........................................................... 23
10 ORDERING SPARE PARTS ......................... 23
11 DRAWINGS AND PARTS LISTS .................. 24
11.1 Exploded view and parts list, SG9200H . 24
11.2 Exploded view and parts list, SG9200H/K_,
SG9200H/I_, SG9200H/D_ .................. 26
11.3 Mounting parts for Metso actuators
with VDI/VDE mounting face................. 28
11.4 Mounting parts for old B series actuators28
11.5 Mounting parts for linear actuators ...... 29
11.6 Connection diagrams........................... 30
12 DIMENSIONS ................................................ 35
13 CONFIGURATION PARAMETERS............... 37
14 TYPE CODING .............................................. 38

7 SG92H 70 en 3
1 SG9200H SWITCHGUARD
INTELLIGENT ON/OFF CONTROLLER
WITH HART COMMUNICATION
1.1 General
This manual incorporates Installation, Maintenance and
Operation Instructions for the Metso’s Neles Switch-
Guard. The SG9200H may be used with either cylinder
or diaphragm type pneumatic actuators for rotary or lin-
ear valves.
1.2 Technical description
The SwitchGuard is a 4–20 mA loop-powered micro-
controller-based on/off controller. Binary 24 V DC signal
can be used via optional U/I converter. The Switch-
Guard operates even at 3.6 mA input signal (see
restrictions in Section 4.5.3) and communicates via
HART. The device contains a Local User Interface ena-
bling local configuration. A PC with FieldCare software
can be connected to the SwitchGuard itself or to the
control loop.
The powerful 32-bit microcontroller controls the valve
position. The measurements include:
❑Input signal
❑Valve position with contactless sensor
❑Actuator pressures, 2 independent measurements
❑Supply pressure
❑Device temperature
Advanced self-diagnostics guarantees that all meas-
urements operate correctly. Failure of one measure-
ment does not cause the valve to fail if the input signal
and position measurements are operating correctly.
After connections of electric signal and pneumatic sup-
ply the micro controller (µC) reads the input signal,
position sensor (α) and pressure sensors (Ps, P1, P2).
A difference between setpoint according to stroke
curve and position sensor (α) measurement is detected
by the control algorithm inside the µC. The µC calcu-
lates a new value for prestage (PR) coil current based
on this information. Changed current to the PR changes
the pilot pressure to the spool valve. Reduced pilot
pressure moves the spool and the actuator pressures
change accordingly. The spool opens the flow to the
driving side of the double-acting actuator (or air side in
the sigle acting-actuator) and opens the flow out from
the other side of the actuator in case of double-acting.
The increasing pressure will move the piston. The actu-
ator and feedback shaft rotate clockwise.
1.3 Markings
The valve controller is equipped with an identification
plate sticker (Fig. 2).
Identification plate markings from top to bottom include:
❑Type designation of the on/off controller
❑Enclosure class
❑Revision number
❑Input signal (voltage range)
❑Input resistance
❑Maximum supply voltage
❑Supply pressure range
❑Operational temperature
❑CE mark
❑Manufacturing serial number TTYYWWNNNN*)
*) Manufacturing serial number explained:
TT= device and factory sign
YY= year of manufacturing
WW = week of manufacturing
NNNN = consecutive number
Example: PH08011234 = controller, year 2008, week 1,
consecutive number 1234.
NOTE:
The selection and use of the valve controller in a specific
application requires close consideration of detailed
aspects. Due to the nature of the product, this manual
cannot cover all the likely situations that may occur when
installing, using or servicing the valve controller.
If you are uncertain about the use of the controller or its
suitability for your intended use, please contact Metso’s
Automation business for more information.
Fig. 1 The principle of operation
Fig. 2 Identification plate

47 SG92H 70 en
1.4 Technical specifications
SG9200H ON/OFF CONTROLLER
General
Loop powered, no external power supply required.
Suitable for rotary and sliding-stem valves.
Actuator connections in accordance with VDI/VDE
3845 and IEC 60534-6 standards.
Action: Double or single acting
Travel range: Linear: 10–120 mm
Rotary: 45–95°
Measurement range 110° with freely
rotating feedback shaft
Environmental influence
Standard temperature range:
-20° to +85 °C / -4° to +185 °F
Optional temperature range:
-40° to +60 °C / -40° to +140 °F
Influence of vibration on valve position
under 2g 5–150 Hz,
1g 150–300 Hz, 0.5g 300–2000 Hz
Open and closed position: no effect
Deviation from profile:<10 %
Enclosure
Material: Anodised aluminium alloy and
glass window
Protection class: IP66, NEMA 4X
Pneumatic ports: SG921_ 1/4 NPT
SG9235 1/2 NPT
SG9237 1 NPT (1/2 NPT supply)
(single acting only)
Conduit entry thread: M20 x 1.5
Weight: SG9210 3.0 kg / 6.6 lb
SG9235 4.6 kg / 10.1 lb
SG9237 5.0 kg / 11 lb
limit switch options plus 1.0 kg / 2.2 lb
Mechanical and digital position indicator visible
through the main cover
Pneumatics
Supply pressure: 3–8 bar/44–116 psi
Air quality: According to ISO 8573-1:2001
Solid particles: Class 7
(5 µm filtration is recommended)
Humidity: Class 1
(dew point 10 °C / 50 °F below minimum
temperature is recommended)
Oil class: 3 (or <1 ppm)
Spool valve identifiers:
Standard version SG921_ SPCZ/2163/2
SG923_ SPCZ/2164/2
Optional cold version
SG921_C_ SPCZ/2163/1
SG923_C_ SPCZ/2164/1
Capacity with 4 bar / 60 psi supply:
SG9212 7 Nm3/h / 4.1 scfm (Cv =0.06)
SG9215 90 Nm3/h / 53 scfm (Cv =0.7)
SG9235 380 Nm3/h / 223 scfm (Cv =3.2)
SG9237 feed 380 Nm3/h / 223 scfm (Cv =3.2)
exhaust 700 Nm3/h / 412 scfm (Cv =6.4)
Consumption with 4 bar / 60 psi supply:
actuator pressurized 0.22 Nm3/h / 1.13 scfm,
actuator vented 0.25 Nm3/h / 1.14 scfm
Electronics
Electrical connections: max. 2.5 mm2
HART
Connections: '+' and '-'
Supply power: Loop powered, 4–20 mA
Minimum signal: 3.6 mA (see restrictions in 4.5.3)
Current max : 23 mA
Load voltage: up to 9.5 V DC/20 mA
(corresponding 475 Ω.)
Voltage: max. 30 V DC
Polarity protection: -30 V DC
Over current protection:
active over 35 mA
Max power dissipation: 1.05 W
with position transmitter 1.74 W
Ex d IIC T3...T4: Ui ≤30 V
Position transmitter (optional)
Connections: PT: '+' and '-'
Output signal: 4–20 mA (galvanic isolation;
600 V DC)
Supply voltage: 12 - 30 V
Resolution: 16 bit / 0.244 µA
Linearity: <0.05 % FS
Temperature effect:<0.35 % FS
External load: max 0–780 Ω
max 0–690 Ωfor intrinsically safe
Ex ia IIC T6
Ui ≤28 V
Ii ≤120 mA
Rx = 0–690 Ω
Pi ≤1 W
Ci = 22 nF
Li = 53 µH
Ex d IIC T3...T4
Ui ≤30 V
Rx = 0–780 Ω
Local user interface functions
❑Monitoring of valve position, input signal, temper-
ature, supply and actuator pressure difference
❑Guided start-up function
❑LUI may be locked remotely to prevent unauthor-
ised access
❑Calibration: Automatic
❑Tu n i n g
❑Mode selection: Automatic/Manual
❑Position trigger level
❑Stroke times, stroke profiles
ATEX NOTE:
This manual contains technical specifications for
several types of the SG9200H valve controller. If in
doubt, refer to the type approval certficate of the
respective version.
The certificate is delivered with the field device and is
also available from the manufacturer.

7 SG92H 70 en 5
❑Dead angle
❑Maximum speed
❑Positioner fail action, open/close
❑Signal direction: Direct/reverse acting
❑Actuator type: double/single acting
❑Valve type: rotary/linear IEC
❑Language selection: English, German and French
Remote user interface functions
Configuration and diagnostic information is presented
in easily understandable way using FDT/DTM technol-
ogy, such as Neles FieldCare™.
APPROVALS
Intrinsically safe and non incendive
ATEX ATEX II 1 G EEx ia IIC T4...T6 (EN50014,
EN50020, EN50284)
II 2 G EEx ia IIC T4...T6 (EN50014,
EN50020)
II 3 G Ex nA IIC T4...T6 (EN60079-0,
EN60079-15)
CSA (pending) IS Class I, Div. 1, Groups A, B, C, D T4...T6
IS Class I, Zone 0, Ex ia IIC T4...T6
NI Class I, Div. 2, Groups A, B, C, D T4...T6
FM (pending) IS Class I, Div. 1, Groups A, B, C, D T4...T6
IS Class I, Zone 0, AEx ia IIC T4...T6
NI Class I, Div. 2, Groups A, B, C, D T4...T6
NI Class I, Zone 2, Ex nA II T4...T6
Flameproof and explosion proof
ATEX ATEX II 2 G Ex d IIC T3...T4
(ZELM 07ATEX 0342 X according to
EN60079-0, EN60079-1)
CSA (pending) Explosion proof Class I, II and III,
Division 1 and 2, Groups B, C, D, E, F
FM (pending) Explosion proof Class I, II and III,
Division 1 and 2, Groups A, B, C, D, E, F
Electromagnetic protection
Electromagnetic compatibility
Emission acc. to EN 61000-6-4 (2001)
and FCC 47 CFR PART 15,
SUBPART B, CLASS B (1994)
Immunity acc. to EN 61000-6-2 (2001)
CE marking
89/336/EEC
Electromagnetic compatibility
94/9/EC
ATEX
1.5 Recycling and disposal
Most valve controller parts can be recycled if sorted
according to material.
Most parts have material marking. A material list is sup-
plied with the valve controller. In addition, separate
recycling and disposal instructions are available from
the manufacturer.
A valve controller may also be returned to the manufac-
turer for recycling and disposal. There will be a charge
for this.
1.6 Safety precautions
CAUTION:
Do not exceed the permitted values!
Exceeding the permitted values marked on the valve
controller may cause damage to the controller and to
equipment attached to the controller and could lead
to uncontrolled pressure release in the worst case.
Damage to the equipment and personal injury may
result.
CAUTION:
Do not remove or dismantle a pressurized controller!
Removing or dismantling a pressurized prestage or
spool valve of an SwitchGuard leads to uncontrolled
pressure release. Always shut off the supply air and
release the pressure from the pipelines and equip-
ment before removing or dismantling the controller.
Otherwise personal injury and damage to equipment
may result.
WARNING:
During calibration and tuning the valve operates
between open and closed positions. Make sure
that the operation does not endanger people or
processes!
WARNING:
Do not operate the device with the cover removed!
Electromagnetic immunity is reduced, valve may
stroke.
ATEX WARNING:
The locking screw (part 107) of the cover is essen-
tial to explosion protection.
The cover has to be locked in place for Ex d protection. The
screw grounds the cover to the housing.
ATEX WARNING:
Spark hazard!
Protect the aluminium housing and cover from impacts.
ATEX WARNING:
Electrostatic charge hazard!
The pointer and display windows are non-conductive.
Clean with a damp cloth only!
ATEX WARNING:
Electrostatic charge hazard!
The paint of the device can enable charging of the
metal parts by high voltage sources. Do not install the
device in proximity of high voltage sources!
Ex i WARNING:
Ensure that the complete installation and wiring is
intrinsically safe before operating the device!
Ex i WARNING:
Do not operate the device with electronics cover
(39) removed!
Electromagnetic immunity is reduced, valve may
stroke. Ex i: intrinsic safety may be impaired.

67 SG92H 70 en
2 TRANSPORTATION, RECEPTION
AND STORAGE
The on/off controller is a sophisticated instrument, han-
dle it with care.
❑Check the controller for any damage that may
have occurred during transportation.
❑Store the controller preferably indoors, keep it
away from rain and dust.
❑Do not unpack the device until installing it.
❑Do not drop or knock the controller.
❑Keep the flow ports and cable glands plugged
until installing.
❑Follow instructions elsewhere in this manual.
3MOUNTING
3.1 General
If the SwitchGuard is supplied with valve and actuator,
the tubes are mounted and the SwitchGuard adjusted in
accordance with the customer’s specifications. If the
controller is ordered separately, the mounting parts for
the assembly must be ordered at the same time.
Sample order: (B1CU13)-Z-SG9235HN
The controller is equipped for connection according to
VDI/VDE 3845. Also the old Neles mounting face is sup-
ported (Z beam) but not recommended for high vibration
environments.
Shaft coupling alternatives for the controller for Metso
actuators are shown in Fig. 4.
For mounting parts for Metso actuators, see 11.3 - 11.5.
3.2 Mounting on Metso actuators with
VDI/VDE mounting face
See figure in Section 11.3.
❑Mount the H-shaped coupling (47) to the shaft.
Apply the thread-locking compound to the screw
(48) and tighten firmly.
❑Remove all protective plastic plugs from the
pneumatic connections (3 pcs.).
❑BJ and other single acting actuators: mount a
metal plug (53) with sealant to the C1 connection.
❑Set the direction arrow of the actuator in the direc-
tion of the valve closure member and attach the ear
(2) to the indicator cover in the position shown in
Section 11.3. Secure the screw of the ear using e.g.
Loctite and tighten firmly.
❑Attach the bracket (1) to the SwitchGuard.
❑Attach the bracket (1) to the actuator. The shaft cou-
pling of the SwitchGuard must fit into the ear (2) so that
the pointer is located in the position shown in Fig.3.
Ex i WARNING:
For intrinsically safe applications, the equipment
must be connected via a certified Zener barrier
placed outside the hazardous area!
Ex d NOTE:
Only persons familiar with Ex d explosion protec-
tion are allowed to work with the device. Special
attention has to be paid to careful handling and
closing of the cover.
Ex d WARNING:
Do not open the cover when an explosive atmos-
phere may be present!
Ex d WARNING:
Use a cable gland with suitable Ex d certification.
For ambient temperature over 70 °C/158 °F use a
heat resistant cable and cable gland suitable for at
least 90 °C/194 °F.
ELECTRICAL SAFETY WARNING:
Use fuses for limit switch installations with
50 V AC/75 V DC or higher.
NOTE:
Avoid earthing a welding machine in close proximity to
an SG9200H valve controller.
Damage to the equipment may result.
NOTE:
The enclosure of SwitchGuard on/off controller meets the
IP66 protection class according to EN 60529 in any posi-
tion when the cable entry is plugged according to IP66.
Based on good mounting practice, the recommended
mounting position is electrical connections placed
downwards. This recommendation is shown in our
mounting position coding for control valves.
If these requirements are not fulfilled, and the cable
gland is leaking and the leakage is damaging valve
controller or other electrical instrumentation, our war-
ranty is not valid.
Fig. 3 Mounting on Metso actuator with VDI/VDE
mounting face
C2
S
C1
The pointer on the coupling must
stay in this sector
11

7 SG92H 70 en 7
3.3 Mounting on linear actuator with IEC
60534 mounting face
See figure in Section 11.5
❑Attach the feedback arm with spacer to the con-
troller shaft. Note the position of the pointer on
the shaft as in 11.5. Apply thread locking com-
pound to the screws and tighten firmly. Attach
the spring to the feedback arm as shown in Sec-
tion 11.5.
❑Mount the controller mounting bracket loosely to
the yoke of the actuator.
❑Remove all plastic plugs from all actuator connec-
tions (3 pcs.).
❑Mount the controller loosely to the mounting
bracket guiding the pin on the actuator stem to
the slot of the feedback arm.
❑Align the bracket and the controller with the actua-
tor stem and adjust their position so that the feed-
back arm is approximately at a 90° angle to the
actuator stem (in the mid-stroke position).
❑Tighten the controller mounting bracket screws.
❑Adjust the distance of the controller to the pin on
the actuator stem so that the pin stays in the lever
slot at full stroke. Ensure also that the maximum
angle of the lever does not exceed 45° in either
direction. Maximum allowed travel of the lever is
shown in Section 11.5. Best control performance
is achieved when the feedback lever utilises the
maximum allowed angle (±45° from horizontal
position). The whole range should be at least 45°.
❑Make sure that the controller is in right angle and
tighten all the mounting bolts.
❑Ensure that the controller complies with previous steps.
Check that the actuator pin does not touch the control-
ler case throughout the entire stroke of the actuator. If
the actuator pin is too long it may be cut to size.
❑Apply grease (Molykote or equivalent) to the con-
tact surfaces of the actuator pin and the feed-
back arm to reduce wear.
3.4 Piping
Table 2 provides the recommended tube sizes in
accordance with actuator sizes. Tube sizes are the mini-
mum values allowed.
Connect the air supply to S.
Connect C1 and C2 to the actuator, see Fig. 5. C1 must
be plugged if single-acting actuator.
Liquid sealants, such as Loctite 577 are recommended
for the pipe threads.
The air supply must be clean, dry and oil-free instrument
air, see Section 1.4.
Fig. 4 Shaft coupling alternatives
45° 45°
VDI/VDE 3845 mounting IEC 60534 mounting
mark on
housing
pointer
mark on
housing
pointer
CAUTION:
Do not exceed the permitted supply pressure of
the SwitchGuard!
CAUTION:
It is important to note, that SwitchGuard mounted
on a spring actuator MUST be connected only as
single-acting. See Fig. 5.
NOTE:
An excess of sealant may result in faulty operation of
the controller.
Sealing tape is not recommended.
Ensure that the air piping is clean.
Table 1 Spring rates
Actuator type Spring rate (bar/psi)
B1JK 3/43
B1J 4.2/61
B1JV 5.5/80
Adjust regulator pressure to a level that is max 1 bar (14.5 psi)
+ spring rate.

87 SG92H 70 en
Table 2 Piping, stroke times and maximum valve speed (MAXS) parameter selection
Actuator
SG_15_
Supply 1/4" NPT
Actuator 1/4" NPT
SG_35_
Supply 1/2" NPT
Actuator 1/2" NPT
SG_37_ (Single acting only)
Supply 1/2" NPT
Actuator 1" NPT
Maximum
Valve
Speed
Parameter
B1C Stroke vol.
dm3/ in3NPT Piping Open
(s)
Close
(s)
Piping Open
(s)
Close
(s)
Piping Open
(s)
Close
(s)
60.3181/4
6 mm
or 1/4" 0.60.6------FST
90.6371/4
6 mm
or 1/4" 1.01.1------FST
11 1.1673/8
10 mm
or 3/8" 0.70.7------FST
13 2.3 140 3/8 10 mm
or 3/8" 1.31.4------STD
17 4.3 262 1/2 10 mm
or 3/8" 2.02.3------STD
20 5.4 330 1/2 10 mm
or 3/8" 2.42.6------STD
25 10.5 610 1/2 10 mm
or 3/8" 4.5 4.9 16 mm or 5/8" 1.3 1.5 - - - SLO (SG_35) STD (SG_15)
32 21 1282 3/4 10 mm
or 3/8" 9.4 9.4 16 mm or 5/8" 2.4 2.7 - - - SLO
40 43 2624 3/4 10 mm
or 3/8" 19 19 16 mm or 5/8" 4.9 5.6 - - - SLO
50 84 5126 1 10 mm
or 3/8" 38 38 16 mm or 5/8" 9.6 11 - - - SLO
60 121 7380 1 10 mm
or 3/8" 54 54 16 mm or 5/8" 14 16 - - - SLO
75 189 11500 1 10 mm
or 3/8" 85 85 16 mm or 5/8" 22 25 - - - SLO
502 195 11900 1 10 mm
or 3/8" 87 87 16 mm or 5/8" 22 25 - - - SLO
602 282 17200 1 10 mm
or 3/8" 126 126 16 mm or 5/8" 32 37 - - - SLO
752 441 26900 1 10 mm
or 3/8" 197 197 16 mm or 5/8" 50 57 - - - SLO
B1J
B1JA
Stroke vol.
dm3/ in3NPT Piping Air
(s)
Spring
(s)
Piping Air
(s)
Spring
(s)
Piping Air
(s)
Spring
(s)
80.9553/8
10 mm
or 3/8" 0.51.0------FST
10 1.8 110 3/8 10 mm
or 3/8" 0.71.4------FST
12 3.6 220 1/2 10 mm
or 3/8" 1.22.7------STD
16 6.7 409 1/2 10 mm
or 3/8" 3.2 4.8 16 mm or 5/8" 0.7 1.3 - - - SLO (SG_35) STD (SG_15)
20 13 793 3/4 10 mm
or 3/8" 4.6 9.3 16 mm or 5/8" 1.4 2.6 - - - SLO
25 27 2048 3/4 10 mm
or 3/8" 8.9 18 16 mm or 5/8" 2.9 5.4 25 mm or 1" 2.5 2.9 SLO
32 53 3234 1 10 mm
or 3/8" 15 38 16 mm or 5/8" 4.9 11 25 mm or 1" 4.3 5.3 SLO
322 106 6468 1 10 mm
or 3/8" 31 77 16 mm or 5/8" 9.8 21 25 mm or 1" 8.5 11 SLO
CAUTION:
Always adjust the maximum valve speed parame-
ter according to Table 2. Erroneous value may
cause instability.
CAUTION:
When extra instrumentation is used the above
table is not valid. The parameter needs to be set
according to the device, which SwitchGuard is
controlling.
- Quick Exhaust Valve (QEV): Maximum Valve
Speed parameter needs to be FST.
- Volume Booster (VB): Maximum Valve Speed
parameter needs to be SLO.
CAUTION:
The stroking times mentioned in Table 2 are trend-
setting. They are measured with 5 bar supply air
pressure, but may vary significantly due to differ-
ent factors such as, but not limited to, pressure
difference of the valve, the stiction of the actuator,
supply air pressure, the capacity of the supply air
system and the dimensions of the supply air pipe-
line.
CAUTION:
The air supply system must be of sufficient size
and capacity to ensure that at maximum flow dur-
ing valve movement the pressure at the Switch-
Guard must not fall below 3 bar. Also note that if
the air supply system allows the pressure at the
SwitchGuard to fall below the actuator minimum
supply pressure during valve movement the stroke
speed will be affected.

7 SG92H 70 en 9
Fig. 5 Operation directions and air connections
SINGLE-ACTING ACTUATOR, SPRING TO OPEN
SINGLE-ACTING ACTUATOR, SPRING TO CLOSE
DOUBLE-ACTING ACTUATOR, REVERSED PIPING
Increasing input signal to open valve (not recommended)
Default setting:
DIR = OPE
ATYP = 2-A
PFA = OPE
A0 and VTYP according to valve type
5.Increasing input signal to open valve (shown)
Default setting:
DIR = OPE
ATYP = 1-A
PFA = CLO (must be in the spring direction)
A0 and VTYP according to valve type
7.Increasing input signal to close valve (shown)
Default setting:
DIR = CLO
ATYP = 1-A
PFA = OPE (must be in the spring direction)
A0 and VTYP according to valve type
6.Increasing input signal to close valve (not recommended)
Default setting:
DIR = CLO
ATYP = 1-A
PFA = CLO (must be in the spring direction)
A0 and VTYP according to valve type
4.Increasing input signal to close valve (shown)
Default setting:
DIR = CLO
ATYP = 2-A
PFA = OPE
A0 and VTYP according to valve type
.
C1
C2
S
C1
C2
S
C1
C2
S
3.
8.Increasing input signal to open valve (not recommended)
Default setting:
DIR = OPE
ATYP = 1-A
PFA = OPE (must be in the spring direction)
A0 and VTYP according to valve type
DOUBLE-ACTING ACTUATOR
Increasing input signal to open valve (shown)
Default setting:
DIR = OPE
ATYP = 2-A
PFA = CLO
A0 and VTYP according to valve type
2.Increasing input signal to close valve (not recommended)
Default setting:
DIR = CLO
ATYP = 2-A
PFA = CLO
A0 and VTYP according to valve type
.
C1
C2
S
1.

10 7 SG92H 70 en
3.5 Electrical connections
The SG9200H is powered by a standard 4-20 mA cur-
rent loop that also functions as a carrier to the HART
communication.
If a 24 V DC (or up to 230 V AC) output from the control
system is used, then an U/I converter is needed as
shown in Fig. 7 below. See typecoding in Section 14 for
different converter options.
The signal cables are led through M20 x 1.5 cable
glands.
Cable shall be one or more single-twisted pair shielded
or multiple-twisted pair with overall shield. Single and
multiple-pair may be combined in a given network pro-
vided all current input devices associated with multiple
pairs of the same cable shall be located nominally at
one end of the multi-pair cable. Unshielded cable may
be used if it is demonstrated that ambient noise or
crosstalk does not affect communication.
Connect the conductors to the terminal strip as shown in
Fig. 6. (Connections '+' and '-').
The optional position transmitter is connected to 2-pole
terminal PT as shown in Fig. 6. The position transmitter
needs an external power supply. The SwitchGuard and
the position transmitter circuits are galvanically isolated
and withstand a 600 V AC voltage.
The earthing of the cables shall be carried out at the
DCS end only.
NOTE:
The SG9200H equals a load of 475 Ωin the current
loop.
Fig. 6 Terminals when LUI is removed and position
transmitter option is in use.
HART connection
Fig. 7 Control wiring
HAZARDOUS LOCATION
Control
system
Uo < Ui
Io < Ii
Po < Pi
Control
system
Uo < Ui
Io < Ii
Po < P
SG9200H_T
Position Transmitter
NONHAZARDOUS LOCATION
AI
(Analog Input)
AO
(Analog Output)
Entity Parameters of
position transmitter
Ui < 28.0 V Rx = 690 Ω
Ii < 120 mA Ci < 22 nF
Pi < 1.0 W Li < 53 µH
Entity Parameters
Ui < 28.0 V
Ii < 120 mA
Pi < 1.0 W
Ci < 22 nF
Li < 53 µH
HAZARDOUS LOCATION
Control
system
Uo < Ui
Io < Ii
Po < Pi
Control
system
SG9200H_ T
Position Transmitter
NONHAZARDOUS LOCATION
U/I converter
AI
(Analog Input)
DO
(Digital Output)
Uo < Ui
Io < Ii
Po < Pi
Uo < Ui
Io < Ii
Po < Pi
Entity Parameters of
position transmitter:
Entity Parameters:
Ui < 28.0 V
Ii < 120 mA
Pi < 1.0 W
Ci < 22 nF
Li < 53 µH
Ui < 28.0 V Rx = 690 Ω
Ii < 120 mA Ci < 22 nF
Pi < 1.0 W Li < 53 µH

7 SG92H 70 en 11
4 LOCAL USER INTERFACE (LUI)
The local user interface may be used to monitor the
device behaviour as well as configuring and commis-
sioning the controller during installation and normal
operation. The local user interface consists of two row
LCD and four button keypad interface. There are also
custom graphical characters for special conditions.
4.1 Measurement monitoring
When the device is powered, it enters the measurement
monitoring view. The following measurements may be
viewed from the display. The Table 3 identifies the default
unit and also optional unit of the measurement.
If the unit selection is altered from the FieldCare software
to US units, the pressure default unit will automatically be
changed to psi and temperature unit to Fahrenheit.
The active unit may be changed by pressing the ?key
constantly. The display shows the current unit selection
on the top row of the display. You may change the selec-
tion by pressing +or -while keeping the ?key
pressed down. When the buttons are released the cur-
rent selection will be activated.
If the device has been idle for 1 hour, and there is no
user activity on the local user interface, the measure-
ments will start scrolling on the display. This enables the
user to view all the measurements through the window of
the main cover.
4.2 Guided start-up
Guided startup offers a fast view of the most critical
parameters of the SwitchGuard controller, actuator and
valve configuration. After verifying the parameters the
valve travel calibration is recommended. The guided
start-up is entered by pressing the =and ?keys
simultaneously.
The configuration parameters are listed in following
order, see explanation from 4.5:
Valve type VTYP
Actuator type ATYP
Maximum Speed MAXS
Positioner fail action PFA
Valve dead angle A0
Stroke Time Open STOP
Stroke Time Close STCL
If you modify any of the parameters you will also need to
calibrate and tune the device. See 4.6 for detailed
description.
Fig. 8 Local user interface (LUI)
Table 3 Default / optional units of measurements
Measurement Default unit Optional unit
valve position Percentage of full
scale Angle, where 0 % refers to 0 (angle)
current loop
setpoint mA Percentage of full scale
actuator
pressure
difference
bar psi
supply pressure bar psi
device
temperature °Celcius °Fahrenheit
Fig. 9 Measurement unit change
— continuous push
— brief push

12 7 SG92H 70 en
4.3 Configuration menu
The local user interface is organised in a menu struc-
ture. To enter the menus press +and -simultaneously
in the measurement monitoring view panel. To move to
the next or previous selection by pressing +or -
accordingly.
4.4 MODE menu
If the user wants to change the valve operating mode,
press the ?key at the MODE selection. The mode will
start to flash and by pressing +or -you may alter the
operation mode selection. User accepts the current
selection by pressing the ? key.
There are two options for the operating mode.
4.4.1 AUTO
During the AUTO mode, the controller controls the valve
position according to the incoming setpoint signal from
the 4–20 mA signal source. This mode is used during the
normal process control service.
Fig. 10 Guided start-up
NOTE:
You may cancel any action by pressing the =button.
Cancelling of operation returns user interface view one
level up in menu hierarchy.
— brief push
Fig. 11 Configuration
— brief push

7 SG92H 70 en 13
4.4.2 MAN
It is possible to control the valve position from the key-
board in the Manual Mode. To do this, you must return to
Measurement Monitoring Menu (main menu).
❑Choose TPOS and press ?. In the upper row
TPOS starts to blink and in the lower row you can
see the current position of the valve.
CLO = valve closed
OPE = valve open
--- = valve is somewhere between open and
closed positions.
❑You can control the valve position as follows:
+Opens the valve, "---" blinks during movement.
-Closes the valve, "---" blinks during move-
ment.
Blinking stops when the valve is again fully open
or closed.
4.5 Configuration parameters
When PAR is on the display you may enter the configura-
tion menu by pressing the ?key. In this menu the most
important configuration and signal modification parame-
ters are viewable. You may view the current value and edit
them by pressing the ?key at the relevant parameter.
The name of the parameter will appear on the upper row
of the display and the current value is on the lower row.
See also table in Section 13.
4.5.1 Stroke time and profile, STOP,STCL,
SPOP,SPCL
Valve open and close profiles can be configured with
Neles SwitchGuard with the limitation set by valve
assembly. Stroke time performance constraints can be
seen from the piping table in Section 3.4. Both stroke
directions can be set without any connection to the
each other.
Opening and closing times can be set with STOP (open)
and STCL (close) parameters. Parameter is given in
seconds.
Used stroke profile shape can be set with parameters
SPOP (open) and SPCL (close). Profile can be chosen
separately for both direction from one of the five profile
shapes: Linear (1), Slow Starting (2), Slow Starting &
Ending (3), Equal Percentage (4) and Quick Starting
(5). If valve stroke is needed to do as fast as possible,
set time stroke time to 0.
4.5.2 Trigger level, LEV
Input setpoint level to start position transition. A fixed
hystereris is applied on this level (trigger level – 5 %).
Default value is 50.0 % and range is 20...80 %.
4.5.3 Signal direction, DIR
The opening and closing direction of the valve with rais-
ing current loop signal is defined by signal direction
parameter DIR.
❑When DIR is displayed press the ?key to enter
the edit state and DIR starts to blink.
❑Select either the OPE or CLO values by pressing
the +and -keys. The value OPE signifies the
raising signal 4–20 mA to open the valve and CLO
means the raising signal to close the valve.
❑To conclude, press the ?key when the desired
value is shown on the display.
See default values in Fig. 5.
Fig. 12 Setpoint change in MAN mode
Fig. 13 Stroke profile shapes, opening
Fig. 14 Stroke profile shapes, closing
NOTE:
In case of signal direction (DIR) is same than Posi-
tioner Fail Action (PFA) 5 mA input signal is recom-
mended as minimum.
0
10
20
30
40
50
60
70
80
90
100
0 102030405060708090100
Linear Slow Starting & Ending Equal Percentage
Quick Starting Slow Starting
% of stroke time
valve travel
0
10
20
30
40
50
60
70
80
90
100
0 102030405060708090100
Linear Slow Starting & Ending Equal Percentage
Quick Starting Slow Starting
% of stroke time
valve travel

14 7 SG92H 70 en
4.5.4 Valve type, VTYP
To compensate for nonlinearity of the position feedback
caused by the actuator linkage mechanism of a linear
control valve, the appropriate selection must be made on
the VTYP display.
❑After selecting VTYP on the display, press the ?
key to enter the edit state and the VTYP starts to
blink.
❑Select between two values rot or LIn using the
+and -keys. The value rot indicates a rotary
valve and LIn a linear valve.
❑To conclude press the ?key when the desired
value is shown on the display.
4.5.5 Actuator type, ATYP
In order to optimise the control performance the device
needs to be informed about the actuator type.
❑After selecting ATYP on the display, press the ?
key to enter the edit state and ATYP starts to blink.
❑Select between two values 2-Aor 1-Ausing the +
and -keys. The value 2-Aindicates a double
acting actuator and 1-Aa single acting actuator.
❑To conclude press the ?key when the desired
value is shown on the display.
4.5.6 Maximum valve speed, MAXS
Maximum Valve Speed parameter does not adjust the
speed of the valve. Parameter describes the pneumatic
capacity of SwitchGuard when compared to actuator size.
❑Once MAXS is displayed, press the ?key to enter
the edit state and the MAXS will start blinking.
❑You may select between three values by press-
ing the +or -key. For small actuators select
FST, medium size actuators STD and large size
actuators SLO. See Table 2 for correct settings.
❑After the desired value is displayed, press the ?
key to conclude the operation.
4.5.7 Positioner fail action, PFA
This section describes the function of the actuator.
Set value according to Fig. 5 for double acting actuators.
For single acting actuators set value in the spring direc-
tion. This action will also take place when the controller
software discovers a fatal device failure. See Fig. 5 for
correct settings.
❑Once PFA is displayed, press the ?key to enter
the edit state and the PFA will start blinking.
❑You may select between two values by pressing
the +or -key. The CLO value indicates that the
valve ought to be closed in fail action situations.
The OPE value indicates the valve to be opened in
fail action situations.
❑After the desired value is displayed, press the
key ?to conclude the operation.
4.5.8 Valve dead angle, A0
The α0setting is made for Metso segment and ball valves.
This setting takes into account the "dead angle" α0of the
ball valves. The entire signal range is then used for effec-
tive valve opening 90° - α0. Use 0 % as the "dead angle"
for the valves not mentioned in Table 4.
CAUTION:
Stroke times are defined by parameters STOP and
STCL. Don’t try to adjust the speed with MAXS.
CAUTION:
Always adjust the maximum valve speed parame-
ter according to Table 2. Erroneous value may
cause instability.
NOTE:
In case of signal direction (DIR) is same than posi-
tioner fail action (PFA) 5 mA input signal is recom-
mended as minimum.
Table 4 Dead angle in percentage
Valve
size
Valve series
MBV
QMBV
1)
MBV
QMBV
2)
D,
P,
C
T5,
QT5
QX-
T5
T25,
QT25
QX-
T25
R,
QR
ER-
SOFT
3)
mm in Dead angle, %
25 1 14 - - 25.5 19.5 - - 15 25.5 27
25/1 1/1
25/2 1/2
25/3 1/3
40 1 1/2 12 - - 24.5 12.5 - - 12 16 21
50 2 10 9 13.5 24.5 12.5 18 8 17 20.5 23
6521/29------13-18
80 3 10 8 12 18 8 16.5 8.5 9 8.5 15.5
100 4 10 8 12 16.5 8.5 16 9 8 7 14.5
125 5 12 - - - - 12 6.5 8 -
150 6 10 8 11.5 16 9 13.5 8 13.5 13
200 8 9 7 8.5 12 6.5 9.5 7 11.5
250 10 9 7 7.5 13.5 9.5 7 10.5
300 12 8 6 6.5 9.5 7.5 6 9.5
350 14 6 6 - 5 9.5
400 16 5 5.5 9.5
(14")
59.5
450 18 6 7.5
(16")
500 20 6 4.5
600 24 5.5
650 26 7
700 28 7
750 30 6
800 32 -
900 36 5.5
1) Seat supported 2) Trunnion 3) Soft seated R-valve
Fig. 15 Principle of setting
100
80
60
40
20
00 20 40 60 80 100
α0α0
POSITION
INPUT SIGNAL
= Basic setting = α0setting
Increasing input signal opens valve Increasing input signal closes valve
cut-off safety range 2 ±0.5 %

7 SG92H 70 en 15
❑After selecting A0 on the display, press the ?
key to enter the edit state and A0 starts to blink.
The value currently selected appears as a per-
centage (%) on the display.
❑Modify the parameter value by pressing +or -
keys alternately until the desired value appears
on the display.
❑Press the ?key to make your selection and
return to the setting state.
4.5.9 Language selection, LANG
❑Select between three languages EnG, GEr or FrE
(English, German or French) using the +and -
keys.
❑To conclude press the ?key when the desired
value is shown on the display.
4.6 Valve travel calibration
Select CAL from the menu by using +or -keys and
press the ?key.
4.6.1 AUTO CAL calibration function
During calibration process a blinking text "CAL run" will
be show on the display. If calibration ends successfully, a
text "CALIBRATION SUCCESSFUL" will be shown. Calibra-
tion can be cancelled with the =key, which will show a
text "CALIBRATION CANCELLED". If calibration fails, the
reason will be shown, eg. "CALIBRATION START FAILED",
"POSITION SENSOR RANGE ERROR", "CALIBRATION TIME-
OUT" or "CALIBRATION FAILED". After calibration the device
will return to the main menu (measurement monitoring).
4.6.2 TUNE Automatic Tuning
After selecting this option the number of strokes will be
asked: NBR 5.
The user is able to change this number between 2…20.
The default value is 5 full strokes (open and close).
During tuning process a blinking text "TUNE run" will be
show on the display. If tuning ends successfully, a text
"CALIBRATION SUCCESSFUL" will be shown. Tuning can
be cancelled with the =key, which will show a text
"CALIBRATION CANCELLED". If tuning fails, the reason will
be shown, eg. "CALIBRATION START FAILED", "POSITION
SENSOR RANGE ERROR", "CALIBRATION TIMEOUT" or
"CALIBRATION FAILED". After tuning the device will return
to the main menu (measurement monitoring).
4.7 Special displays
4.7.1 User interface locked
In order to prevent unauthorised access, the Local User
Interface may be locked. In this mode measurements
may be viewed but configurations and calibrations are
prohibited. You may lock and unlock the device only via
HART. When the Local User Interface is locked the lock
symbol will be activated on the display.
4.7.2 Online-alarm active
If an online alarm has been detected the &symbol is
activated. This symbol will disappear after the recovery
from online alarm. You may view the reason for the
alarm by viewing the latest event while pushing the =
and -keys simultaneously or by using FieldCare soft-
ware where all events may be viewed.
Fig. 16 Dead angle
NOTE:
Valve travel calibration is possible only when the valve
controller is in AUTO mode.
Fig. 17 Calibration selection
WARNING:
Automatic calibration drives the valve against the
mechanical open and closed travel limits of the
valve-actuator assembly and a tuning procedure is
performed. Make sure that these procedures can
be safely executed.
Fig. 18 LUI locked
Fig. 19 Online alarm message
scrolling text

16 7 SG92H 70 en
4.7.3 HART Communication active
When double arrow symbol is indicated, HART commu-
nicaton is activated to device.
4.7.4 Viewing of latest event
You may view the latest event by pressing the =and -
keys simultaneously in the measurement monitoring
view. The message is scrolled on the top row of the dis-
play twice. You may stop the scrolling by pressing the ?
key. By pressing the =key, the message will disappear.
For the list of events see Chapter 6.
4.7.5 Fail-safe active
When the SwitchGuard detects serious device failure
(setpoint, valve position and control signals) it enters fail-
safe mode, which drives the control valve into the posi-
tion defined in the parameter controller fail action (PFA).
Fail-safe mode is indicated by the display as seen in Fig
19. The error message is displayed until the cause of
error is eliminated and the SwitchGuard unit is restarted,
i.e. the power loop is momentarily disconnected.
4.8 HART write protection
The SG9200H is delivered from the factory with the
default set as HART write protection OFF. Reading and
changing parameters is allowed. HART protection may
be enabled with a switch (DIP1) located on the commu-
nication circuit board under the Local User Interface
module, Fig. 22. Changes that may influence the valve
position cannot be made using the FieldCare software or
HART hand held when switch no. 1 (on the left-hand side
of the switch block) is ON.
5 MAINTENANCE
The maintenance requirements of the SwitchGuard
valve controller depend on the service conditions, for
instance, the quality of instrument air. Under normal
service conditions there is no requirement for regular
maintenance.
When maintaining the SwitchGuard ensure that the
supply air is shut off and pressure is released. In the
following text the numbers in brackets ( ) correspond to
the part numbers in the exploded view as shown in
Chapter 11, unless otherwise stated.
The Switchguard SG9200H includes the following mod-
ules: prestage unit (120), spool valve (420), communi-
cation circuit board with optional position transmitter
(215) and controller circuit board with position and
pressure sensors (210 ).
The spool valve is located on the bottom side of the
device while the other modules are located below the
cover 100. In the event of failure the whole module must
be changed. The module retrofit must be assembled in
a clean, dry environment. On reassembly apply a
thread-locking compound (for instance, Loctite 243)
and tighten the screws firmly.
Fig. 20 HART communication activated
Fig. 21 Failsafe display
scrolling text
Fig. 22 HART write protection
Ex d NOTE:
Maintenance of the parts of the flameproof enclo-
sure is not allowed!
Device type SG9200H_E1_:
Housing (2), Cover (100), Shaft assembly (11), Limit
switch housing (300).
NOTE:
Whenever any maintenance operations have been
done for the SG9200H, the device should be cali-
brated and tuned.
12
ON

7 SG92H 70 en 17
5.1 Prestage
5.1.1 Removal
❑Loosen the M8 stop screw (110) in the position
indicator (109) and turn the position indicator
from the shaft (11). Remove the inner cover (39)
attached with M3 screws (42, 3 pcs.).
❑Unplug the prestage wire connector from the
connector board (180). Unscrew the M4 screws
(139, 2 pcs.) and lift up the prestage unit (120).
Remove the O-ring (140).
5.1.2 Installation
❑Place a new O-ring (140) into the groove in the
prestage mounting plate (400) and press the
prestage into place. Make sure the nozzle is
guided into the O-ring properly. The screws
guide the prestage body into the correct posi-
tion. Tighten the screws (139) evenly.
❑Push the prestage 2-pole wire connector into the
socket on the connector board (182). The wire
connector can only be fitted in the correct posi-
tion. Replace the inner cover (39) and tighten the
M3 screws
5.2 Spool valve
5.2.1 Standard capacity
5.2.1.1 Removal
For spool valve removal it is usually necessary to
unmount the valve controller from the actuator.
❑Working from the bottom side of the valve con-
troller, unscrew the M5 screws (4 pcs.). Remove
the spool valve (420) with gasket. The spool
valve may be opened and cleaned if special
attention is paid to a clean environment and
proper procedure.
❑Clean the spool and the bore of the body with
care. Do not leave any fibres from cleaning mate-
rials in the bore or on the spool. Do not scratch
the mating surfaces of the spool and body.
5.2.2 Installation
❑Ensure that the gasket (174) is properly located
in the grooves on the bottom of the housing.
Mount the spool valve mounting plate (421) and
the spool valve (420) to the housing, and tighten
the four M5 screws evenly. Required torque is
4.5 Nm.
The spool valve mounting plate (421) can be
exchanged to convert capacity between resctricted
(SG9212) and normal (SG9215).
5.2.3 High capacity
5.2.3.1 Removal
❑Unscrew the M5 screws (4 pcs.). Remove the
spool valve (420) with gasket from the mounting
block (421). The spool valve may be opened
and cleaned if special attention is paid to a clean
environment and proper procedure.
❑Clean the spool and the bore of the body with
care. Do not leave any fibres from cleaning mate-
rials in the bore or on the spool. Do not scratch
the mating surfaces of the spool and body.
5.2.4 Installation
❑Ensure that the gasket (63) is properly located in
the grooves in the bottom of the spool valve.
Mount the spool valve (420) to the mounting
block (421), and tighten the four M5 screws
evenly. Required torque is 4.5 Nm.
5.3 Restrictor
The restrictor is located in the prestage mounting plate. If
clogged it can be cleaned if special attention is paid to
proper procedure.
❑Remove the prestage as described in Section
5.1.
❑Remove screw (412) and remove the mounting
plate (400). Retain the O-rings (411, 2 pcs.).
Open the M4 (407, 2 pcs.) and open the restric-
tor cover (406). Take the restrictor (405) out and
retain the O-ring (405).
❑Clean the restrictor and it's bore in the mounting
plate if necessary.
❑To reassemble, insert the O-ring (404) and the
restrictor into the bore and install the restrictor
NOTE:
The prestage must be handled carefully. In particular
the moving parts of the prestage should not be
touched when the inner cover (39) is not in place.
NOTE:
Each spool valve body has an individual correspond-
ing spool which cannot be replaced by any other
spool. Never alter the orientation of the spool, see Fig.
23.
NOTE:
If the maintenance operations have been done for the
spool valve assembly, the device must always be cal-
ibrated and tuned.
NOTE:
Each spool valve body has an individual correspond-
ing spool which cannot be replaced by any other
spool. Never alter the orientation of the spool, see Fig.
23.
Fig. 23 Spool valve assembly

18 7 SG92H 70 en
cover (406). Take care not to shear the O-ring on
the cog of the restrictor cover. When reinstalling
the prestage mounting plate place the O-rings
(411) carefully into their grooves in the mounting
plate.
5.4 Communication circuit board
5.4.1 Removal
❑Loosen the M8 stop screw (110) in the position
indicator (109) and turn the position indicator
from the shaft (11). Remove the inner cover (39)
attached with M3 screws (42, 3 pcs.).
❑Remove the M3 screws (217, 4 pcs.). Hold the
sides of the circuit board and lift it directly
upwards and outwards. Handle the board care-
fully, touching only the sides.
5.4.2 Installation
❑Mount the new communication circuit board
carefully.
❑Locate the pins with the matching connector on
the board. Tighten the M3 screws (217) evenly.
❑Install the inner cover (39).
❑Mount the position indicator (109) on the shaft
and tighten the M8 stop screw (110) temporarily.
The final orientation and locking of the position
indicator should be done after installation of the
valve controller to the actuator.
6 ERROR MESSAGES
6.1 Failsafe errors
6.2 Alarms
NOTE:
Ground yourself on the body of the device before
touching the circuit board.
ATEX WARNING:
Grounding of the circuit board is essential to
explosion protection.
The board is grounded to the housing by the mount-
ing screw next to the terminal blocks.
Fig. 24 Communication board
215
Display message Description
CONTINUED INTERNAL
BOOT Too many consecutive internal resets have been
generated
FAILSAFE ACTIVATED Device is in failsafe state
PARAMETERS DATABASE
ERROR Parameter database initialization failed
PRESTAGE SHORTCUT
ERROR Prestage coil shortcut has been detected
SETPOINT SENSOR ERROR Setpoint sensor defect has
been detected
SUPPLY PRESSURE
FAILSAFE ACTIVATED Supply pressure has dropped below user defined alarm
limit. This causes the device
to go to the failsafe state
Display message Description
PNEUMATICS PROBLEM Actuator pressure difference
has not changed even it
should have been. Spool
valve may be jammed
TOO FAST VALVE CLOSING
ALARM Valve was closed faster than was determined by alarm
limit parameter
TOO FAST VALVE OPENING
ALARM Valve was opened faster than was determined by alarm
limit parameter
TOO SLOW VALVE CLOSING
ALARM Valve was closed slower than was determined by alarm
limit parameter
TOO SLOW VALVE OPENING
ALARM Valve was opened slower than was determined by
alarm limit parameter
UNALLOWED VALVE
MOVEMENT ALARM Valve position has changed but setpoint is still in open or
close position
VALVE CLOSE STUCK
ALARM Over 5 % difference between setpoint and valve position.
Valve may be jammed at
close position. Difference is a
user configurable parameter
VALVE INTERMEDIATE
STUCK ALARM Over 5 % difference between setpoint and valve position.
Valve may be stuck between
open and close positions.
Difference is a user
configurable parameter
VALVE OPEN STUCK ALARM Over 5 % difference between
setpoint and valve position.
Valve may be jammed at
open position. Difference is a
user configurable parameter

7 SG92H 70 en 19
6.3 Errors 6.4 Warnings
6.5 Notifications
Display message Description
CALIBRATION FAILED Calibration process has
failed
CALIBRATION START
FAILED Calibration process could not be started
CALIBRATION TIMEOUT Calibration process has
taken too long time
FACTORY SETTINGS
CREATE FAIL Factory settings creation failed
FACTORY SETTINGS
RESTORE FAIL Factory settings restoration failed, i.e. current parameter
set could not be loaded with
factory settings
INTERNAL BOOT RESET Software has lost the control
and internal watchdog
generated reset
POSITION SENSOR FAILURE Position sensor defect has
been detected
POSITION SENSOR RANGE
ERROR Too narrow position sensor range was detected in
position calibration process
PRESSURE SENSOR 1
FAILUR E Pressure sensor #1 defect has been detected
PRESSURE SENSOR 2
FAILUR E Pressure sensor #2 defect has been detected
PRESSURE SENSOR 3
FAILUR E Pressure sensor #3 defect has been detected
PRESTAGE CUT ERROR Prestage coil cut has been
detected
PRESTAGE SHORTCUT
ERROR Prestage coil shortcut has been detected
PT COMMUNICATION
ERROR Communication with position transmitter was lost
STATISTICS DATABASE
ERROR Error occurred when writing statistics to database
TEMPERATURE SENSOR
FAILUR E Temperature sensor defect has been detected
Display message Description
ACTUATOR FULL STROKES
WARNING Actuator full stroke counter has exceeded the warning
limit
CLOSE STROKE DEVIATION
WARNING Valve close stroke deviation time trend has exceeded the
warning limit
OPEN STROKE DEVIATION
WARNING Valve open stroke deviation time trend has exceeded the
warning limit
REDUCED PERFORMANCE
ACTIVATED Controller can not perform boosting due to pressure
sensor failure. Also, position
sensor failure cause device to
act like any normal solenoid
device: position can not be
controlled
SPOOL REACTION TIME
CLOSE WARNING Spool valve reaction time close trend has exceeded
the warning limit
SPOOL REACTION TIME
OPEN WARNING Spool valve reaction time open trend has exceeded
the warning limit
SUPPLY PRESSURE OUT OF
LIMITS Supply pressure is out of warning limits
SUPPLY PRESSURE TREND
WARNING Supply pressure trend value has exceeded the warning
limits
TEMPERATURE OUT OF
LIMITS Temperature is out of warning limits
TEMPERATURE TREND
WARNING Temperature trend value has exceeded the warning limits
TOTAL OPERATION TIME
WARNING Total operating time has exceeded the warning limit
VALVE FULL STROKES
WARNING Valve full stroke count has exceeded the warning limit
VALVE REACTION TIME
CLOSE WARNING Valve reaction time close trend has exceeded the
warning limit
VALVE REACTION TIME
OPEN WARNING Valve reaction time open trend has exceeded the
warning limit
Display message Description
CALIBRATION CANCELLED Calibration process has
been cancelled
CALIBRATION
SUCCESSFUL Calibration process has ended successfully
EXTERNAL RESET Device has been booted, i.e.
power-up reset
FACTORY DEFAULTS
ACTIVATED Device parameters were changed to factory settings
REDUCED PERFORMANCE
DEACTIVATED Recovery for reduced performance activation

20 7 SG92H 70 en
7 TROUBLE SHOOTING
Mechanical/electrical defects
1. A change in the valve position setpoint will not affect
the position of the actuator
❑Supply pressure too low
❑Spool valve sticks
❑Incorrect configuration parameters
❑Actuator and/or valve jammed
❑Signal wires incorrectly connected, no value on
display
❑Circuit boards are defective
❑Calibration has not been carried out
❑Device is in manual mode
❑Prestage is defective
❑Device is in fail-safe mode
❑Spool mounted backwards into spool valve
2. Inaccurate positioning
❑Spool valve dirty
❑Too high actuator load
❑Supply pressure too low
❑Spool or pressure sensors are defective
❑Actuator leakage
3. Overshooting or positioning too slow
❑Spool valve dirty
❑Supply air tube too small or supply air filter dirty
❑Valve sticks
❑Check leakages in tubes between controller and
actuator
❑Check leakages in mechanical stop screws
❑Check correctness of MAXS parameter. Change
it from "slow" to "fast" or "moderate".
4. Error during valve travel calibration
❑Valve controller is in MAN mode
❑Check the coupling alignment with the pointer,
see Fig. 4
❑The parameter setting PFA incorrectly selected
❑The actuator or valve did not move or was stuck
during calibration
❑Supply pressure too low
❑Spool valve dirty