Metso Neles ND9100P Installation Maintenance And Operating Instructions Download Page 1 | Manualshive

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INTELLIGENT
VALVE CONTROLLER

ND9100P

Rev. 2.2

Installation, Maintenance and
Operating Instructions

7 ND9

1

P 70 e

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• 1/20

09

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Summary of Contents for Neles ND9100P

Page 1: ...INTELLIGENT VALVE CONTROLLER ND9100P Rev 2 2 Installation Maintenance and Operating Instructions 7 ND91P 70 en 1 2009 ...

Page 2: ...ing 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 Write protection 19 6 MAINTENANCE 19 6 1 Prestage 19 6 2 Spool valve assembly 20 6 3 Communication circuit board 20 7 ERROR MESSAGES 21 7 1 Failsafe errors 21 7 2 Alarms 21 7 3 Errors 21 7 4 Warnings 22 7 5 Notifications 22 8 TROUBLE S...

Page 3: ...us PA profile version 3 0 PNO certified Easy to upgrade can be done by replacing the HART communication board to fieldbus commu nication 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 feed back signal from the position sensor No special supplementary modul...

Page 4: ...e spool valve Reduced pilot pres sure 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 pis ton The actuator and feedback shaft rotate clockwise The position sensor α measures the rotation for the µC The...

Page 5: ... 6 scfm spool valve 6 Electronics Power supply taken from bus Bus voltage 9 to 32 V DC reverse polarity protection Max basic current 17 2 mA Fault current FDE 3 9 mA EEx ia IIC T6 Ui 24 V Ii 380 mA Pi 5 32 W Ci 5 nF Li 10 µH EEx nL IIC Ui 32 V Ii 380 mA Pi 5 32 W Ci 5 nF Li 10 µH ATEX approval is valid under these conditions Performance with moderate constant load actuators EC05 EC10 Values at 20 ...

Page 6: ...antle a pressurized controller Removing or dismantling a pressurized prestage or spool valve of an ND9100 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 per sonal injury and damage to equipment may result WARNING During automatic or manual calibration and tuning ...

Page 7: ... the controller Mount the O ring 49 into the square groove in the bottom of the controller Place the valve controller on top of the actuator so that the pointer of the shaft washer 16 is located in the position shown in Fig 5 Fasten the screws 4 4 3 Mounting on Metso actuators with VDI VDE mounting face See figures in Section 12 4 12 6 Mount the H shaped coupling 47 to the shaft Apply the thread l...

Page 8: ...he bottom of the controller Mount the valve controller loosely to the mount ing 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 s...

Page 9: ...mended for the pipe threads The air supply must be clean dry and oil free instrument air see Section 2 4 CAUTION Do not exceed the permitted supply pressure of the ND9100P 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 ai...

Page 10: ... 6 40 43 2624 3 4 x x 6 50 84 5126 1 x x 6 502 195 11900 1 x x 6 B1J B1JA Stroke vol dm3 in3 NPT 6 10 1 4 3 8 Spool valve 8 0 9 55 3 8 x x x x 3 10 1 8 110 3 8 x x 3 12 3 6 220 1 2 x x 6 16 6 7 409 1 2 x x 6 20 13 793 3 4 x x 6 25 27 1648 3 4 x x 6 32 53 3234 1 x x 6 322 106 6468 1 x x 6 QP Stroke vol dm3 in3 NPT 6 10 1 4 3 8 Spool valve 1 0 62 37 3 8 x x x x 2 3 2 1 08 66 3 8 x x x x 3 3 2 18 133...

Page 11: ...closing Default setting 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 4 Self opening Default setting 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 C1 C2 S C1 C2 S C1 C2 S 1 DOUBLE ACTING ACTUATOR REVERSED PIPING Self opening Default setting ROT cC ...

Page 12: ...e left unconnected by using the empty terminal 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...

Page 13: ...been idle for 1 hour and there is no user activity on the local user interface the measure ments will start scrolling on the display This enables the user to view all the measurements through the window of the main cover 5 2 Guided start up Guided startup offers a fast view of the most critical parameters of the ND9100P controller actuator and valve configuration After verifying the parameters the...

Page 14: ... 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 acti vated In order to change the manual setpoint return to the measurement monitoring view and go to tar...

Page 15: ...e geometry is not needed to be corrected by valve controller firmware To conclude press the key when the desired value is shown on the display 5 5 4 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...

Page 16: ... GEr or FrE using the and keys To conclude press the key when the desired value is shown on the display 5 5 10Low limit high cutoff high limit ND9100P supports signal cutoff and limiting in both ends of the operating range The configuration parame ters are low cutoff low limit high cutoff and high limit If the input signal is smaller than low cutoff the valve will be fully closed If the input sign...

Page 17: ...he valve posi tion control At any time you may interrupt the tuning sequence by pressing the key The tuning will not alter the PERF parameter If calibration and tuning are performed in sequence the cancelling of tuning does not restore the old calibration values 5 6 4 1 Point Calibration 1 point calibration is useful in cases in which the valve controller needs to be changed but it is not possible...

Page 18: ...control signals it enters fail safe mode which drives the control valve into the posi tion defined in the parameter controller fail action PFA Fail safe mode is indicated by the display as seen in Fig 19 The error message is displayed until the cause of error is eliminated and the ND9100P unit is restarted i e the power loop is momentarily disconnected 5 7 5 Reduced Performance When the ND9100P de...

Page 19: ...15 The modules are located below the covers 39 and 43 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 thread locking compound for instance Loctite 243 and tighten the screws firmly 6 1 Prestage 6 1 1 Removal Open the prestage cover 43 attached with M4 screw 44 Unplug the prestage wire connector on the spo...

Page 20: ...r 109 and turn the position indicator from the shaft Remove the cover off the prestage 43 Remove the cover of the circuit boards attached with M3 screws 42 4 pcs Remove the M3 screws 217 4 pcs Hold the sides of the circuit board and lift it directly upwards and outwards Handle the board care fully touching only the sides 6 3 2 Installation Mount the new communication circuit board carefully Locate...

Page 21: ...enance activity PRESSURE SENSOR 3 FAILURE Supply pressure sensor has failed This does not affect the performance level SPOOL VALVE SENSOR FAILURE 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 SENSOR FAILURE Temperature measurement failed The accuracy of the measuremen...

Page 22: ...bilize valve Check that the spool valve capacity is suitable for the actuator REDUCED PERFORMANCE ACTIVATED Valve controller performance is reduced due to defective spool valve sensor Change the spool valve assembly TOO LOW SUPPLY PRESS FOR 1 ACT ACTUATOR Too low supply pressure level for 1 acting actuator VALVE REVERSALS TREND WARNING Warning that valve reversals per day has exceeded the limit SE...

Page 23: ...tuator are incor rect see Fig 6 The parameter settings PFA and ROT are incor rectly 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 t...

Page 24: ...otection class of cover IP66 DIN 40050 IEC 60529 Conduit entry M20 x 1 5 Ambient temperature 40 to 80 C 40 to 176 F Weight Approx 0 8 kg 1 8 lbs limit switches only Materials Body Aluminium alloy epoxy coated Internal parts Stainless steel and polymer Sealing Nitrile and neoprene rubber 9 2 Installing ND9100P B06 on a valve controller The limit switch may be installed on an existing valve controll...

Page 25: ...en adjustment is completed turn the pointer 109 so that the yellow line is parallel with the valve closure member 9 5 Removal of the limit switches ND9100P B06 Remove the cover 100 and the pointer 109 Detach the cam discs 313 Remove the LUI cabling from the circuit board Loosen the screws 303 and remove the hous ing 300 Remove the electronics cover 39 Proceed with the valve controller as applicabl...

Page 26: ...47 3 Screw 48 2 Screw 49 1 Screw 100 1 Cover x 107 4 Screw 109 1 Pointer 110 1 Grub screw 120 1 Prestage unit x 139 2 Screw 193 1 Spool valve assembly x 210 1 Valve Controller board 215 1 Communication circuit board x 217 4 Screw 218 1 Support 219 2 Screw 220 2 Threaded spacer 221 3 O ring 222 1 Insulation plate 223 1 Local user interface LUI x 228 2 Screw Mounting parts coupling 12 screws 14 100 ...

Page 27: ...ser interface LUI 300 1 Housing 301 1 Gasket 302 1 Screw 303 4 Screw 304 1 Bracket 305 2 Screw 306 1 Bed of Local User Interface LUI 307 3 Screw 308 2 Screw 311 1 Shaft 312 2 Screw 313 2 Cam disc 314 2 Screw 315 6 Terminal block 355 2 Microswitch 357 2 Spring washer 358 2 Screw 358 357 355 100 110 109 107 313 302 301 300 311 315 303 306 307 308 314 305 304 312 223 36 ...

Page 28: ... O ring 53 2 Plug 54 1 Plug EJ only Item Qty Description 1 1 Mounting bracket 2 1 Ear 3 4 Washer 4 4 Screw 28 4 Screw 29 1 Screw 36 1 Couplings jacket 47 1 Coupler socket 48 2 Screw 53 1 Plug BJ actuators only 54 2 Plug Item Qty Description 1 1 Mounting bracket 2 1 Draught piece 3 4 Washer 4 4 Screw 13 2 Screw 14 2 Hexagon nut 28 4 Screw 29 1 Screw 47 1 Coupler socket 48 2 Screw 53 1 Plug BJ actua...

Page 29: ...ators only 54 2 Plug ND9100 Item Qty Description 1 1 Mounting bracket 2 1 Ear 4 4 Screw 28 4 Screw 29 1 Screw 30 4 Screw 35 1 Adapter plug QP II 1 S 6 S only 35 1 Adapter plate QP II 2B K thr 6_ K 36 1 Couplings jacket 47 1 Coupler socket 48 2 Screw 53 1 Plug 54 2 Plug Item Qty Description 1 1 Mounting bracket 2 2 Coupling half 3 1 Adapter 4 4 Screw 5 4 Hex nut 6 1 Screw 7 4 Screw 8 4 Washer 9 4 S...

Page 30: ...elesCV Globe 3 4 31 28 48 47 16 54 38 53 39 Item Qty Description 3 2 Washer 4 2 Screw 16 1 Conical plug 28 4 Screw 31 1 O ring 38 2 O ring 39 1 Mounting plate 47 1 Feedback lever 48 4 Screw 53 2 Plug 54 1 Plug Set conical plug to the scale according to the stroke ...

Page 31: ...asher 9 4 Hexagon screw 11 4 Spring washer 12 2 Hexagon nut 14 2 Clamp 15 1 Fixing plate 16 1 Special screw 17 1 Hexagon nut 18 2 Washer 19 2 Hexagon screw 54 2 Plug 1 11 9 14 12 11 3 6 5 19 18 15 8 7 2 4 Scale on this side Stroke 10 120 mm 16 17 Feedback lever in horizontal position at mid travel of stroke Plane in the shaft in this position with feedback lever 54 Allowed travel range 45 90 45 90...

Page 32: ...32 7 ND91P 70 en 12 9 Connection diagram 12 9 1ND9100P B06 1 LS1 open 2 LS2 closed 3 GND 12 13 15 16 O C 1 2 3 LS2 LS1 ...

Page 33: ...em except to a leakage current of 50 µA for each connected device Separately powered equipment needs a galvanic isolation to insure that the intrinsically safe Fieldbus circuit remains passive HAZARDOUS CLASSIFIED LOCATION Class I Division 1 and 2 Groups A B C D Class I Zone 0 AEX ia Group IIB IIC T4 T5 T6 T4 Ta 40 80 C T5 Ta 40 65 C T6 Ta 40 50 C NONHAZARDOUS LOCATION METSO Automation OY ND9100PU...

Page 34: ...s A B C and D Class I Zone 2 Groups IIC IIB IIA T4 T5 T6 hazardous classified locations and need to be connected to an associated apparatus with a max output voltage of 24 0V 12 No revision to drawing without prior Factory Mutual Approval Installation Notes for FISCO Concepts in CSA 13 The Intrinsic Safety FISCO concept allows the interconnection of CSA Approved Intrinsically safe devices with FIS...

Page 35: ... 10 G1 8 15 5 0 61 18 0 71 ND9100 19 0 74 14 0 55 26 8 1 05 ø6 ø0 23 33 1 29 27 1 06 35 4 1 39 35 4 1 39 F05 ø50 VDI VDE3845 6 0 23 10 5 0 41 13 0 51 20 0 78 26 1 02 M6 10 G1 4 G1 4 G1 4 G1 8 G1 8 G1 8 33 1 29 ND9100 B 170 6 69 56 2 20 38 1 49 4 41 1 61 23 5 0 92 29 5 1 16 32 1 25 140 5 51 54 5 2 14 51 2 0 134 5 27 81 3 18 24 0 94 49 1 92 35 1 37 M20 x 1 5 0 15 49 5 1 95 20 0 78 ...

Page 36: ...36 7 ND91P 70 en 14 EC DECLARATION OF CONFORMITY ...

Page 37: ...ps A B C D T4 T6 IS Class I Zone 0 AEx ia IIC T4 T6 ND91_PU1 Ui 24 V Ii 380 mA Pi 5 32 W Ci 5 nF Li 10 µH Temperature range T4 40 to 80 C 40 to 176 F T5 65 C 149 F T6 50 C 122 F Not available with any limit switches 8 sign B 6 APPROVALSOFSTANDARDENCLOSUREVALVECONTROLLER U2 FM CSA certifications NI Class I Division 2 Groups A B C D T4 T6 NI Class I Zone 2 Ex nA II T4 T6 ND91_PU2 Ui 24 V Ii 380 mA P...

Page 38: ...38 7 ND91P 70 en ...

Page 39: ...7 ND91P 70 en 39 ...

Page 40: ...caba 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 T...

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