Installation and operating instructions for AVID ZR & ZR Plus
Contents
1. Solenoid Valve Assembly note 1 Note 1 Items 5 amp 6 are supplied with ZR Plus Control Position Monitors only ws a aN SA d 9 or ny G As SER Pentair reserves the right to change the contents without notice page 2 AVID ZR amp ZR Plus Position Monitors Installation amp Operating Instructions Technical data V3 Mechanical Switches Electrical Version SPDT form C Electrical Rating 15 amps 125 250 VAC 6 amps 24 VDC 0 5 amps 125 VDC 0 25 amps 250 VDC Proximity Type Inductive Intrinsically Safe Sensing Range 2mm Electrical Version D C voltage 2 wire in accordance DIN19234 NAMUR Hysteresis Approx 5 Nominal Voltage 8 VDC Inout Voltage Range 5 25 VDC Output Load Target Present lt 1mA Current Target Absent gt 3mA 15 mA Max Optional Proximity Type Inductive The ZR position monitor is also available with 2 amp 3 wire DC PNP NPN NO NC inductive proximity sensors 5 36 VDC and 2 wire AC DC inductive proximity sensors 20 140 AC 10 140 DO T Sensor for EEx m e Classification Electrical Version SPDT Form C Normally Open Contacts Rhodium Electrical Rating 2A 120VAC 1 5A 24VDC 1 0A 230VAC Contact Resistance 0 08 Ohms Seal Encapsulation Materials of Construction Housing Engineered Resin Cover Clear Engineered Resin Shaft Stainless Steel Fasteners Stainless Steel HiVue Copolyester ModMount Engineered Resin Area Classificati2. change the contents without notice AVID ZR amp ZR Plus Position Monitors Installation amp Operating Instructions Note All ZR Plus units are factory installed with a solenoid valve No internal installation is required General Description The solenoid valve incorporates elastomer static seals through which a shaped spool moves which are designed for 5 way operation 5 way valves are normally used to control the action of double acting cylinders The seal spacer assembly forms individual annular chambers opposite each valve port and the grooved spool either closes or allows flow between adjacent chambers The position of the spool determines which ports are open or closed The spool is moved by way of a manually or mechanically operated mechanism normally against a return spring Operation may be by application or removal of a pilot air supply acting on a pilot piston This form of control is utilized for electrical actuation where integral solenoid valves control the pilot air supply Specifications Operating Pressure 45 120 PSIG Operating Temperature 20 C to 65 C I S only 20 C to 82 C Operating Media Non Lubricated Filtered Air to 20 Microns Field Wiring Complete the electrical wiring in accordance with local and National Electrical Codes The ground wire should be secure under the green screw Check all screws for tightness If the installation is in a hazardous area all electri
3. gt PENTAIR AVID ZR Position Monitor e ModMount Actuator Figure 1 Twist cover 45 then lift straight up f a Figure 2 Top Cam Push down turn amp release Bottom Cam Lift up turn amp release Figure 3 www pentair com valves AVID ZR amp ZR Plus Position Monitors Installation amp Operating Instructions Installation and operating instructions for AVID ZR amp ZR Plus Corrosion resistant ATEX approved position monitors for General Purpose Hazardous Area and Intrinsically Safe Applications Note All AVID Products are factory equipped with Pentair direct mounting For standard Namur mounting see Appendix A Please ensure that the Pentair Keystone actuator is provided with the standard 16 dia x 11 af drive 1 Operate the actuator to full closed position 2 Fasten the ZR Position Monitor to the actuator using 4 M5 x 12 mm long socket head cap screws and 4 M5 washers while engaging its output shaft into the actuator s input fig 1 3 Loosen the 4 captive screws which fasten the ZR Position Monitor cover Twist cover approximately 45 and lift up fig 2 Wiring diagram inside ZR Position Monitor cover 4 Toset switches lift bottom cam and turn until closed switch is activated and th
4. long radius return bend used Air Flow Pipe sizes are normally determined on semi empirical lines basis for selection being an acceptable pressure drop e g not more than 10 of the applied pressure In sizing pipes consideration should be given to likely future demands as a system will be inefficient if the demand outgrows the supply It is always better to over size mains as this will reduce air velocity and make water separation more effective Air Service Equipment The importance of proper filtration 20 Micron and lubrication of the air supply to pneumatic equipment can never be over emphasized as a means of decreasing friction and preventing corrosion and wear due to moisture and abrasive solids being present in the air supply At higher pressures than recommended pneumatic equipment can wear excessively with no significant increase in output and compressed air is consequently wasted There is much to be gained therefore from providing pneumatic equipment with serviced air by including suitable air line filters pressure regulators and lubricants in the installation Pentair reserves the right to change the contents without notice AVID ZR amp ZR Plus Position Monitors Installation amp Operating Instructions Tubes and Fittings The use of copper stainless steel nylon or polyethylene tube is recommended for piping up air circuits and equipment As a general rule pipe threaded fittings should not be assembled to a s
5. cal leads must be sealed with an approved compound in accordance with local and National Electrical Codes unless the switches are hermetically sealed NEC 5051 5 Always check the nameplate to make sure the approval ratings coincide with the application CAUTION To prevent ignition of hazardous atmospheres replace cover before actuating the electrical circuits Keep cover tightly closed when in operation Air Line Designation 1 4 NPT or 1 4 BSP air ports for inlet outlet and exhaust Description of Operation Solenoid De energized air flows from Inlet Port 1 to Port 2 and exhausts from Port 4 to Ports Solenoid Energized air flows from Inlet Port 1 to Port 4 and exhausts from Port 2 to Forta Air Line Installation Considerations Air Mains and lines should be large enough to avoid excessive pressure loss under conditions of maximum flow Air lines should be installed with as few restrictions as possible if the cost of compressed air is to be kept to a minimum Sharp turns in piping should be avoided for more efficient air flow and economical air power It is advisable to pitch the mains in the direction of air flow so that both gravity and air flow will carry the water to traps or water legs located at frequent intervals To help in preventing condensed moisture from reaching the point of usage down pipes should never be taken directly from the bottom of air pipes or mains Connection should be made at the top of the main and a
6. en release Spring will push cam back onto the splined shaft Operate the actuator to the opposite extreme push down on the top cam and turn until the open switch is activated fig 3 5 Operate actuator from one extreme to the other several times to check switch operation 6 Replace housing cover Confirm that you have noted the final position of the valve full open or full closed 7 Make sure the HiVue visual display coincide with the position of the valve fig 4 8 The inner HiVue indicator should show either Open or Closed If the position indicated is the opposite of the actuator position Remove the outer indicator by removing the four 4 slot head screws and rotate the inner indicator 90 to correct the visual display 9 Secure the outer HiVue indicator to the housing cover with 4 slot head screws 10 Ensure the correct gland is installed to provide the appropriate rating Important Do not exceed 1 13 Nm of torque for each screw HiVue Valve open Valve closed Figure 4 AVDSB 0029 EN 1305 Pentair reserves the right to change the contents without notice AVID ZR amp ZR Plus Position Monitors Installation amp Operating Instructions Exploded parts list ZR amp ZR Plus parts description Item Qty Description 1 1 Housing Assembly 2 1 Shaft Assembly 3 1 Cover Assembly 4 1 Direct Mount Assembly 5 1 RFX Coil Assembly note 1 6 1 RFX
7. nections 4 Note the wire route of the coil leads and cut the wire tie that holds the coil leads to the terminal post 5 Loosen and remove the coil retaining nut 6 Turn the coil 90 so the leads are positioned from the top of the coil to the side and slide the coil off of the core tube 7 With the coil leads positioned to the right of the coil as in Step 6 slide the replacement coil over the core tube until it bottoms The lettering on the coil should be right side up with respect to the valve body 8 Install the new coil retaining nut until it is hand tight 9 Route the coil lead wires as before insuring sufficient clearance for moving parts and using the replacement wire tie affix the coil leads to the terminal post 10 Following the wiring diagram on the inside of the cover assembly insert and fasten coil lead wires into the terminal block Ensure that bare wires are clamped 11 Re install the clear exhaust tube over the barbed fittings making sure the collars are secure behind the barbed recess Valve Replacement 1 Verify that the electrical power to the coil and air supply to the valve as both off Remove all piping from the valve assembly Remove the coil as described above in the Coil Replacement procedure steps 1 6 Note If the coil is not to be replaced skip steps 3 amp 4 Remove the barbed fitting from the bottom of enclosure if damaged Remove the valve retaining nut and lock washer from the
8. on amp Approvals Weatherproof IP67 ATEX V 12 G 3DEExiallCT6 Ex II 2 G 3 D T80 C EEx me IIT 6 Conduit Entries 2 x M20 2 x 1 2 NPT 2xPG 135 Temperature Range ZR with V3 Mech 40 C to 80 C ZR Plus with V3 Mech 40 C to 80 C ZR with NJ2 V3 N 25 C to 80 C Temperature Rating 40 C to 150 C Appendix A Instructions for ZR amp ZR Plus Mounting Using Standard Namur Output 1 Remove Pentair direct mounting bracket assembly from the ZR or ZR Plus position monitor Note The ZR amp ZR Plus position monitor comes with a standard Namur output shaft 2 Replace bracket assembly with a standard Namur mounting bracket Note Standard Namur mounting bracket is not included Pentair reserves the right to change the contents without notice AVID ZR amp ZR Plus Position Monitors Installation amp Operating Instructions Dimensions mm ZR Position Monitor Pentair Direct Mounting M20 PG 13 5 1 2 NPT 2 places 98 8 ModMount Actuator 108 Side View Standard Pentair Keystone output shaft M5 Clearance Holes 0 il P p Lono Flat Dimensions mm ZR Plus Position Monitor Pentair Direct Mounting 1 4 NPT lt G1 4 ISO 228 M20 PG 13 5 pe a is 1 2 NPT 2 places P Actuator m 108 s Side View Top View Standard Pentair Keystone output shaft M5 Clearance Holes a 11 0 Flat Pentair reserves the right to
9. pecific torque because the torque required for a reliable joint varies with thread quality port and fitting materials sealant used and other factors The suggested method of assembling pipe threaded connections is to assemble them finger tight and then wrench tighten further to a specified number of turns from finger tight The assembly procedure given below is for reference only the fitting should not be over tightened for this will lead to distortion and most likely complete valve failure 1 Inspect port and connectors to ensure that the threads on both are free of dirt burrs and excessive nicks 2 Apply sealant lubricant or Teflon tape to the male pipe threads With any sealant tape the first one or two threads should be left uncovered to avoid system contamination 3 Screw the connector into the port to the finger tight position 4 Wrench tighten the connector approximately 1 2 turns to seal from finger tight Again this is only reference the fitting should NOT be over tightened Maintenance Routine maintenance is usually confined to the periodic replenishment of Dow Corning Ill lubricant or equivalent to spool and spring Coil Replacement 1 Verify that the electrical power to the coil is off 2 Carefully remove the clear exhaust tube from the fitting by sliding each collar to the middle of the tube and then sliding the tube off of the barbed ends 3 Remove the coil leads from the terminal block noting terminal con
10. valve assembly Remove the valve assembly from the conduit entry Verify that the o ring is in position on the replacement valve assembly Pass the core tube through the conduit entry and position the valve as desired increments Namur shaft details of 90 Verify that the locating pins are completely inserted into the locating holes on the enclosure 9 Replace the lock washer and valve retainer nut and tighten until lock washer is flat 10 Replace the coil as described above in the Coil Replacement procedure steps 7 11 11 Reinstall the piping to the valve assembly MN a w 8 89 T 3 98 te A 4 85 o NOJN A Pentair reserves the right to change the contents without notice
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