intelligent valve controller
INTELLIGENT
VALVE CONTROLLER
ND9200H
Rev. 2.3
Installation, Maintenance and
Operating Instructions
7 ND92H 70 en • 10/2010
2
7 ND92H 70 en
Table of Contents
1
2
3
4
5
6
7
ND9000 PRODUCT FAMILY SUMMARY ....... 3
1.1 Key features........................................... 3
ND9200H INTELLIGENT VALVE CONTROLLER
WITH HART COMMUNICATION..................... 4
2.1 General .................................................. 4
2.2 Technical description ............................ 4
2.3 Markings ................................................ 4
2.4 Technical specifications ........................ 5
2.5 Recycling and disposal ......................... 6
2.6 Safety precautions ................................. 6
TRANSPORTATION, RECEPTION AND
STORAGE ....................................................... 7
MOUNTING...................................................... 7
4.1 General .................................................. 7
4.2 Mounting on EC and EJ actuators ......... 7
4.3 Mounting on Metso actuators with
VDI/VDE mounting face ......................... 7
4.4 Mounting on linear actuator of
nelesCV Globe....................................... 8
4.5 Mounting on linear actuator with IEC 60534
mounting face ........................................ 8
4.6 Piping..................................................... 9
4.7 Electrical connections.......................... 12
LOCAL USER INTERFACE (LUI) ................. 13
5.1 Measurement monitoring ..................... 13
5.2 Guided start-up.................................... 13
5.3 Configuration menu ............................. 14
5.4 Mode menu.......................................... 14
5.5 Configuration parameters .................... 15
5.6 Valve travel calibration......................... 17
5.7 Special displays................................... 18
5.8 HART write protection.......................... 19
MAINTENANCE............................................. 20
6.1 Prestage............................................... 20
6.2 Spool valve .......................................... 20
6.3 Flame arrestor assembly ..................... 21
6.4 Diaphragms ......................................... 21
6.5 Communication board ......................... 21
ERROR MESSAGES..................................... 22
7.1 Failsafe errors ...................................... 22
8
9
10
11
12
13
14
15
7.2 Alarms.................................................. 22
7.3 Errors ................................................... 22
7.4 Warnings.............................................. 23
7.5 Notifications ......................................... 23
TROUBLE SHOOTING.................................. 24
ND92_H/K00 and ND92_H/I00
(WITH LIMIT SWITCHES) ............................. 25
9.1 Introduction.......................................... 25
9.2 Installing ND92_H/K00 and ND92_H/I00
on a valve controller............................. 26
9.3 Electrical connections.......................... 26
9.4 Adjustment........................................... 26
9.5 Removal of the limit switches ND92_H/K00
and ND92_H/I00 for accessing the
valve controller..................................... 26
9.6 Circuit diagrams .................................. 27
9.7 Maintenance ........................................ 27
TOOLS........................................................... 27
ORDERING SPARE PARTS ......................... 27
DRAWINGS AND PARTS LISTS .................. 28
12.1 Exploded view and parts list,
ND9200H ............................................. 28
12.2 Exploded view and parts list,
ND92_H/K_, ND92_H/I___ .................. 30
12.3 Mounting parts for EC05-14/EJ05-14
actuators, rising signal opens valve .... 32
12.4 Mounting parts for B1C/B1J 6-20
actuators .............................................. 32
12.5 Mounting parts for B1C/B1J 25-50,
B1C 502 and B1J322 actuators........... 33
12.6 Mounting parts for Quadra-Powr®
actuators .............................................. 33
12.7 Mounting parts for linear actuators
of nelesCV Globe................................. 34
12.8 Mounting parts for linear actuators...... 35
12.9 Connection diagrams .......................... 36
DIMENSIONS ................................................ 39
EC DECLARATION OF CONFORMITY ........ 41
TYPE CODING .............................................. 42
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about the safe handling and operation of the intelligent valve 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.
7 ND92H 70 en
1
1.1
❑
❑
❑
❑
❑
❑
❑
ND9000 PRODUCT FAMILY SUMMARY
Key features
Benchmark control performance on rotary and
linear valves
Reliable and robust design
Ease of use
Language selection: English, German and French
Local / remote operation
Expandable architecture
Advanced device diagnostics including
❑ Self-diagnostics
❑ Online diagnostics
❑ Performance diagnostics
❑ Communication diagnostics
❑ Extended off-line tests
❑ Dynamic Diagnostics Diamond
3
❑
❑
❑
❑
❑
❑
1.1.1 Options
❑
❑
❑
❑
❑
Interchangeable communication options:
❑ HART
❑ FOUNDATION Fieldbus
❑ Profibus PA
Limit switches
Position transmitter (in HART only)
Special corrosion resistant finish
Exhaust adapter
❑
1.1.2 Total cost of ownership
❑
❑
❑
❑
Low energy and air consumption
Future proof design allows further options at a
reduced cost
Optimised spares program. Reduced number of
spares
Retro-fit to existing installations (Neles or 3rd party)
1.1.3 Minimised process variability
❑
❑
❑
❑
Linearisation of the valve flow characteristics
Excellent dynamic and static control performance
High-speed of response
Accurate internal measurements
❑
❑ FOUNDATION Fieldbus ITK version 5.01 certified
❑ Profibus PA profile version 3.0 PNO certified
Easy to upgrade; can be done by replacing the
HART communication board to fieldbus communication board
Excellent maintainability with firmware download
feature
Advanced communication diagnostics
Digital communication via the fieldbus includes
not only the set point, but also the position feedback signal from the position sensor. No special
supplementary modules for analog or digital
position feedback are needed when using the
fieldbus valve controller.
Back up LAS functionality available in FOUNDATION Fieldbus enviroment
Input selector and output splitter blocks available
in FOUNDATION Fieldbus devices allowing
advanced distributed control
Multipurpose functionality
❑ Standard function blocks enables the freedom
to use ND9000 intelligent valve controller either
in continuous or on-off control applications
❑ Open and close information directly available
via the fieldbus
❑ Open and close detection is based on either
position measurement (soft limit switch) or
mechanical limit switch information
ND9000 download page:
www.metso.com/automation/nd9000
1.1.7 ND9000 mounting on actuators and
valves
❑
❑
❑
❑
❑
Mounted on single and double acting actuators
Both rotary and linear valves
Flush mounting capability
Ability to attach options to electronics and
mechanics later
Possibility to mount also on valves that are in
process with 1-point calibration feature
1.1.4 Easy installation and configuration
1.1.8 Product reliability
❑
❑
❑
❑
❑
Same unit for linear and rotary valves, double
and single-acting actuators
Simple calibration and configuration
❑ using Local User Interface
❑ using FieldCare software in a remote location
Flush mounting capability to avoid tubing and
mounting parts
Low power design enables installation to all common control systems
❑
1.1.5 Open solution
Metso is committed to delivering products that freely interface with software and hardware from a variety of manufacturers; and the ND9000 is no exception. This open
architecture allows the ND9000 to be integrated with other
field devices to give an unprecedented level of controllability.
❑
FDT based multi-vendor support configuration
ND9000 DTM download page:
www.metso.cm/automation/nd9000
1.1.6 ND9000 in fieldbus networks
❑
Approved interoperability
❑ Host interoperability ensured
Designed to operate in harsh environmental conditions
❑ Rugged modular design
❑ Excellent temperature characteristics
❑ Vibration and impact tolerant
❑ IP66 enclosure
❑ Protected against humidity
Maintenance free operation
❑ Resistant to dirty air
❑ Wear resistant and sealed components
❑ Contactless position measurement
1.1.9 Predictive maintenance
❑
Easy access to collected data with FieldCare software
❑ Ingenious Valve Diamond to visualise control
valve performance and diagnostics
❑ Logical trend and histogram collection
❑ Information collected on service conditions
❑ Extensive set of off-line tests with accurate
key figure calculations
❑ Fast notifications using on-line alarms
❑ Condition monitoring tool available
❑ Real time monitoring of valve control parameters
4
7 ND92H 70 en
2
ND9200H INTELLIGENT VALVE
CONTROLLER WITH HART
COMMUNICATION
2.1
General
This manual incorporates Installation, Maintenance and
Operation Instructions for the Metso ND9200H intelligent
valve controller. The ND9200H may be used with either
cylinder or diaphragm type pneumatic actuators for
rotary or linear valves.
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.
2.2
Technical description
The ND9200H is a 4–20 mA loop-powered microcontroller-based intelligent valve controller. The device operates
even at 3.6 mA input signal and communicates via HART.
The device contains a Local User Interface enabling
local configuration. A PC with FieldCare software can be
connected to the ND9200H itself or to the control loop.
Fig. 1
2.3
The principle of operation
Markings
The valve controller is equipped with an identification
plate sticker (Fig. 2).
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
❑
Spool valve position
❑
Device temperature
Advanced self-diagnostics guarantees that all measurements operate correctly. Failure of one measurement
does not cause the valve to fail if the input signal and
position measurements are operating correctly. After
connections of electric signal and pneumatic supply the
micro controller (µC) reads the input signal, position sensor (α), pressure sensors (Ps, P1, P2) and spool position
sensor (SPS). A difference between input signal and
position sensor (α) measurement is detected by the control algorithm inside the µC. The µC calculates a new
value for prestage (PR) coil current based on the information from the input signal and from the sensors.
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
diaphragm actuator and opens the flow out from the
other side of the actuator. The increasing pressure will
move the diaphragm piston. The actuator and feedback
shaft rotate clockwise. The position sensor (α) measures
the rotation for the µC. The µC using control algorithm
modulates the PR-current from the steady state value
until a new position of the actuator according to the input
signal is reached.
Fig. 2
Example of the identification plate
Identification plate markings include:
❑
Type designation of the valve controller
❑
Revision number
❑
Enclosure class
❑
Input signal (voltage range)
❑
Input resistance
❑
Maximum supply voltage
❑
Operational temperature
❑
Supply pressure range
❑
Contact details of the manufacturer
❑
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: PH10011234 = controller, year 2010, week 1,
consecutive number 1234.
7 ND92H 70 en
2.4
5
Technical specifications
ND9200H INTELLIGENT VALVE 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.
Flush mounting on nelesCV™ control valves.
Action:
Travel range:
Double or single acting
Linear; 10–120 mm with standard IEC parts.
Larger strokes possible with suitable kits
Rotary; 45–95°.
Measurement range 110° with freely
rotating feedback shaft.
Environmental influence
Standard temperature range:
-40° to +85 °C / -40° to +185 °F
Influence of temperature on valve position:
< 0.5 % / 10 °K
Influence of vibration on valve position:
< 1 % under 2g 5–150 Hz,
1g 150–300 Hz, 0.5g 300–2000 Hz
Enclosure
Material:
Anodised aluminium alloy and
polymer composite
Protection class: IP66, NEMA 4X
Pneumatic ports: 1/4 NPT
Electrical connection: max. 2.5 mm2
Cable gland thread: M20 x 1.5 (E1), 1/2 NPT (E2)
Weight:
3.4 kg / 7.5 lb
Mechanical and digital position indicator visible
through the main cover
Special corrosion resistant finish available
Pneumatics
Supply pressure: 1.4–8 bar / 20–115 psi
Effect of supply pressure on valve position:
< 0.1 % at 10 % difference in inlet pressure
Air quality:
According to ISO 8573-1:2001
Solid particles: Class 5
(3–5 µm filtration is recommended)
Humidity: Class 1
(dew point 10 °C/50 °F below minimum
temperature is recommended)
Oil class: 3 (or <1 ppm)
Capacity with 4 bar / 60 psi supply:
5.5 Nm3/h / 3.3 scfm (spool valve 2)
12 Nm3/h / 7.1 scfm (spool valve 3)
38 Nm3/h / 22.4 scfm (spool valve 6)
Consumption with 4 bar / 60 psi supply
in steady state position:
< 0.6 Nm3/h / 0.35 scfm (spool valves 2 & 3)
< 1.0 Nm3/h / 0.6 scfm (spool valve 6)
Electronics
Supply power:
Minimum signal:
Current max :
Loop powered, 4–20 mA
3.6 mA
120 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
Performance with moderate constant-load,
actuators EC05-EC10
Values at 20 °C / 68 °F and without any additional instruments, such as boosters or quick exhaust valves etc.
Dead band acc. to IEC 61514:
≤ 0.1 %
Hysteresis acc. to IEC 61514:
< 0.5 %
Local user interface functions
❑
❑
Local control of the valve
Monitoring of valve position, input signal, temperature, supply and actuator pressure difference
❑
Guided start-up function
❑
LUI may be locked remotely to prevent unauthorised access
❑
Calibration: Automatic/Manual
❑
1-point calibration
❑
Control configuration: aggressive, fast, optimum,
stable, maximum stability
❑
Mode selection: Automatic/Manual
❑
Rotation: valve rotation clockwise or counterclockwise to close
❑
Dead angle
❑
Low cut-off, cut-off safety range (default 2 %)
❑
Positioner fail action, open/close
❑
Signal direction: Direct/reverse acting
❑
Actuator type, double/single acting
❑
Valve type, rotary/linear IEC/nelesCV Globe/FLI
❑
Language selection: English, German and French
Approvals
Flameproof, explosion proof and dust exclusion
ATEX
II 2 G Ex d IIC T4...T6
(EN 60079-0:2006, EN 60079-1:2004)
II 2 D Ex tD A21 IP66 T100 °C
(EN 61241-0:2006, EN 61241-1:2004)
Certificate KEMA 04ATEX2098 X
IECEx
Ex d IIC T4...T6
(IEC 60079-0:2004, IEC 60079-1:2003)
Ex tD A21 IP66 T100 °C
(IEC 61241-0:2004 and IEC 61241-1)
Certificate IECEx KEM 10.0055X
Pending
CSA
Explosion proof Class I, II and III,
Division 1 and 2, Groups B, C, D, E, F
FM
Explosion proof Class I, II and III,
Division 1 and 2, Groups A, B, C, D, E, F
INMETRO
BR-Ex d IIC, T4/T5/T6, IP66
(IEC 60079-0/00, IEC 60079-1/01,
NBR 9518/97, NBR 5363/98, IEC 60529/01)
TIIS (JIS)
Ex d II C T6
Pending
6
7 ND92H 70 en
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
POSITION TRANSMITTER (optional)
Output signal:
4–20 mA (galvanic isolation;
600 V DC)
Resolution:
16 bit / 0.244 µA
Linearity:
<0.05 % FS
Temperature effect:<0.35 % FS
EEx d IIC T4/T5/T6
Ui ≤ 30 V
Rx= 0–780 Ω
PROXIMITY SENSORS AND MICRO SWITCHES, 2 PIECES
(OPTIONAL WITH EXTENSION MODULE)
Code I02 P+F NJ2-12GK-SN
Code I09 P+F; NCB2-12GM35-N0
Code I56 IFC 2002-ARKG/UP
Code K05 Omron D2VW-5, micro switch
Code K06 Omron D2VW-01 gold plated, micro switch
2.5
Recycling and disposal
Most valve controller parts can be recycled if sorted
according to material.
Most parts have material marking. A material list is supplied 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 manufacturer for recycling and disposal. There will be a charge
for this.
2.6
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 ND9200H leads to uncontrolled pressure release. Always shut off the supply air and release
the pressure from the pipelines and equipment before
removing or dismantling the controller. Otherwise personal injury and damage to equipment may result.
WARNING:
During automatic or manual 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.
Ex WARNING:
Electrostatic charge hazard!
The windows and identification plate are non-conductive. Clean with a damp cloth only!
Ex WARNING:
The locking screw (part 107) of the cover is essential to explosion protection.
The cover has to be locked in place for Ex d protection. The
screw grounds the cover to the housing.
Ex d WARNING:
Do not open the device when energized!
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.
Ex tD WARNING:
Accumulation of dust shall be avoided!
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 ND9200H valve controller.
Damage to the equipment may result.
7 ND92H 70 en
3
TRANSPORTATION, RECEPTION AND
STORAGE
7
❑
The valve controller is a sophisticated instrument, handle it with care.
❑
❑
❑
❑
❑
❑
❑
❑
Check the controller for any damage that may
have occurred during transportation.
Store the uninstalled 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.
4
MOUNTING
4.1
General
NOTE:
The enclosure of ND9200H intelligent valve controller
meets the IP66 protection class according to EN 60529
in any position 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 warranty is not valid.
If the ND9200H is supplied with valve and actuator, the
tubes are mounted and the ND9200H 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-ND9206HN
Mount the O-rings (38, 4 pcs.) into the air connections in the bottom of the controller and the
mounting plate (64).
Install the mounting plate (64) on the actuator as
shown in 12.2 .
Place the valve controller on top of the actuator
so that the pointer is located in the position
shown in Fig. 5.
Fasten the screws (4).
❑
O-rings
Fig. 3
4.3
Mounting on Metso actuators with
VDI/VDE mounting face
See figures in Section 12.3 -12.5.
❑
Mount the H-shaped coupling (47) to the shaft.
Apply the thread-locking compound to the screw
(48) and tighten firmly.
Remove the protective plastic plugs from pneumatic connections C2, S and C1. Leave the metal
plugs (54) in the unused connections at the bottom of the controller.
BJ and other single acting actuators: install a
metal plug (53) with sealant to the C1 connection.
Set the direction arrow of the actuator in the
direction of the valve closure member and attach
the ear (2) to the indicator cover in the position
shown in Section 12.3. Secure the screw of the
ear using e.g. Loctite and tighten firmly.
Attach the bracket (1) to the ND9200H.
Attach the bracket (1) to the actuator. The shaft
coupling of the ND9200H must fit into the ear (2)
so that the pointer is located in the position
shown in Fig. 4.
❑
❑
❑
The controller is equipped with the Metso flush mounting
face, the old Neles mounting face and for connection
according to VDI/VDE 3845.
Shaft coupling alternatives for the controller for Metso
actuators are shown in Fig. 5.
❑
❑
For mounting parts for Metso actuators, see 12.2 - 12.7.
4.2
Mounting on EC and EJ actuators
Mounting on EC and EJ actuators
See figure in Section 12.2.
❑
❑
Mount the U-shaped coupling (47) to the shaft.
Apply thread-locking compound to the screws
(48) and tighten firmly.
Remove the protective plastic plugs from pneumatic connections C2, S and C1. Mount the
metal plugs (53) to the unused controller connections with sealant.
For EC (double acting) actuators, remove the
metal plugs (54, 2 pcs) from the connections at
the bottom of the controller.
For EJ (single acting, spring to close) and EJA
(single acting, spring to open) actuators, leave
the metal plug (54) in the C1 connection at the
bottom of the controller and remove the metal
plug from the C2 connection at the bottom.
C2
11
S
C1
Fig. 4
The pointer on the coupling must
stay in this sector
Mounting on Metso actuator with VDI/VDE
mounting face
8
7 ND92H 70 en
4.4
Mounting on linear actuator of
nelesCV Globe
See figure in Section 12.6
❑
Attach the J-shaped feedback lever (47) to the
valve controller shaft. Apply the thread-locking
compound to the screws and tighten firmly.
Remove the protective plastic plugs from pneumatic connections C2, S and C1. Mount the
metal plugs (53) to the unused controller connections with sealant.
Leave metal plug (54) in the connection C1 at the
bottom of the controller. Remove the metal plug
(54) from the C2 connection at the bottom. Mount
the O-rings (38, 2 pcs.) to the connections.
Attach the mounting plate (64) to the valve controller with screws (65).
Mount the O-rings (38, 2 pcs.) and attach the
mounting plate (39) to the valve controller with
screws (28).
Mount the conical plug (16) to the lever and select
the position on the scale according to the valve
stroke.
Install the O-ring (31) to the actuator. Place the conical plug into the frame on the stem and tighten the
screws (4).
❑
❑
❑
❑
❑
❑
4.5
Mounting on linear actuator with IEC
60534 mounting face
See figure in Section 12.7
❑
Attach the feedback arm with spacer to the valve
controller shaft. Note the position of the pointer
on the shaft as in 12.7. Apply thread locking
compound to the screws and tighten firmly.
Attach the spring to the feedback arm as shown
in Section 12.7.
❑
❑
❑
❑
❑
❑
❑
❑
❑
VDI/VDE 3845 mounting
Mount the valve controller mounting bracket
loosely to the yoke of the actuator.
Remove the protective plastic plugs from pneumatic connections C2, S and C1. Leave the metal
plugs (54) in the unused connections at the bottom of the controller. Single acting actuators:
install a metal plug (53) with sealant to the C1
connection.
Mount the valve 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 valve controller with the
actuator stem and adjust their position so that the
feedback arm is approximately at a 90° angle to the
actuator stem (in the mid-stroke position).
Tighten the valve controller mounting bracket
screws.
Adjust the distance of the valve 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 12.7. 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 valve controller is in right
angle and tighten all the mounting bolts.
Ensure that the valve controller complies with
previous steps. Check that the actuator pin does
not touch the valve controller 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 contact surfaces of the actuator pin and the feedback arm to reduce wear.
nelesCV Globe mounting
45°
45°
shaft end
shaft end
1520
pointer
pointer
mark on
housing
mark on
housing
EC/EJ flush mounting
IEC 60534 mounting
45°
45°
shaft end
shaft end
pointer
pointer
mark on
housing
mark on
housing
Fig. 5
Shaft coupling alternatives
30
7 ND92H 70 en
4.6
Piping
CAUTION:
Do not exceed the permitted supply pressure of
the ND9200H!
Table 2 provides the recommended tube sizes in
accordance with actuator sizes. Tube sizes are the minimum values allowed. Operating times may be tested by
the FieldCare software.
Connect the air supply to S (1/4 NPT ).
Connect C1 and C2 (1/4 NPT) to the actuator, see Fig. 6.
ND9200H is connected direct to the EC or EJ actuator.
Connections C1 and C2 (1/4 NPT) must be plugged, see
12.2.
Liquid sealants, such as Loctite 577 are recommended
for the pipe threads.
NOTE:
A valve controller mounted on a spring actuator must
be connected only as single-acting. See Fig. 6.
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.
The air supply must be clean, dry and oil-free instrument
air, see Section 2.4.
Table 1 Spring rates
Actuator type
Spring rate (bar/psi)
B1JK
3 / 43
B1J
4.2 / 61
B1JV
5.5 / 80
QPB
3 / 43
QPC
4.3 / 62
QPD
5.6 / 81
EJK
3 / 43
EJ
4 / 57
EJV
5 / 72
Adjust regulator pressure to a level that is max 1 bar (14.5 psi)
+ spring rate.
9
10
Table 2
EC
05
07
10
12
14
16
25
EJ
05
07
10
12
14
16
25
B1C
6
9
11
13
17
20
25
32
40
50
502
B1J
B1JA
8
10
12
16
20
25
32
322
QP
1
2
3
4
5
6
7 ND92H 70 en
Piping
Actuator
Stroke vol.
dm3 / in3
0.09 / 5
0.2 / 12
0.5 / 31
1.2 / 73
3.0 / 183
7.7 / 470
20.5 / 1250
Stroke vol.
dm3 / in3
0.18 / 11
0.4 / 24
1 / 61
2.4 / 145
6 / 366
15 / 915
41 / 2500
Stroke vol.
dm3 / in3
0.3 / 18
0.6 / 37
1.1 / 67
2.3 / 140
4.3 / 262
5.4 / 330
10.5 / 610
21 / 1282
43 / 2624
84 / 5126
195 / 11900
Stroke vol.
dm3 / in3
0.9 / 55
1.8 / 110
3.6 / 220
6.7 / 409
13 / 793
27 / 1648
53 / 3234
106 / 6468
Stroke vol.
dm3 / in3
0.62 / 37
1.08 / 66
2.18 / 133
4.34 / 265
8.7 / 531
17.5 / 1068
Actuator piping
10
1/4
Spool valve
G
6
3/8
1/4
1/4
1/4
1/4
1/4
3/8
3/8
x
x
x
x
G
6
1/4
1/4
1/4
1/4
1/4
3/8
3/8
x
x
x
NPT
6
1/4
1/4
3/8
3/8
1/2
1/2
1/2
3/4
3/4
1
1
x
x
(x)
NPT
6
10
1/4
3/8
3/8
3/8
1/2
1/2
3/4
3/4
1
1
(x)
x
x
x
x
x
x
x
x
(x)
x
x
x
x
x
x
x
x
NPT
6
10
1/4
3/8
3/8
3/8
3/8
3/8
3/8
3/4
(x)
(x)
x
x
x
x
x
x
(x)
(x)
x
x
x
x
x
x
x
x
x
x
x
x
x
10
x
x
x
1/4
3/8
x
x
x
x
x
x
x
10
x
x
x
x
x
x
x
x
x
x
x
x
x
1/4
x
x
(x)
3/8
x
x
x
x
x
x
x
x
x
Air supply piping 10 mm or 3/8" for all actuators.
Pipe sizes are nominal, i.e. approximately outer diameter. Inner diameter is typically 2 mm smaller.
x = Standard pipe size used in Neles control valves.
(x) = Minimum pipe size (if smaller than standard).
*) Spool size 2 is preferred for accurate control and standard for Neles control valves.
Spool size 3 can be used if fast full stroke times are required.
2
2
3
3
6
6
6
Spool valve
2
2, 3*
3
3
6
6
6
Spool valve
2, 3*
3
3
3
6
6
6
6
6
6
6
Spool valve
3
3
6
6
6
6
6
6
Spool valve
2, 3*
3
3
6
6
6
7 ND92H 70 en
11
DOUBLE-ACTING ACTUATOR
1. Increasing input signal to open valve (shown)
Default setting:
DIR = OPE
ROT = cC (close valve to clockwise)
ATYP = 2-A
PFA = CLO
A0, CUTL and VTYP according to valve type
C2
S
C1
2. Increasing input signal to close
. valve (not recommended)
Default setting:
DIR = CLO
ROT = cC (close valve to clockwise)
ATYP = 2-A
PFA = CLO
A0, CUTL and VTYP according to valve type
DOUBLE-ACTING ACTUATOR, REVERSED PIPING
3. Increasing input signal to open valve (not recommended)
Default setting:
DIR = OPE
ROT = cC (close valve to clockwise)
ATYP = 2-A
PFA = OPE
A0, CUTL and VTYP according to valve type
C2
S
C1
4. Increasing input signal to close
. valve (shown)
Default setting:
DIR = CLO
ROT = cC (close valve to clockwise)
ATYP = 2-A
PFA = OPE
A0, CUTL and VTYP according to valve type
SINGLE-ACTING ACTUATOR, SPRING TO CLOSE
5. Increasing input signal to open valve (shown)
Default setting:
DIR = OPE
ROT = cC (close valve to clockwise)
ATYP = 1-A
PFA = CLO (must be in the spring direction)
A0, CUTL and VTYP according to valve type
C2
S
C1
6. Increasing input signal to close valve (not recommended)
Default setting:
DIR = CLO
ROT = cC (close valve to clockwise)
ATYP = 1-A
PFA = CLO (must be in the spring direction)
A0, CUTL and VTYP according to valve type
SINGLE-ACTING ACTUATOR, SPRING TO OPEN
7. Increasing input signal to close valve (shown)
Default setting:
DIR = CLO
ROT = cC (close valve to clockwise)
ATYP = 1-A
PFA = OPE (must be in the spring direction)
A0, CUTL and VTYP according to valve type
C2
S
C1
8. Increasing input signal to open valve (not recommended)
Default setting:
DIR = OPE
ROT = cC (close valve to clockwise)
ATYP = 1-A
PFA = OPE (must be in the spring direction)
A0, CUTL and VTYP according to valve type
Fig. 6
Operation directions and air connections
12
4.7
7 ND92H 70 en
Electrical connections
The ND9200H is powered by a standard 4–20 mA current loop that also functions as a carrier to the HART
communication.
HART connection
The input signal cable is led through a M20 x 1.5 (E1)/
1/2 NPT (E2) cable gland. Connect the conductors to the
terminal strip as shown in Fig. 7. It is recommended that
the earthing of the input cable shield be carried out from
the DCS end only.
The position transmitter is connected to 2-pole terminal
PT as shown in Fig. 7. The position transmitter needs an
external power supply. The ND9200H and the position
transmitter circuits are galvanically isolated and withstand a 600 VAC voltage.
Fig. 7
Terminals
Please note following before mounting the cover of
the valve controller:
❑
❑
Attach the LUI (223) cabling to the sticker on the
reverse side of the LUI.
Check that the cabling does not get squeezed by
the electronics cover (39) or the device cover
(100).
Check using a feeler gauge that the clearance
between the position indicator (109) and the
electronics cover is 1 mm.
NOTE:
The ND9200H equals a load of 475 Ω in the current
loop.
NONHAZARDOUS LOCATION
Control
system
HAZARDOUS LOCATION
Position Transmitter
Uout max 30 V
ND9200H_T
Control
system
Uout max 30 V
Fig. 8
Control wiring
7 ND92H 70 en
5
13
LOCAL USER INTERFACE (LUI)
The local user interface may be used to monitor the
device behaviour as well as configuring and commissioning the controller during installation and normal
operation. The local user interface consists of 2 row LCD
and 4 button keypad interface. There are also custom
graphical characters for special conditions.
Fig. 9
5.1
user to view all the measurements through the window of
the main cover.
Local user interface (LUI)
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.
— continuous push
— brief push
Fig. 10
5.2
Table 3
Default / optional units of measurements
Measurement
valve position
target position
Default unit
Percentage of full
scale
Percentage of full
scale
mA
current loop
setpoint
actuator
bar
pressure
difference
supply pressure bar
device
°Celcius
temperature
Optional unit
Angle, where 0%
refers to 0 (angle)
none
Percentage of full
scale
psi
psi
°Fahrenheit
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 selection by pressing + or - while keeping the ? key
pressed down. When the buttons are released the current 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 measurements will start scrolling on the display. This enables the
Measurement unit change
Guided start-up
Guided startup offers a fast view of the most critical
parameters of the ND9200H 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 5.5:
Valve type
Actuator type
Positioner fail action
Valve rotation direction
Valve dead angle
VTYP
ATYP
PFA
ROT
A0
If you modify any of the parameters you will also need to
calibrate and tune the device. See 4.6 for detailed
description.
14
7 ND92H 70 en
— brief push
Fig. 11
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.
5.3
Configuration menu
The local user interface is organised in a menu structure. 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.
5.4
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.
5.4.1 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.
— brief push
Fig. 12
Configuration
5.4.2 MAN
During this mode the valve position may be controlled
manually by using the keyboard and pressing the + or buttons. The position of the manually driven valve is not
saved in the memory of the controller, i.e. the valve will not
return to the same position after signal failure. However, the
valve may be driven back into position after signal failure
by using + and - keys.The manual control starts from
the current position of the valve after the MAN-mode is
activated. In order to change the manual setpoint return to
the measurement monitoring view and go to target position
measurement. Press the ? key shortly to activate the target position editing, text TPOS starts to blink and now you
are able to edit the setpoint by pressing + or - button.
The setpoint changes in 0.1 % increments/decrements in
spite of the selected unit and the valve starts to move
immediately. A continuous push changes the setpoint
faster. In order to view other measurements, press the ?
or = keys and select a measurement. Repeat the previous steps if you would like to alter the setpoint value again.
7 ND92H 70 en
15
❑
❑
Modify the parameter value by pressing + or keys alternately until the desired value appears
on the display.
After the desired value is displayed, press the
key ? to conclude the operation.
5.5.3 Signal direction, DIR
Fig. 13
Setpoint change in MAN mode
The opening and closing direction of the valve with raising current loop signal is defined by signal direction
parameter DIR.
❑
When PAR is on the display you may enter the configuration menu by pressing the ? key. In this menu the most
important configuration and signal modification parameters 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.
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. 6.
5.5.1 Performance level, PERF
5.5.4 Valve type, VTYP
If you want to change the tuning of the valve position
control, the PERF selection is available. The default factory value is C.
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.
5.5
Configuration parameters
❑
Once PERF is displayed press the ? key to
enter the edit state and PERF starts to blink.
Select between five values by pressing the + or
- key.
❑
Table 4
Performance level
Selection
Meaning
Aggressive
Description
Immediate response to
signal changes, overshoots
Fast
Fast response to signal
b
changes, small overshooting
Optimum
Very small overshoot with
C
minimum step response
time
Stable
No overshooting, slow
d
response to input signal
changes
Maximum stability No overshooting,
E
deadband may increase,
slow but stable behaviour
For use with volume boosters and/or very fast actuators,
additional performance levels A1 to D1 can be used.
Characteristics of these extended levels are the same as
those in the table above. However, with performance level
settings A1 to D1, adaptive properties of the ND9000
control algorithm are disabled.
A
❑
After the desired value is displayed, press the
key ? to conclude the operation
5.5.2 Low cut-off, CUTL
Low cut-off safety range CUTL ensures the valve closing
against mechanical travel stops. The factory default
value is 2 %.
❑
Once CUTL is displayed press the ? key to
enter the edit state and the CUTL will start to
blink. The currently selected value appears as a
percentage (%) on the display
❑
❑
❑
After selecting VTYP on the display, press the ?
key to enter the edit state and the VTYP starts to
blink.
Select between four values rot, LIn, nCG or FLI
using the + and - keys. The value rot indicates a rotary valve and LIn a linear valve. Use
nCG only for nelesCV Globe valves to accommodate special linkage geometry. Use FLI only for
linear valves when linkage geometry is needed to
be corrected by valve controller.
To conclude press the ? key when the desired
value is shown on the display.
NOTE:
Perform valve calibration and tuning always when
VTYP has been changed.
5.5.5 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-A or 1-A using the +
and - keys. The value 2-A indicates a double
acting actuator and 1-A a single acting actuator.
To conclude press the ? key when the desired
value is shown on the display.
NOTE:
Perform valve calibration and tuning always when
ATYP has been changed.
16
7 ND92H 70 en
5.5.6 Positioner fail action, PFA
Table 5
Positioner fail action will take place in case of signal
failure or when the controller software discovers a fatal
device failure. For single acting actuators set value in
the spring direction. For double acting actuators see
Fig. 6 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
NOTE:
Perform valve calibration and tuning always when controller fail action parameter has been changed.
Valve
size
Dead angle in percentage
Valve series
MBV MBV D,
QMBVQMBV P,
1)
2)
C
mm
in
15
1/2
20
3/4
25
1
T5, QX- T25, QX- R,
QT5 T5 QT25 T25 QR
E
R- FL
SOFT
3)
15
15
14
-
-
25.5 19.5
-
-
15
25.5
27
14.5
25/2 1/2
8
11 16.5
25/3 1/3
8
10
25/4
8
40 1 1/2 12
-
50
9
2
10
-
24.5 12.5
-
13.5 24.5 12.5 18
65 2 1/2
9
-
-
-
-
80
3
10
8
12
18
8
100
4
10
8
12
125
5
12
-
-
-
150
6
10
8
11.5
200
8
9
7
8.5
16.5 8.5
-
11
15
-
12
16
21
12.5
8
17
20.5
23
12.5
-
13
-
18
16.5 8.5
9
8.5 15.5
16
9
8
7
14.5
-
12
6.5
8
-
16
9
13.5
8
13.5
12
6.5
9.5
7
11.5
10.5
8.5
9.5
13
10
9
7
7.5 13.5
9.5
7
300
12
8
6
6.5
9.5
7.5
6
9.5
350
14
6
6
-
5
9.5
The application-specific parameter ROT defines the relationship between position sensor rotation and valve
action.
400
16
5
5.5
9.5
(14")
5
9.5
450
18
6
7.5
(16")
❑
500
20
6
4.5
600
24
5.5
6
650
26
7
700
28
7
750
30
6
800
32
-
900
36
5.5
❑
12.5
25/1 1/1
250
❑
4)
Dead angle, %
5.5.7 Valve rotation direction, ROT
Once ROT is displayed press the ? key to enter
the edit state and ROT starts to blink.
Now you may select between two values by
pressing the + or - key. The value cC indicates
clockwise rotation for closing the valve and ccC
means counterclockwise to close.
After the desired value is displayed, press the
key ? to conclude the operation.
ZX
6
1) Seat supported 2) Trunnion 3) Soft seated R-valve 4) Low Cv Finetrol
NOTE:
Perform valve calibration and tuning always when ROT
has been changed.
5.5.8 Valve dead angle, A0
The α0 setting is made for Metso segment and ball valves.
This setting takes into account the "dead angle" α0 of the
ball valves. The entire signal range is then used for effective valve opening 90° - α0. Use 0 % as the "dead angle"
for the valves not mentioned in Table 5.
Increasing input signal closes valve
Increasing input signal opens valve
Fig. 15
❑
POSITION
100
80
❑
60
40
❑
20
α0
α0
0
0
20
40
60
80
cut-off safety range 2 ± 0.5 %
= Basic setting
Fig. 14
Principle of setting
100
INPUT SIGNAL
= α0 setting
Dead angle
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 percentage (%) 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.
5.5.9 Low cut-off, low limit, high cut-off,
high limit
ND9200H supports signal cut-off and limiting in both
ends of the operating range. The configuration parameters are; low cut-off, low limit, high cut-off and high limit.
7 ND92H 70 en
❑
If the input signal is smaller than low cut-off,
valve will be fully closed.
❑
If the input signal is smaller than low limit,
valve stays in the low limit.
❑
If the input signal is greater than high cut-off,
valve will be fully opened.
❑
If the input signal is greater than high limit,
valve stays in the high limit.
The cut-off overrides the limit as follows:
17
the
the
the
the
❑
If the low cut-off > low limit, the low limit is not
active.
❑
If the low cut-off < low limit, both low cut-off and
limit are active.
❑
If the low cut-off is set to zero, the low cut-off is
not active.
❑
If the high cut-off < high limit, the high limit is not
active.
❑
If the high cut-off > high limit, both high cut-off
and limit are active.
❑
If the high cut-off is set to 100 %, the high cut-off
is not active.
Only the low cut-off is adjustable using the LUI. Low
limit, high cut-off and high limit are configurable via
FieldCare software.
5.5.10Language selection, LANG
❑
❑
Select between three languages EnG, GEr or FrE
using the + and - keys.
To conclude press the ? key when the desired
value is shown on the display.
Fig. 16
5.6
Valve travel calibration
During the calibration the ND9000 controller searches
for optimum internal control parameters for the valve
position control. Also it defines open and close ends.
After the calibration sequence is finished, press the =
key to get back to the measurement view.
You may interrupt the calibration sequences at any time
by pressing the = key, then device returns to basic
measurement display. Calibration parameters will not
be changed if calibration is cancelled or failed. If calibration fails, LUI and DTM event log shows error message. See Chapter 7 for more information. The
calibration will not alter the PERF parameter.
Select CAL from the menu by using + or - keys and
press the ? key. Define the calibration type AUTO, MAN,
1PT CAL, LCAL 3P or LCAL 9P, see Fig. 16. In case of
LCAL 3P and LCAL 9P, see more information from
5.6.4.
When CAL menu from the LUI is opened again, the last
started travel calibration will be showed first on the list.
NOTE:
If AUTO CAL, MAN CAL, LCAL 3P or LCAL 9P is selected,
the valve controller must be in AUTO mode. 1-point calibration may run in both AUTO and MAN mode.
WARNING:
Automatic calibration drives the valve against the
mechanical open and closed travel limits of the
valve-actuator assembly. Make sure that these
procedures can be safely executed.
Calibration selection
5.6.1 AUTO calibration function
During the calibration process the display will show blinking CAL and numbers run from 1 to 100 to show calibration
progress. After calibration the display shows scrolling
CALBRATION SUCCESSFUL text and device returns to
basic measurement display after one hour. Press the =
key to get back to the basic measurement view immediately.
If you cannot drive the valve into a fully open position or if
there is no mechanical limit stop, a manual calibration is
required.
18
7 ND92H 70 en
5.6.2 MAN calibration function
After selecting the MAN calibration function from the
menu press the ? key to activate the procedure. First
there will be short valve speed identification. Then user
is asked to drive valve manually into open or close end
(depends on installation), the diaplay shows CAL OPE
or CAL CLO. With the + or - keys drive the valve
manually to the open (100 %) or closed (0 %) position
and then press the ? key. The display shows blinking
CAL and numbers continue to run from 6 to 100 to show
the calibration progress. After calibration the display
shows scrolling CALIBRATION SUCCESSFUL text and
device returns to basic measurement display after one
hour. Press the = key to get back to the basic measurement view immediately.
5.6.3
1-Point calibration
1-point calibration is useful in cases in which the valve
controller needs to be changed but it is not possible to
run the normal calibration and the valve is not allowed
to change position (the valve is active, for example).
This procedure does not ensure the best possible
control performance, and it is always recommended
to run either AUTO or MAN calibration and tuning,
as soon as possible. The primary way to calibrate
valve position is to use either AUTO or MAN calibration.
Before starting 1-point calibration, read the warnings
and notes below and check that the valve is mechanically locked. Before starting 1-point calibration,
adjust the TPOS value in the MAN mode (see section 5.4.2) to correspond with the physical position
of the valve.
NOTE:
If an incorrect valve operation angle is given to the
valve controller during 1-point calibration, valve operation will be incorrect. In this case, you must perform
1-point calibration again with correct valve operation
angle value.
NOTE:
If the valve position is not stable (due to heavy vibration etc) during 1-point calibration, the calibration will
not end successfully. Check that the valve position is
fully stable during this operation.
5.6.4
Linearization
Linearization FLI can be used for linear valves when
linkage geometry is needed to be corrected by valve
controller.
Linearization can be done with 3 points (and end
points) or with 9 points (and end points).
3-point linearization will be done in positions 25 %,
50 % and 75 %.
9-point linearization will be done in positions 10 %,
20 %, 30 %, 40 %, 50 %, 60 %, 70 %, 80 % and 90 %.
NOTE:
There have to be external position measurement in linear valve that you can compare actual position and
given position.
Before linearization:
❑
Once the 1-point calibration is started, the first view
shows ANG above and NN.N below (see Fig. 16). NN.N
presents the maximum turning angle (in degrees) that
the valve can perform.
Perform the Valve travel calibration (auto or manual).
❑
Before 3-point or 9-point linearization is visible on
the display, Valve type VTYP has to be set as
Fixed Linear FLI.
Linearization:
To change the value:
❑
❑
Press the ? key, NN.N begins blink
❑
Press the + and - keys to change the value
After the correct valve operation angle is set, press the
? key.
During the calibration process the display will show the
following text: CALrun. After calibration the ND9200H
scrolls CALIBRATION SUCCESSFUL text. You may interrupt the calibration sequences at any time by pressing
the = key.
After the calibration sequence is finished, press the =
key twice to get back to the measurement view.
Please refer to Chapter 7 if this sequence has failed
and an error message is displayed.
The valve can now be unlocked.
WARNING:
Supply pressure can be connected to the valve
controller only after 1-point calibration is successfully completed. If supply pressure is connected to
the valve controller before successful 1-point calibration, the valve may move and cause danger.
Select 3-point LCAL 3P or 9-point LCAL 9P linearization from CAL by pressing the ? key.
❑
The display shows SET 10 % or SET 25 % depending on which is selected: 3-point or 9-point calibration.
❑
Drive valve position manually with the + and keys to 10 % or 25 %.
❑
When required position is reached (according to
position measured by external measurement)
press the ? key.
❑
The display starts to blink next position (50 % or
20 %). When last point have confirmed, the LUI
displays that calibration is successful and
returns to basic measurement display.
❑
User can terminate linearization any time by
pressing the = key. Linearization is cancelled
and device returns to basic measurement display. No changes to linearization curve and corresponding message is shown to user.
If linearization fails, a message about the reason will be
shown on the LUI display and also in event log that can
be read with DTM. If linearization is not successfully
completed, there will be no changes in linearization
table.
7 ND92H 70 en
5.7
19
Special displays
5.7.1 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.
scrolling text
Fig. 19
Failsafe display
failure, it enters reduced performance mode. This is
indicated by the blinking & in the display, see Fig. 20.
In reduced performance mode valve control can not be
optimized. To correct the problem replace the spool
valve assembly and perform auto calibration.
Fig. 17
LUI locked
5.7.2 Online-alarm active
If an online alarm has been detected the solid & 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 software where all events may be viewed.
scrolling text
Fig. 18
Fig. 20
5.8
Reduced performance display
HART write protection
The ND9200H 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 communication circuit board under the Local User Interface
module, Fig. 21. 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.
Online alarm message
5.7.3 Viewing of latest event
1
ON
2
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 display 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 7.
5.7.4 Fail-safe active
When the ND9200H detects serious device failure (setpoint, valve position and control signals) it enters failsafe mode, which drives the control valve into the position 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 ND9200H unit is
restarted, i.e. the power loop is momentarily disconnected.
5.7.5
Reduced performance
When the ND9200H detects spool valve measurement
Fig. 21
HART write protection
20
6
7 ND92H 70 en
MAINTENANCE
Ex d WARNING:
Service of the cylindrical flameproof joints is not
allowed.
This includes the diaphragm cover (part 171), flame
arrester plunger (part 200), their mating surfaces in
the housing (part 2) and the shaft assembly fixed in
the housing.
The maintenance requirements of the ND9200H 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.
6.2
6.2.1 Removal
For spool valve removal it is usually necessary to
unmount the valve controller from the actuator.
❑
❑
When maintaining the ND9200H 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 ND9200H valve controller includes the following
interchangeable modules: prestage unit (120), spool
valve (193), communication circuit board with optional
position transmitter (215).
The spool valve is located on the bottom side of the
device while the other modules are located below the
covers (100) and (39). In the event of failure the whole
module must be changed. The module retrofit must be
assembled in a clean, dry environment. In reassembly
apply a thread-locking compound (for instance, Loctite
243) and tighten the screws firmly.
6.1
Prestage
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.
6.1.1 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
spool sensor board (180). Unscrew the M4
screws (139, 2 pcs.) and lift up the prestage
module. Remove the O-ring (140).
Spool valve
❑
❑
Working from the bottom side of the valve controller, unscrew the M4 screws (47, 3 pcs.).
Remove the spool valve cover (61) and the spool
valve (193) with gasket (174). Hold the ends of
the body with your fingers to avoid dropping the
spool from the body.
Spool valve removal is only possible in the
spring-forced failsafe position of the spool. In the
case of a stuck spool it might be necessary to
remove the secondary diaphragm cover (167),
the spool spring (166) with its disc (164) and the
secondary diaphragm (162) with its plate. After
the removal of these parts it is possible to use a
punch to force the spool to the failsafe position.
The spool valve may be 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 materials in the bore or on the spool. Do not scratch
the mating surfaces of the spool and body.
NOTE:
Each spool valve body has an individual corresponding spool which cannot be replaced by any other
spool. Never alter the orientation of the spool. The orientation of the spool is marked on the device, see
Fig. 22.
6.2.2 Installation
❑
Ensure that the gaskets (174) and (63) are properly located in their grooves on the bottom of the
housing. Mount the spool valve and the spool
valve cover (61) to the housing, and tighten M4
screws evenly.
195
174 194
6.1.2 Installation
❑
❑
Place a new O-ring (140) into the groove in the
housing 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 position. Tighten the screws (139) evenly.
Push the prestage 2-pole wire connector into the
socket on the spool sensor board. The wire connector can only be fitted in the correct position.
Replace the inner cover (39) and tighten the M3
screws.
63
61
Sticker
Fig. 22
Spool valve assembly
7 ND92H 70 en
6.3
Flame arrestor assembly
21
6.5.2 Installation
The flame arrestor and the restrictor are fit into the same
plug which is located under the diaphragm cover (171).
This assembly can not be disassembled and should be
replaced if clogged.
❑
❑
❑
❑
6.4
To remove the flame arrestor assembly, unscrew
the screws (173, 4 pcs.) and remove the diaphragm cover (171) with its O-ring. Turn a M3
screw into the threaded hole of the flame arrestor
assembly to extract it from the housing. Installation is the reversal of removal. Place the O-rings
carefully.
Diaphragms
The diaphragms (169, 162) may be replaced by removing the respective covers (171, 167). The unit should be
unmounted from the actuator and the side to be worked
on turned upwards in order to avoid loss of small parts.
When replacing the secondary diaphragm (162), the
spool spring (166) with its guide (164) has to be
removed first. When reassembling, pay special attention to the installation of the diaphragms and O-rings.
6.5
❑
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.
Ex WARNING:
Grounding of the circuit board is essential to
explosion protection.
The board is grounded to the housing by the mounting screw next to the terminal blocks.
Communication board
215
6.5.1 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.).
NOTE:
Ground yourself on the body of the device before
touching the circuit board.
❑
Remove the M3 screws (217, 4 pcs.). Hold the
sides of the circuit board and lift it directly
upwards and outwards. Handle the board carefully, touching only the sides.
NOTE:
Do not remove the Valve Controller Board (210)!
Removing the board will void the warranty.
Fig. 23
Communication board
22
7 ND92H 70 en
7
ERROR MESSAGES
7.1
Failsafe errors
Display message
Description
POSITION SENSOR FAILURE Position sensor measurement
failed. Change the ND9000
device to a new one.
SETPOINT SENSOR
mA measurement failed.
FAILURE
Change the ND9000 device
to a new one.
PRESTAGE SHORTCUT
Shortcut in the prestage unit.
ERROR
FAE nnn
Fatal malfunction in the device.
nnn is a number between 001 004. Change the ND9000
device to a new one.
7.2
Alarms
Display message
DEVIATION ALARM
STICTION LOW ALARM
STICTION HIGH ALARM
LOAD FOR OPENING LOW
ALARM
LOAD FOR OPENING HIGH
ALARM
SPOOL VALVE PROBLEM
PNEUMATICS PROBLEM
FRICTION PROBLEM
7.3
Description
Valve deviation out of limits.
Stiction has exceeded the
low limit.
Stiction has exceeded the
high limit.
Load for opening has
exceeded the low limit.
Load for opening has
exceeded the high limit.
Spool valve problem in the
controller. Check the spool
valve unit and replace if
necessary.
Inconsistent actuator
pressures. Check pneumatic
connections and actuator
leakage.
Valve is not moving correctly.
Check load factor.
Errors
Display message
PRESTAGE CUT ERROR
PRESSURE SENSOR 1
FAILURE
PRESSURE SENSOR 2
FAILURE
PRESSURE SENSOR 3
FAILURE
SPOOL VALVE SENSOR
FAILURE
TEMPERATURE SENSOR
FAILURE
Description
Prestage wire is cut or
connector is loose.
Actuator pressure sensor has
failed. The device
performance level is reduced.
Change the ND9000 device to
a new one during next
maintenance activity.
Actuator pressure sensor has
failed. The device
performance level is reduced.
Change the ND9000 device to
a new one during next
maintenance activity.
Supply pressure sensor has
failed. This does not affect
the performance level.
Spool valve sensor failed.
Check the sensor
connections. The device
performance level is reduced.
Change the ND9000 device to
a new one during next
maintenance activity.
Temperature measurement
failed. The accuracy of the
measurements is reduced.
Change the ND9000 device
to a new one during next
maintenance activity.
STATISTICS DATABASE
ERROR
EVENT DATABASE ERROR
POSITION CALIBRATION
FAILED
POSITION CHANGE TOO
SMALL
LINEARIZATION FAILED
FACTORY SETTINGS
RESTORE FAILED
TOO SMALL VALVE
MOVEMENT
POSITIONER SHAFT
MOVEMENT OUT OF
RANGE
CALIBRATION TIMEOUT
Failed to store statistics. New
measurements will be lost.
Failed to store events. The
new events will be lost.
Travel calibration failed.
Check the configuration
parameters and controller
mounting. Check that the
controller shaft is correctly
aligned.
Given samples in
Linearization are closer than
5 % to each other, i.e. there's
not enough change between
two consequent samples.
3P/9P linearisation failed.
Factory settings restoring
failed.
Position sensor range failed
during calibration. Valve
controller shaft failed to
rotate minimum 45 degrees.
Check the configuration
parameters and controller
mounting. Check that the
controller shaft is correctly
aligned.
Pointer out of mark on
housing, see Figure 5.
Calibration timeout occurred.
Check configuration and
installation.
CALIBRATION START
The calibration starting
FAILED
conditions are not met.
Check the supply pressure.
TOO SMALL SPOOL VALVE Spool sensor range failed
MOVEMENT
during position calibration.
Check the configuration
parameters. Check the
prestage and spool valve
unit.
POOR VALVE PACKAGE
Position calibration takes too
CONTROLLABILITY
long time due to weak
controllability.
CHECK ASSEMBLY
Check assembly and
RELATED PARAMETERS
assembly related parameters
and start calibration again.
CALIBRATION FAILED DUE Supply pressure out of range
TO SUPPLY PRESSURE OUT during position calibration.
OF RANGE
CALIBRATION FAILED DUE Sensor failure (valve position/
TO SENSOR FAILURE
spool position) is detected
during position calibration.
CALIBRATION FAILED DUE Valve position out of range is
TO VALVE POSITION OUT
detected during position
OF RANGE
calibration.
7 ND92H 70 en
7.4
Warnings
Display message
TOTAL OPERATION TIME
WARNING
VALVE FULL STROKES
WARNING
VALVE REVERSALS
WARNING
ACTUATOR FULL STROKES
WARNING
ACTUATOR REVERSALS
WARNING
SPOOL FULL STROKES
WARNING
SPOOL REVERSALS
WARNING
STEADY STATE DEVIATION
WARNING
DYNAMIC STATE DEVIATION
WARNING
STICTION LOW WARNING
Description
Operating time exceeded
limit.
Valve stroke counter limit
reached.
Valve reversals counter limit
reached.
Actuator stroke counter limit
reached.
Actuator stroke counter limit
reached.
Spool stroke counter limit
reached.
Spool reversals counter limit
reached.
Warning that steady state
deviation has increased.
Warning that dynamic state
deviation has increased.
Warning that stiction has
exceeded the low limit.
STICTION HIGH WARNING Warning that stiction has
exceeded the high limit.
LOAD FOR OPENING TOO
Warning that load for
LOW
opening has exceeded the
low limit.
LOAD FOR OPENING TOO
Warning that load for
HIGH
opening is has exceeded the
high limit.
SUPPLY PRESSURE OUT OF Supply pressure has
LIMITS
exceeded the specified
operating conditions.
TEMPERATURE OUT OF
Temperature has exceeded
LIMITS
the specified operating
conditions.
HUNTING DETECTION
Valve hunting detected.
WARNING
Change performance level to
less aggressive to stabilize
valve. Check that the spool
valve capacity is suitable for
the actuator.
REDUCED PERFORMANCE Valve controller performance
ACTIVATED
is reduced due to defective
spool valve sensor. Change
the spool valve assembly.
TOO LOW SUPPLY PRESS
Too low supply pressure level
FOR 1-ACT ACTUATOR
for 1-acting actuator.
VALVE REVERSALS TREND Warning that valve reversals
WARNING
per day has exceeded the
limit.
SETPOINT REVERSALS
Warning that setpoint
TREND WARNING
reversals per day has
exceeded the limit.
VALVE TRAVEL TREND
Warning that valve travel per
WARNING
day has exceeded the limit.
VALVE REVERSALS WH
Warning that valve reversals
STABLE SETP WARNING
while setpoint is stable, per
day, has exceeded the limit
23
7.5
Notifications
Display message
CALIBRATION
SUCCESSFULL
LINEARIZATION
SUCCESSFUL
TEST CANCELLED
Description
Position calibration
successfully performed.
3P/9P linearisation
successfully performed.
Off-line test has been
cancelled.
TEST DONE
Off-line test has been
successfully performed.
TEST FAILED
Off-line test failed. Repeat
the test sequence.
CALIBRATION CANCELLED Calibration has been
cancelled.
FACTORY DEFAULTS
Factory settings activated.
ACTIVATED
Device have to be configured
and calibrated.
PT NOT ACTIVATED
(Only with position
transmitter option).
The position transmitter is not
energized.
1PT CAL FAILED
1-point calibration failed.
Check the mounting of the
valve controller. Verify input
parameter (range) value.
Check rotation parameter
(ROT).
REDUCED PERFORMANCE Spool valve measurement
DEACTIVATED
and normal valve control is
recovered.
24
8
7 ND92H 70 en
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 and tuning 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. The actuator goes to the end position with a small
change of input signal
❑
Tubes between controller and actuator are incorrect, see Fig. 6
❑
The parameter settings PFA and ROT are incorrectly selected.
3. Inaccurate positioning
❑
Spool valve dirty
❑
Too high actuator load
❑
Supply pressure too low
❑
Spool or pressure sensors are defective
❑
Actuator leakage
4. Overshooting or positioning too slow
❑
❑
❑
❑
❑
Change PERF value
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
5. Error during valve travel calibration
❑
❑
❑
❑
❑
❑
Valve controller is in MAN mode
Check the coupling alignment with the pointer,
see Fig. 5.
The parameter settings PFA and ROT are incorrectly selected
The actuator or valve did not move or was stuck
during calibration
Supply pressure too low
Spool valve dirty
7 ND92H 70 en
25
9
ND92_H/K00 and ND92_H/I00
(WITH LIMIT SWITCHES)
9.1
Introduction
9.1.1
General description
ND9200H can be equipped with limit switches.
ND9200H/K00 has two microswitches and ND9200H/I00
has two inductive proximity switches. Limit switches are
used for electrical position indication of the valves and
other devices.
The switching points may be chosen freely.
2 micro switches
2 cams
terminals
ground
potential
equalization
Fig. 24
M20 x 1.5
2 cams
terminals
ground
potential
equalization
Fig. 25
ND92_H/I__ layout
9.1.2
Markings
Example of the identification plate
9.1.3
Technical specifications
9.1.3.1 ND92_H/K00
Microswitch type:
OMRON D2VW-5 (K05)
OMRON D2VW-01 (K06)
(gold-plated contacts)
Protection class IP67
Resistive load:
3A: 250 V AC
(K05)
5A: 30 V DC
0.4A: 125 V DC
100 mA: 30 V DC / 125 V AC (K06)
Switch accuracy:
< 2°
Number of switches:
2 (K05 or K06)
Protection class of cover: IP66 (DIN 40050, IEC 60529)
Conduit entry:
M20 x 1.5
Ambient temperature:
-20° to +80 °C / -4° to +176 °F
Weight:
Approx. 1.0 kg / 2.2 lb
(limit switches only)
9.1.3.2 ND92_H/I00
Proximity switch:
ND92_H/K_ layout
2 proximity
switches
Fig. 26
M20 x 1.5
The limit switch is provided with an identification plate
sticker, see Fig. 26. Identification plate markings from
top to bottom are:
❑
Type designation
❑
Electrical values
❑
Temperature range
❑
Enclosure class
❑
Conduit entry
❑
Manufacturing serial number
The type designation is described in Chapter 14.
Inductive, diameter 8–14 mm
(0.31–0.55 in)
Sensing range 2 mm / 0.08 in
Protection class IP67
P+F NJ2-12GK-SN
(02)
ifm IFC2002-ARKG/UP (56)
Other switch types on special
order
Electrical values:
According to switch type
Switch accuracy:
< 1°
Number of switches:
2
Protection class of housing: IP66 (DIN 40050, IEC 60529)
Conduit entry:
M20 x 1.5
Ambient temperature:
-20° to +51 °C /-4° to +124 °F (02)
-20° to +80 °C / -4° to +176 °F(56)
Weight:
Approx. 1.0 kg / 2.2 lb
(limit switches only)
26
9.2
7 ND92H 70 en
Installing ND92_H/K00 and ND92_H/I00
on a valve controller
16
15
14
13
12
11
The limit switch may be installed on an existing valve
controller.
❑
❑
❑
❑
❑
❑
❑
❑
9.3
If the valve controller is already mounted on an
actuator/valve assembly, operate the actuator
into the closed or open position.
Remove the cover (100), the pointer (109), the
LUI (223) and electronics cover (39).
Turn the shaft (311) onto the shaft (11). Fasten
the screw (312) using a locking agent such as
Loctite.
Mount the electronics cover (39) and the limit
switch housing (300) on the valve controller. Lock
the housing in place with screw (326). Install the
base plate (324) with the limit switches and connector block into the limit switch housing. Fasten
the base plate with screws (325), 3 pcs.
Install the cam discs (313) and spacers (346) to
the shaft.
Mount the LUI (223) on the holder (306).
Replace the plastic plugs with metal ones in conduit entries which will not be used.
Mount the pointer (109) on the shaft (311). Adjust
the limit switch according to 9.4.
Electrical connections
Before connecting the power, make sure that the electrical specifications and the wiring meet the installation
conditions. See the diagrams in 12.9. Refer to the information on the identification plate.
ND9200/I: Observe the functioning of the proximity
switch; activated when the active face is either covered
or free.
9.4
Adjustment
The pointer (109) need not be removed for adjustment.
When the limit switch is ordered together with the valve
and the actuator, the valve controller switches are factory-adjusted. The limits may be adjusted by altering
the position of the cam discs (313) on the shaft. The
lower switch is activated at the closed limit and the
upper switch at the open limit.
❑
With the actuator in the open or closed position,
locate the switching point by turning the cam
disc so that the switch state changes approx. 5°–6°
before the limit.
❑
ND9200/I00: Use the LED indicator or a separate
measuring instrument as an aid.
❑
After re-installation of the actuator, first adjust its
mechanical limits according to the valve, then
the valve controller, and finally the limit switch.
❑
When adjustment is completed, turn the pointer
(109) so that the yellow line is parallel with the
valve closure member.
Fig. 27
9.5
❑
❑
❑
❑
❑
❑
❑
❑
Close
Open
Limit switch adjustment, 2 switches
Removal of the limit switches
ND92_H/K00 and ND92_H/I00
for accessing the valve controller
Remove the cover (100) and the pointer (109).
Loosen the screws (314) in the cam disks (313)
and remove the cam disks and spacers (346)
from the shaft.
Remove the LUI cabling from the circuit board.
Disconnect and remove all cabling which enters
the limit switch housing (300).
Remove screws (325), 3 pcs and lift out the limit
switch base plate (324) complete with switches,
LUI and connector block.
Open screw (326) and turn the limit switch housing (300) from the positioner housing.
Remove the electronics cover (39).
Proceed with the valve controller as applicable.
Re-install the limit switch according to 9.2 and
check the adjustment according to 9.4.
ATEX WARNING:
The locking screw of the limit switch housing (Part
326) is essential to explosion protection.
The limit switch housing has to be locked in place for
Ex d protection. The screw grounds the limit switch
housing to the housing of the valve controller.
7 ND92H 70 en
9.6
Circuit diagrams
The internal circuitry of the limit switch is shown in the
connection diagrams in 12.9 and inside the cover.
9.7
Maintenance
Regular maintenance of the limit switch is not necessary.
10
TOOLS
No special tools required.
11
ORDERING SPARE PARTS
Spare parts are delivered as modules. The modules
available are indicated in 12.1.
When ordering spare parts, always include the following
information:
❑
❑
Valve controller type designation and serial
number from the ID plate
The code of this manual, the part number, the
part name and quantity required
27
28
12
7 ND92H 70 en
DRAWINGS AND PARTS LISTS
12.1 Exploded view and parts list, ND9200H
100
107
110
109
228
223
42
39
217
218
215
219
220
210
19
139
183
182
18
104
120
222
140
173
221
111
165
167
166
164
162**
163
36
57
176
181
196
2
174
193
199
15
197
63
16
171
61
14*
47
12*
173
200
184
170
169**
177
7 ND92H 70 en
Item
Qty Description
2
1
Housing
15
1
O-ring
16
1
Washer
18
1
Wave spring
19
1
Bushing
36
1
Grounding screw
39
1
Inner cover
42
3
Screw
47
3
Screw
57
1
Conduit entry adapter
61
1
Spool valve cover
63
1
Gasket
100
1
Cover
104
1
O-ring
107
1
Screw
109
1
Pointer
110
1
Stop screw
111
1
Spring
120
1
Prestage unit
139
2
Screw
140
1
O-ring
162** 1
Supply pressure diaphragm
163
1
Diaphragm plate
164
1
Spring guide
165
1
O-ring
166
1
Spring
167
1
Diaphgram cover
169** 1
Pilot pressure diaphgram
170
1
Diaphragm plate
171
1
Diaphragm cover
173
8
Screw
174
1
Gasket
176
1
Bushing
177
1
O-ring
181
1
Sleeve
182
1
Spool sensor board
183
1
Screw
184
1
Plunger
193
1
Spool valve
196
1
Bushing
197
1
Flame arrester assembly
199
1
O-ring
200
1
Flame arrester plunger
210
1
Valve controller board
215
1
Communication board
217
4
Screw
218
1
Support
219
2
Screw
220
2
Threaded spacer
221
3
O-ring
222
1
Isolation part
223
1
Local user interface (LUI)
228
2
Screw
*) Mounting parts: coupling (12), screws (14)
**) Diaphgram set
29
Spare modules
x
x
x
x
x
x
x
x
30
7 ND92H 70 en
12.2 Exploded view and parts list,
ND92_H/K_, ND92_H/I___
100
107
I_ _
351
K0_
308
223
349
358
357
355
110
109
350
347
348
313
307
346
306
314
315
325
305
304
324
301
302
300
111
326
104
311
312
111
7 ND92H 70 en
Item
100
104
107
109
110
111
223
300
301
302
304
305
306
307
308
311
312
313
314
315
324
325
326
346
347
348
349
350
351
355
357
358
Qty
1
1
1
1
1
1
1
1
1
1
1
2
1
3
2
1
2
2 or 4
2 or 4
1
1
2
1
1
2
1
2
1
1
2 or 4
2
2
31
Description
Cover
O-ring
Screw
Pointer
Stop screw
Spring
Local user interface (LUI)
Housing
O-ring
Screw
Bracket
Screw
Bracket
Screw
Screw
Extension shaft
Screw
Cam disc
Screw
Terminal block
Base plate
Screw
Screw
Bearing bushing
Proximity switch
Fixing plate
Screw
Washer
Screw
Microswitch
Spring washer
Screw
Spare modules
32
7 ND92H 70 en
12.3 Mounting parts for EC05-14/EJ05-14
actuators, rising signal opens valve
Item
15
27
38
47
48
53
54
64
65
66
E_05 - 14
15
27
Qty
1
2
4
1
2
2
1
1
4
4
Description
Coupling
Screw
O-ring
Coupler socket
Screw
Plug
Plug (EJ only)
Mounting plate
Screw
Screw
66
48
47
65
ND9200
38
38
64
54
38
53
12.4 Mounting parts for B1C/B1J 6-20
actuators
Note:
Different mounting
position
ND9200
ND9200
VDI/VDE 3845
attachment face
Item
1
2
3
4
28
29
36
47
48
53
Qty
1
1
4
4
4
1
1
1
2
1
Description
Mounting bracket
Ear
Washer
Screw
Screw
Screw
Couplings jacket
Coupler socket
Screw
Plug (BJ actuators only)
Neles
attachment face
Item
1
2
3
4
13
14
28
29
47
48
53
Qty
1
1
4
4
2
2
4
1
1
2
1
Description
Mounting bracket
Draught piece
Washer
Screw
Screw
Hexagon nut
Screw
Screw
Coupler socket
Screw
Plug (BJ actuators only)
Note: See 12.5 for old series B actuators
7 ND92H 70 en
33
12.5 Mounting parts for B1C/B1J 25-50,
B1C 502 and B1J322 actuators
Note: Old series B actuators
°
new hole drilled
ø5.5 through
21
90
45°
Note:
Different
position
Arrow
mounting
ND9200
Item
1
2
3
4
27
28
47
48
53
Qty
1
1
4
4
4
4
1
2
1
Description
Mounting bracket
Draught piece
Washer
Screw
Washer
Screw
Coupler socket
Screw
Plug (BJ actuators only)
Item
1
2
4
28
29
30
35
Qty
1
1
4
4
1
4
1
35
1
36
47
48
53
1
1
2
1
Description
Mounting bracket
Ear
Screw
Screw
Screw
Screw
Adapter plug
(QP II 1/S- 6/S only)
Adapter plate
(QP II 2B/K thr. 6_/K)
Couplings jacket
Coupler socket
Screw
Plug
Item
1
2
3
4
5
6
7
8
9
10
47
48
53
Qty
1
2
1
4
4
1
4
4
4
4
1
2
1
Description
Mounting bracket
Coupling half
Adapter
Screw
Hex nut
Screw
Screw
Washer
Screw
Washer
Coupler socket
Screw
Plug
12.6 Mounting parts for Quadra-Powr®
actuators
ND9200
ND9200
34
7 ND92H 70 en
12.7 Mounting parts for linear actuators of
nelesCV Globe
28
4
3
16
38
54
38
53
31
48
39
47
64
Set conical plug to the scale according to the stroke
65
Item
3
4
16
28
31
38
39
47
48
53
54
64
65
Qty
2
2
1
4
1
2
1
1
4
2
1
1
4
Description
Washer
Screw
Conical plug
Screw
O-ring
O-ring
Mounting plate
Feedback lever
Screw
Plug
Plug
Mounting plate
Screw
7 ND92H 70 en
35
12.8 Mounting parts for linear actuators
Feedback lever in horizontal position
at mid travel of stroke.
54
Stroke 10 - 80 mm
9
11
Stroke 60 - 120) mm
Plane in the shaft in this position
with feedback lever
45°
45°
12
11
14
3
6
5
19
18
15
17
16
Maximum stroke 80 mm
1
4
45°
2
7
45°
Maximum stroke 120 mm
Scale on this side
8
Allowed travel range 45–90°
Item
1
2
3
4
5
6
7
8
9
11
12
14
15
16
17
18
19
54
Qty
1
1
1
1
4
4
4
4
4
4
2
2
1
1
1
2
2
2
Description
Bracket
Feedback lever
Filling piece
Clearance remove spring
Cross rec head screw
Washer
Hexagon screw
Washer
Hexagon screw
Spring washer
Hexagon nut
Clamp
Fixing plate
Special screw
Hexagon nut
Washer
Hexagon screw
Plug
36
7 ND92H 70 en
12.9 Connection diagrams
See Section 9.1.3 for additional limit switch data.
ND92_H/K05, ND92_H/K06
OPEN
CLOSED
A
K
red
11
blue
12
black
13
red
14
blue
15
black
16
Connection diagram shows limitswitch when actuator is in
intermediate position. Switch A (upper) is activated at the
open limit of the travel and switch K (lower) at the closed
limit.
Electrical characteristics:
OMRON D2VW-5 (K05):
5 A - 30 V DC, 0.4 A - 125 V DC,
3 A - 250 V AC
OMRON D2VW-01, gold-plated contacts (K06):
100 mA - 30 V DC / 125 V AC
Ambient temperature -40 ° ... +80 °C / -40° ... +176 °F
7 ND92H 70 en
37
ND92_H/I02
OPEN
CLOSED
blue
11
A
+
brown
13
blue
14
K
+
brown
16
Factory adjustment:
Active faces of proximity switches are covered when the actuator is in intermediate position.
Active face A (upper switch) becomes free at open limit of travel and face K (lower switch) at closed limit.
The function can be inverted on site by re-adjusting the cam discs.
PROXIMITY SWITCH
Intrinsically safe II 2 G Ex ia IIC T6
According to CENELEC EN60079-0 and EN60079-11
Voltage (Umax), current (Imax), inductance (Li) and
capacitance (Ci) according to certificate of switch,
see table.
Type of proximity switch
Electrical values
Umax Imax Li
(V) (mA) (µH)
Ex classification
Certificate
Ci
(nF)
02
P+F NJ2-12GK-SN
16
52
150
50
II 1 G Ex ia IIC T6
PTB 00 ATEX 2049 X
07
P+F NJ2-12GM-N
16
52
50
30
II 1 G Ex ia IIC T6
PTB 00 ATEX 2048 X
38
7 ND92H 70 en
ND92_H/I56
OPEN
CLOSED
A
K
black
11
black
13
black
14
black
16
DC
+
DC
+
Factory adjustment:
Active faces of proximity switches are free when the actuator is
in the intermediate position. Active face A (upper switch)
becomes covered at the open limit of the travel and face K
(lower switch) at the closed limit.
The function may be inverted on site by re-adjusting the cam
discs.
Connections: Either wire can be connected to + or -.
PRO XIMITY SWITCH
ifm electronic IFC2002-ARKG/UP
2-wire type
Sensing distance 2 mm
Rated voltage U = 10 - 36 V DC
Output current < 150 mA
active face covered, LED on
Quiescent current < 0.6 mA
active face free
Ambient temperature -20˚ ... +80 ˚C / -13˚ ...+176 ˚F
7 ND92H 70 en
DIMENSIONS
35.4
1.39
ND9200
M6
35.4
1.39
M20x1.5
(1/2 NPT)
15
0.59
52
2.05
47
1.85
133
5.23
1/4 NPT
4
52
2.05
25
0.98
1/4 NPT
162
6.37
35.4
1.39
33
1.30
ø6
ø0.23
F05-ø50
(VDI/VDE 3845)
35.4
1.39
33
1.30
39
1.54
14
0.55
33
1.30
63
2.48
ND9200
33
1.30
161
6.33
0.16
39
1.54
3
0.12
M6 x 12
25
0.98
14
0.55
26.8
1.05
M6
101.2
3.98
6
0.23
0.41
13
0.51
10.5
13
39
40
7 ND92H 70 en
25
0.98
1/4 NPT
162
6.37
33
1.30
63
2.48
35.4
1.39
F05-ø50
(VDI/VDE 3845)
35.4
1.39
ø6
ø0.23
33
1.30
26.8
1.05
161
6.33
52
2.05
39
1.54
14
0.55
161
6.33
174
6.85
63
2.48
103
4.05
4
0.16
3
0.12
M6 x 12
25
0.98
14
0.55
M20x1.5
(1/2 NPT)
15
0.59
47
1.85
95
3.74
190
7.48
min. 60
2.4
ND921_/I00
M6
101.2
3.98
7 ND92H 70 en
14
41
EC DECLARATION OF CONFORMITY
EC DECLARATION OF CONFORMITY
Manufacturer:
Metso Automation Oy
00811 Helsinki
Finland
Product:
Intelligent Valve Controller Neles ND 9000-series
Approvals:
Type
ND 9…PA (Profibus PA)
ND9…F (Foundation Fieldbus)
ND9…HNT (Hart)
ND910.HX1, ND930.HX1
ND910.FX1, ND930.FX1
ND910.PX1, ND930.PX1
ND910.HX2, ND930.HX2
ND910.FX2, ND930.FX2
ND910.PX2, ND930.PX2
ND910.HX3, ND930.HX3
ND910.FX3, ND930.FX3
ND910.PX3, ND930.PX3
ND910.HX4, ND930.HX4
ND910.FX4, ND930.FX4
ND910.PX4, ND930.PX4
ND920..E1, ND930..E1
Approval
(EMC 2004/108/EC) EN61000-62(2001)
(EMC 2004/108/EC) EN61000-62(2001)
(EMC 2004/108/EC) EN61000-63(2001)
EN61000-6-2(2001), FCC 47 CFR Part
15, subpart B, Class B (2002)
ATEX II 1 G Ex ia IIC T4/T5/T6 Ga
ATEX II 1 D Ex tD A20 T90 °C
ATEX II 2 G Ex ia IIC T4/T5/T6 Gb
ATEX II 2 D Ex tD A21 T90 °C
ATEX II 3 G Ex nA IIC T4/T5/T6
ATEX II 3 D Ex tD A22 T90 °C
ATEX II 3 G Ex nL IIC T4/T5/T6
ATEX II 3 D Ex tD A22 T90 °C
ATEX II 2 G Ex d IIC T4…T6
ATEX II 2 GD Ex tD A21 IP66 T 100°C
EC Type examination Certificate
NEMKO 101425 & NEMKO 1052749
(Same HW as ND9...PA)
NEMKO 56164 & NEMKO 80628
VTT 09ATEX 033X
VTT 09ATEX 034X
KEMA 04ATEX2098X
Applicable directives:
EMC 2004/108/EC Electrical
ATEX 94/9/EC
Approved and Ex marked types
As the products within our sole responsibility of design and manufacture may be used as parts or components in machinery and are not alone
performing functions as described in Article 6(2) in the Machinery Directive (2006/42/EC), we declare that our product(s) to which this Declaration of
Conformity relates must NOT be put into service until the relevant machinery into which it is to be incorporated has been declared in conformity with
the provisions of the Machinery Directive.
The product above is manufactured in compliance with the applicable European directives and technical specifications/standards.
Protection from e.g. static electricity caused by the process or connected equipment must be considered by the user ( EN 60079-14 §6 ).
The product do not possess any residual risk according to hazard analyses made under the applicable directives providing that the procedures
stated by the Installation, Operation and Maintenance manual are followed and the product is used under conditions mentioned in the technical
specifications.
Manufacturer’s certificates:
Standard / Directive
Notified Body
Certificate No.
ISO 9001:2000
ATEX 94/9/EC Annex IV
DNV
DNV
24888-2008-AQ-FIN-FINAS
DNV-2006-OSL-ATEX-0260Q
0575
Helsinki 29th Sptember 2009
Ralf Liljestrand, Quality Manager
Authorized person of the manufacturer within the European Community
42
7 ND92H 70 en
15
TYPE CODING
INTELLIGENT VALVE CONTROLLER ND9200H /
LIMIT SWITCH (ND9200H/I00 and ND9200H/K00)
1.
ND
2.
9
1.
2.
3.
4.
5.
6.
7.
ND
9
20
3
H
E1
T
PRODUCT GROUP
SERIES CODE
Series 9000 valve controller with universal shaft and
attachment face according to standard VDI/VDE 3845,
EC/EJ actuators and old Neles standard.
Relevant shaft adapter included in mounting kits. When valve
controllers are separate deliveries, shaft adapter kit is supplied.
ENCLOSURE
E5
PNEUMATIC CONNECTIONS
(S, C1, C2)
SPOOL VALVE
2
Low capacity. Stroke volume
of actuator < 1 dm3
3
Medium capacity. Stroke volume 1/4 NPT
of actuator 1...3 dm3
6
High capacity. Stroke volume 1/4 NPT
of actuator > 3 dm3
1/4 NPT
COMMUNICATION / INPUT SIGNAL RANGE
H
4–20 mA, HART communication.
Supply voltage 30 V DC. Load voltage: up to 9.5 V DC at
20 mA corresponding to 475 Ω (maximum voltage drop).
6.
APPROVALS OF STANDARD ENCLOSURE VALVE CONTROLLER
E1
Flameproof enclosure, M20 x 1.5 conduit entry.
ATEX and IECEx (pending) certifications:
II 2 G Ex d IIC T4...T6
II 2 D Ex tD A21 IP66 T100 °C
ND92_HE1: Ui ≤ 30 V
Temperature range: T4: -40° to +85 °C / -40° to +185 °F
T5: < +75 °C / < +167 °F ; T6: < +60 °C / < +140 °F.
7.
FM certification:
Class I, Div 1. Groups A, B, C, D. Class II, Div 1,
Groups E, F, G, Class III T4/T5/T6
Class I, Zone 1, AEx d IIC, T4/T5/T6, IP66/Type 4X
CSA certification:
Class I, Div 1. Groups B, C, D,
Class II, Div 1, Groups E, F, G, Class III T4/T5/T6
Ex d IIC T4/T5/T6, DIP A21, Ta 100 °C, IP66/NEMA 4X
ND92_HE2: Ui ≤ 30 V
Temperature range: T4: -40° to +85 °C / -40° t o +185 °F
T5: < +75 °C / < +167 °F ; T6: < +60 °C / < +140 °F.
Flameproof enclosure, G 1/2 or 1/2 NPT conduit entry.
Temperature range: -20° to +60 °C / -4° to +140 °F.
TIIS (JIS) certifications: Pending
Ex d II C T6
Not available with any limit switches (8. sign I, B or K )
E4
APPROVALS OF STANDARD ENCLOSURE VALVE CONTROLLER
Delivered always with TIIS (JIS) approved cable gland and
conduit entry nipple (accessory CG8 or CG9), see type
code from Accessories for Positioners item 10:
CG42: G 1/2 Conduit entry and Cable entry adapter
CG41: 1/2 NPT Conduit entry and Cable entry adapter
ND92_HE4: Ui ≤ 30 V
Temperature range: T6; -20° to +60 °C / -4° to +140 °F.
INMETRO certifications:
BR-Ex d IIC, T4/T5/T6, IP66
OPTIONS OF VALVE CONTROLLER
ND9_H_T only: Internal 2-wire (passive) position transmitter.
Analogue position feedback signal, output 4–20 mA, supply
voltage 12–30 V DC, external load resistance 0–780 Ω..
T
ND92_HE1T and ND92_HE5T: Ui ≤ 30 V,
Pmax = device limits itself, external load resistance 0–780 Ω..
ND92_HE2T: Ui ≤ 30 V, Pmax = device limits itself,
external load resistance 0–780 Ω.
M
Special corrosion resistant finish. External aluminium
surfaces protected by hard anodizing with PTFE. Coating
thickness 20 µm. Not painted. Not available with 7. sign G.
G
Exhaust adapter. 1 x 1/2 NPT thread,
Not available with 7. sign M.
Y
Special construction, to be specified.
8.
LIMIT SWITCH TYPE
Inductive proximity switches, 2 pcs.
IP66 / NEMA 4X enclosure. M20 x 1.5 conduit entry (2 pcs.).
Option E2: 1/2 NPT conduit entry (2 pcs.).
I02
P+F; NJ2-12GK-SN, 2-wire type, DC; > 3 mA; < 1 mA.
Intrinsically safe according to ATEX II 2 G Ex ia IIC T6.
Temperature range -40° to +85 °C / -40° to +185 °F.
I09
P+F; NCB2-12GM35-N0, 2-wire type, DC; > 3 mA; < 1 mA.
Intrinsically safe according to ATEX II 2 G Ex ia IIC T6.
Temperature range -25° to +85 °C / -13° to +185 °F.
I56
ifm IFC2002-ARKG/UP, 2-wire type, DC; 150 mA, 10–36 V DC,
leakage current < 0.6 mA.
Temperature range -20° to +80 °C / -4° to +176 °F.
Flameproof enclosure, 1/2 NPT conduit entry.
Temperature range: -40° to +85 °C / -40° to +185 °F.
E2
K05
ND92_HE5: Ui ≤ 30 V
Temperature range: T4: -40° to +85 °C / -40° to +185 °F
T5: < +75 °C / < +167 °F ; T6; < +60 °C / < +140 °F.
Flameproof (Ex d) IP66 / NEMA 4X enclosure.
4.
5.
/
9.
Flameproof enclosure, 1/2 NPT conduit entry.
Temperature range: -40° to +85 °C / -40° to +185 °F.
Intelligent Valve Controller
3.
20
6.
8.
Mechanical micro switches, 2 pcs.
IP66 / NEMA 4X enclosure. M20 x 1.5 conduit entry (2 pcs.).
Option E2: 1/2 NPT conduit entry (2 pcs.).
K05
OMRON D2VW-5; 3 A - 250 V AC, 0.4 A - 125 V DC, 5 A - 30 V DC.
Temperature range -40° to +80 °C / -40° to +176 °F.
K06
OMRON D2VW-01; gold plated contacts, 100 mA - 30 V DC / 125 V AC.
Temperature range -40° to +80 °C / -40° to +176 °F.
9.
Y
OPTIONS OF LIMIT SWITCH
Special construction, to be specified.
7 ND92H 70 en
43
44
7 ND92H 70 en
Metso Automation Inc.
Europe, Levytie 6, P.O. Box 310, 00811 Helsinki, Finland. Tel. +358 20 483 150. Fax +358 20 483 151
North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, MA 01545, USA. Tel. +1 508 852 0200. Fax +1 508 852 8172
Latin America, Av. Independéncia, 2500-Iporanga, 18087-101, Sorocaba-São Paulo, Brazil. Tel. +55 15 3235 9700. Fax +55 15 3235 9748/49
Asia Pacific, 238A Thomson Road, #25-09 Novena Square Tower A, 307684 Singapore. Tel. +65 6511 1011. Fax +65 6250 0830
China, 19/F, the Exchange Beijing, No. 118, Jianguo Lu Yi, Chaoyang Dist, 100022 Beijing, China. Tel. +86-10-6566-6600. Fax +86-10-6566-2575
Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai, United Arab Emirates.
Tel. +971 4 883 6974. Fax +971 4 883 6836
www.metso.com/automation
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