StoneL Prism PI Operating and maintenance manual

Prism™ PI by StoneL
Installation, Maintenance and
Operating instructions
7 PI 70 en • 01/2021StoneL publication 105431revC

7 PI 70 en2 | Prism PI
StoneL publication 105431revC
Read these instructions rst!
These instructions provide information about safe handling and operation of the Prism PI by StoneL. 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 General 3
1.1 Introduction 3
1.2 Title plate markings 3
1.3 CE markings 3
1.4 Recycling and disposal 3
1.5 Safety precautions 3
1.6 Assembly drawing 4
1.7 Specications for all models 4
1.8 Pneumatic valve specications 5
1.9 Pneumatic valve schematics 5
1.10 Dimensions 6
2 Assembly and mounting 7
2.1 Instructions 7
2.2 Prism PI assembly gure 8
3 Maintenance, repair and installation 9
3.1 Maintenance and repair 9
3.2 Installation 9
3.3 Special conditions of use 9
4 Function specic details 10
4.1 Sensor/switching modules 10
4.1.1 SST NO sensor (33S) 10
4.1.2 NAMUR sensor (45S) 11
4.1.3 Expeditor, standard stroke (80S & 80W) 13
4.1.4 Expeditor, long stroke (81S & 81W) 14
4.2 Valve communication terminals (VCT) 16
4.2.1 VCT with DeviceNet™ communication (92S & 92W) 16
4.2.2 VCT with AS-Interface communication (96S & 96W) 18
4.2.3 VCT with AS-Interface communication and extended addressing (97S & 97W) 20
5 Wireless Link user guide 22
5.1 Getting started 22
5.2 Home screen 22
5.3 Locked screen 22
5.4 Device detail screen 23
5.5 More information screen 24
5.6 Diagnostics screen 25
5.7 Federal Communication Commission (FCC) statement 26
6 Model/Type code 27
7 Regulatory, specic conditions of use, and product marking 28
8 Appendix 30
8.1 Controlled installation drawings 30

StoneL publication 105431revC
7 PI 70 en Prism PI | 3
Logo
Warning:
Note:
Sensor Ratings:
Haz. Loc.: CI I, Div 1, Gp B, C, D; CI II, Div 1, Gp E,F,G;
sample only
Approval markings
Serial
Model
Date
™
1.2 Title plate markings
The Prism PI has an identication plate attached to the cover.
1. Identication plate markings:
2. Model
3. Serial number
4. Date
5. Electrical rating(s)
6. Protection class information*
7. Note
8. Warning
9. Approval markings*
10. Logo
Note
* See page28 for specic product markings.
1 General
1.1 Introduction
This manual incorporates the Installation, Maintenance and Operation (IMO) instructions for the Prism PI series valve controllers. The Prism PI is
designed to provide position feedback indication and pneumatic control of on/o automated valves.
Note
The selection and use of the Prism PI in a specic 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 Prism PI. If you are uncertain about the use
of this device, or its suitability for your intended use, please contact StoneL for assistance.
1.3 CE markings
The Prism PI by StoneL meets the requirements of European Directives
and has been marked according to the directive.
1.4 Recycling and disposal
Most Prism PI parts can be recycled if sorted according to material.
In addition, separate recycling and disposal instructions are available
from us. A Prism PI can also be returned to us for recycling and
disposal for a fee.
1.5 Safety precautions
Do not exceed the permitted values! Exceeding the permitted values
marked on the limit switch may cause damage to the switch and to
equipment attached to the switch and could lead to uncontrolled
pressure release in the worst case. Damage to the equipment and
personal injury may result.
To prevent ignition of hazardous atmospheres, replace cover before
energizing the electrical circuits. Keep cover tightly closed when in
operation.
10
5
8
1
7
3
9
6
24

7 PI 70 en4 | Prism PI
StoneL publication 105431revC
Specications
Materials of construction
Cover Clear polycarbonate
Housing & mounting system Fiber reinforced polycarbonate and stainless steel
Fasteners Stainless steel
Mounting system Fiber reinforced polycarbonate and stainless steel
Seals Buna N
Valve manifold Polycarbonate with stainless steel reinforced
⁄“NPT porting
Trigger (magnetic) Polysulfone with black chromated zinc
reinforcement
Operating life Over 1 million cycles
Operating temperature range
Unit without solenoid
Unit with solenoid
-20° C to 60° C (-4° F to 140 ° F)
See 1.8 Pneumatic valve specifications
Enclosure protection Type 4, 4X, 6 and IP66 / IP67
Warranty
Sensing & communication
module
Five years
Mechanical components Two years
Unit weights
Standard stroke 0.77 kg / 1.7 lb
Long stroke 0.95 kg / 2.1 lb
Unit dimensions
Standard stroke no visual indicator Unit height
Cover removal clearance
84.1 mm [3.31 in]
25 mm [1 in]
Standard stroke with visual indicator Unit height
Cover removal clearance
107.9 mm [4.01 in]
25 mm [1 in]
Long stroke Unit height
Cover removal clearance
163.3 mm [6.43 in]
70 mm [2.75 in]
Position sensing
Accuracy 1.0 mm [0.04 in]
Repeatability 0.5 mm [0.02 in]
Setting buffer (factory settings) Open - 25% of stroke length
Closed - 25% of stroke length up to 3.2 mm [0.125 in]
Deadband (factory settings) Open - 30% of stroke length
(variable; based on actual stroke)
Closed - 30% of stroke length or 3.8 mm [0.15 in]
(whichever is less)
Environmental conditions
Location Indoor and outdoor
Maximum altitude 5000 m
Maximum humidity 90%
Pollution degree 4
Ratings and approvals* See page28 or StoneL.com/approvals
* Only models listed on StoneL’s official website are approved per specific rating.
1.7 Specications for all models
See page10 for function specic details.
6
8
5
9
4
10
11
7
1.6 Assembly drawing
1. Title plate
2. Cover
3. Trigger
4. Sensing module
5. Internal ground lug
6. Body screws
7. Body
8. Mounting screws
9. Trigger assembly shaft
10. Mounting plate
11. Actuator
1
2
3

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7 PI 70 en Prism PI | 5
Specications
General pneumatic specications
Conguration 3-way, 2-position, spring return
Type Direct acting
Porting ⁄” NPT (stainless steel reinforced)
Medium Air or inert gas
Medium temperature range (TS) -40° C to 80° C (-40° F to 176 ° F)
Operating pressure 25 psi to 120 psi (1.72 to 9.65 bar)
Operating life 1million cycles
Manual override Internal momentary
Solenoid coil specications
1K (33_, 92_, 96_, 97_)
Operating voltage
Power consumption
Flow rating
Operating temperature
Filtration requirements
24 VDC
1.0 watt
0.2 Cv (Kv = 0.17 based on ow m3/hr)
-10° C to 50° C (14° F to 122° F)
40 microns
2K (80_, 81_,)
Operating voltage
Power consumption
Flow rating
Operating temperature
Filtration requirements
24 VDC
1.0 watt
0.2 Cv (Kv = 0.17 based on ow m3/hr)
-10° C to 50° C (14° F to 122° F)
40 microns
1M (33_)
Operating voltage
Power consumption
Flow rating
Operating temperature
Filtration requirements
120 VAC 50/60 Hz
1.0 watt
0.2 Cv (Kv = 0.17 based on ow m3/hr)
-10° C to 50° C (14° F to 122° F)
40 microns
1N (33_)
Operating voltage
Power consumption
Flow rating
Inrush current
Operating temperature
Filtration requirements
20 - 125 VAC 50/60 Hz; 20 - 55 VDC
12 mA @ 20 - 125 VAC (1.0 watt typical)
20 mA @ 20 - 55 VDC (0.5 watts typical)
0.1 Cv (Kv = 0.08 based on ow m3/hr)
3.75 A @ 125 VAC (typical)
0.15 A @ 24 VDC (typical)
-20° C to 60° C (-4° F to 140 ° F)
50 microns
1N (92_, 96_, 97_)
Operating voltage
Power consumption
Flow rating
Operating temperature
Filtration requirements
24 VDC
0.5 watts
0.1 Cv (Kv = 0.08 based on ow m3/hr)
-20° C to 60° C (-4° F to 140 ° F)
50 microns
1N (45_)
Operating voltage
Power consumption
Flow rating
Operating temperature
Filtration requirements
Entity parameters
18 - 28 VDC
0.3 watts
0.1 Cv (Kv = 0.08 based on ow m3/hr)
-20° C to 60° C (-4° F to 140 ° F)
50 microns
Ui=28 VDC, Ii=120 mA, Ci=3 nF, Li=0 mH, Pi=0.84 W
1.8 Pneumatic valve specications 1.9 Pneumatic valve schematics
3-way, 2-position, direct acting
P E
A
Actuator
Manifold
Solenoid

7 PI 70 en6 | Prism PI
StoneL publication 105431revC
1.10 Dimensions
Note
Prism PI certied dimensional drawing can be found under
the download tab at www.stonel.com/en/products/valve-
communication/prism-pi/
(1 or 2) 1/2" NPT or M201/8" NPT (3)
E P A 1.14 in
[28.9 mm]
0.39 in [9.9 mm]*
*Part of mounting system
no visual
indicator
3.31 in
[84.1 mm]
standard with
visual indicator
4.01 in
[101.9 mm]
long stroke
6.43 in
[163.3 mm]
3.95 in
[100.5 mm]
4.38 in
[111.1 mm]

StoneL publication 105431revC
7 PI 70 en Prism PI | 7
2 Assembly and mounting
2.1 Instructions
Steps
Refer to Prism PI assembly gure on page8 when performing
mounting and assembly procedures. Prism PI unit and mounting kit
are supplied separately. From Prism PI shipping container, ensure
items A, and F are present. From the mounting kit, ensure items G, H, I,
and J are present.
1. From the mounting kit package, locate the trigger shaft (ItemG),
Prism mounting plate (ItemJ), and mounting plate fasteners
(ItemH). Ensure unit O-ring (Item I) and mounting plate O-ring
(ItemK) are present in the mounting plate.
2. Thread the trigger shaft into the actuator (ItemL) (it is
recommended that a drop of blue Loctite® be used on the trigger
shaft threads). Tighten to approximately 15 - 20 in.lbs (1.7 - 2.3Nm)
with a small adjustable wrench.
3. Place the mounting plate onto the actuator and fasten down with
provided screws (2-4). (use of blue Loctite® on these screws is
optional). Tighten to approximately 15 - 20 in.lbs (1.7 - 2.3Nm).
4. Take o cover (ItemB) and remove the trigger assembly (ItemF)
from within the unit.
5. Place Prism PI unit (ItemA) onto the mounting plate in the
orientation desired (Prism PI body can be rotated on the mounting
plate in 45° increments). Tighten the two body screws (ItemD)
with a M3 allen wrench to approximately 25 - 30 in.lbs (2.8 -
3.4Nm).
6. Back out the trigger assembly adjustment screw (ItemE)
approximately ⁄”with a M2 allen and place the trigger assembly
into the corresponding slot of the sensing module (ItemC), with
a nger, press down rmly onto the trigger assembly shaft (See
Detail-Fig.1).
7. Turn the trigger assembly adjustment screw until the yellow marks
on the trigger assembly are ush with the yellow marks on the
sensing module (See Detail-Fig.2) To remove trigger assembly
from shaft, turn in adjustment screw until released.
8. After all wiring and sensor setting procedures have been
completed, re-install cover and place unit in service.
Special notes:
• Mounting of the Prism PI requires a StoneL mounting kit specic to
the actuator the Prism PI is to be mounted to.
• In high cycle or high vibration applications, blue Loctite® may
be used on the Trigger shaft threads (ItemG) and the Prism PI
mounting plate screws (ItemH).
• It is highly recommended that exhaust port E be tted with a low
restriction muer or breather vent cap to prevent ingestion of
water or debris into the pneumatic valve.
Fig. 2 Sensing module detailFig. 1 Trigger assembly detail
Trigger assembly
adjustment screw
Yellow alignment
marks

7 PI 70 en8 | Prism PI
StoneL publication 105431revC
E
P
2.2 Prism PI assembly gure
A. Prism unit
B. Cover
C. Sensing module
D. Body screws (2)
E. Trigger assembly adjustment screw
F. Trigger assembly
G. Trigger shaft
H. Mounting plate fasteners
I. Unit O-ring
J. Mounting plate
K. Mounting plate O-ring
L. Actuator
F
E
G
H
L
K
J
C
I
D
B
A

StoneL publication 105431revC
7 PI 70 en Prism PI | 9
3 Maintenance, repair and installation
3.1 Maintenance and repair
No routine maintenance of Prism units is required when installed in environments for which they are designed. If installed in severe environments,
pneumatic components may require replacement at more frequent intervals for maximum performance. Repair of Prism units must be done by
StoneL or by qualied personnel that are knowledgeable about the installation of electromechanical equipment in hazardous areas. All parts
needed for repair must be purchased through a StoneL authorized distributor to maintain warranty and to ensure the safety and compliance of
the equipment.
3.2 Installation
Attention: If required, the Prism housing can be grounded
to earth potential by the internal lug. (See Assembly
drawing 1.6 item 5 on page4)
Attention: In order to maintain enclosure type and IP
ratings, cover shall be tightened by hand until it stops on
the surface of the base not to exceed 10 ft. lbs (13.5Nm).
Do not use any tool to tighten the cover.
Attention: If the unit is used in a manner not specied by
StoneL, the protection provided by it may be impaired.
WARNING
Solenoid power supplied must be limited with a fuse or circuit
breaker rated to 2 Amps maximum.
Field wiring
• It is the responsibility of the installer, or end user, to install this
product in accordance with the National Electrical Code (NFPA 70)
or any other national or regional code dening proper practices.
• This product comes shipped with conduit covers in an eort to
protect the internal components from debris during shipment and
handling. It is the responsibility of the receiving and/or installing
personnel to provide appropriate permanent sealing devices to
prevent the intrusion of debris or moisture when stored or installed
outdoors.
Caution: To maintain safety, only power supplies that
provide Double/Reinforced insulation, such as those with
PELV/SELV outputs, shall be used. (As applicable)
3.3 Special conditions of use
For units with quick connect receptacles, when installed in Division 2 areas, an appropriate FM approved mating cord must be used in
conjunction with tamper proof guard at the mating point that requires a tool to remove, rendering the connection not normally arcing.

7 PI 70 en10 | Prism PI
StoneL publication 105431revC
4 Function specic details
4.1 Sensor/switching modules
4.1.1 SST NO sensor (33S)
Common receptacle options pin-out
Signal
OPEN NO
4-PIN MICRO CONNECTOR (M12)
CLOSED NO
CLOSED C
OPEN C
Pin
1
2
3
4
MALE (PINS)
1 2
43
With solenoid
No solenoid
CLOSED C
MALE (PINS)
MALE (PINS)
1
1
2
2
5
5
4
4
3
3
5-PIN MICRO CONNECTOR (M12)
5-PIN MINI CONNECTOR
CLOSED NO
not used
OPEN NO
OPEN C
Pin
1
2
3
4
5
OPEN/CLOSED C
CLOSED NO
OPEN NO
SOL PWR 2
SOL PWR 1
Pin
1
2
3
4
5
Caution: A series load resistor must be used when
bench testing in order to ensure proper module operation.
Caution: Performing this procedure will cause the sensor
inputs to change states. Performing this procedure is not
recommended during a live process.
Bench test procedure and sensor setting instructions
Power must be applied to both sensors to ensure proper circuit
operation. Use a 24VDC power supply with series load resistor, (2K -
6K Ω), connected to the 24VDC+.
1. Connect 24VDC+ to the CLOSED C (common) and OPEN C
(common) terminals. Connect 24VDC- to the CLOSED NO and
OPEN NO terminals.
2. Operate actuator to the closed position.
3. Press and hold SET CLOSED button until the red LED is lit
(2seconds). Release button.
4. Operate actuator to the open position.
5. Press and hold SET OPEN button until the green LED is lit
(2seconds). Release button.
6. Setpoints are retained even after power is removed.
To electrically test solenoid, apply power to the SOL PWR 1 and SOL
PWR 2 terminals only.
Note
If using only one of the sensors for valve position feedback, the closed
sensor (red) must be used.
Expanded dead band setting feature
The Prism PI sensing module has the capability of changing the dead
band of the open sensor from the factory setting of 30% of stroke
to an expanded setting of 45%. It may be necessary to perform this
procedure for applications in which the valve stroke varies between
normal batch processing and SIP/CIP evolutions.
1. Ensure the open and closed sensors have been set before running
this procedure. Valve can be in either the open or closed position.
2. With power applied to the Sensing Module press and hold both
SET OPEN and SET CLOSED buttons until the red and green LEDs
ash (ve seconds). Release buttons.
3. Press and hold SET OPEN button until the green LED is lit (one
second). Release button. Open sensor now has a 45% dead band.
4. To revert back to the factory default of 30% dead band, press and
hold both SET OPEN and SET CLOSED buttons until the red and
green LEDs ash (ve seconds). Release buttons.
5. Press and hold SET CLOSED button until red LED is lit (one second).
Release button.
6. Settings are retained even after power is removed.
Wiring diagrams
Set Open
push button
Set Closed
push button
Valve
Open LED
Solenoid
power LED
Y
G
Valve
Closed LED
R
LED indication bar
PWR
2 1
SOL OPEN CLOSEDSOL
1 NO C CNO 2
Specications
Conguration (2) N.O. 2-wire solid state sensors
Voltage range 20 - 125 VAC 50/60 Hz; 20 - 125 VDC
Minimum on current 2.0 mA
Maximum continuous current 0.1 amps
Maximum leakage current 0.5 mA
Maximum voltage drop 6.5 volts @ 10 mA
7.0 volts @ 100 mA
Circuit protection Protected against short circuits and direct
application of voltage with no load.