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Metso NELES NDX 511 Series, Installation Maintenance And Operating Instructions

The Metso NELES NDX 511 Series is a cutting-edge industrial valve system designed for precision control in demanding applications. Ensure seamless operation with our comprehensive Installation, Maintenance, and Operating Instructions manual, available for FREE download from manualshive.com. Maximize efficiency and reliability with this invaluable resource.

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GENER

AL

 INFO

SPECS

MOUNTING

ST

AR

T UP

OPER

ATION

M

AINTENANCE

DIMENSIONS

HO

W

 TO

 ORDER

LOGISTICS

 73

NDX VALVE CONTROLLER

14.1 

GENERAL

The maintenance requirements for the NDX 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.

 

WARNING

When maintaining the NDX, ensure that the 

supply air is shut off and pressure is released.

NDX valve controller includes following interchangeable 

modules:

• 

Relay valve

• 

Prestage unit

• 

Local User Interface

• 

Electronics module (including optional PT)

• 

Pressure gauge block

• 

Main cover

• 

Relay cover

• 

Prestage cover (NDX1510_ only)

• 

Exhaust cover

• 

Prestage bottom filter assembly

14.2 

ORDERING SPARE PARTS

Use the following order codes for NDX1510_:
H137041 PRESTAGE UNIT ASSEMBLY (Part number: 100)
H137043 MAIN COVER ASSEMBLY (Part number: 15)
H137045 RELAY COVER ASSEMBLY (Part number: 37)
H137047 PRESTAGE UNIT COVER ASSEMBLY (Part number: 42)
H137059 RELAY VALVE ASSEMBLY (Part number: 140)
H137060 LUI MODULE (Part number: 207)
H149891 SILENCERS, IP COVER 3/8” NPT   M10 WITH O RING 
(Part number: 87)
H137258 PRESTAGE BOTTOM FILTER (Part number: 32)
H141371 PNEUMATIC SET  
(includes H137041 and H137059 assembly)
ELECTRONICS MODULE: Contact Metso

Use the following order codes for NDX_511_:
H162178 RELAY COVER ASSEMBLY (Part number: 37)
H166049 RELAY VALVE ASSEMBLY for NDX1_ (Part number: 140)
H149515 RELAY VALVE ASSEMBLY for NDX2_ (Part number: 140)
H162063 PRESTAGE UNIT ASSEMBLY (Part number: 100)
H162064 MAIN COVER ASSEMBLY (Part number: 15)
H161999 SILENCERS IP COVER 3/8” NPT WITH O­RING  
(Part number: 87)
H149518 LUI MODULE (Part number: 207)
H162067 PNEUMATICS SET for NDX1511_  
(includes H162063 and H166049)
H162068 PNEUMATICS SET for NDX2511_  
(includes H162063 and H149515)
ELECTRONICS MODULE: Contact Metso

Use the following order codes for NDX_512_:
H137045 RELAY COVER ASSEMBLY (Part number: 37)
H137059 RELAY VALVE ASSEMBLY for NDX1_ (Part number: 140) 
H149515 RELAY VALVE ASSEMBLY for NDX2_ (Part number: 140)
H149508 PRESTAGE UNIT ASSEMBLY (Part number: 100)
H149509 MAIN COVER ASSEMBLY (Part number: 15)
H149512 SILENCERS IP COVER 3/8” NPT WITH O­ RING  
(Part number: 87)
H149518 LUI MODULE (Part number: 207)
H149527 PNEUMATIC SET for NDX1512_  
(includes H149508 and H137059 assembly)
H149528 PNEUMATIC SET for NDX2512_  
(includes H149508 and H149515 assembly)
ELECTRONICS MODULE: Contact Metso

14.3 

REPLACING PARTS

14.3.1 

Prestage

Prestage location:

• 

NDX1510_

• 

under prestage cover with prestage symbol (Fig. 74)

• 

NDX_511_ and NDX_512_

• 

under main cover and LUI module (Fig. 75)

 

 

 

 

© Metso 2015

  

 

-  NDX valve controller 

-  Relay valve 

-  Prestage unit 

-  Local User Interface 

-  Printed circuit board module (including optional PT) 

-  Pressure gauge block 

REPLACING NDX ON NELES GLOBE 

Follow instructions in mounting chapter. 

REPLACING SPARE PARTS 

Prestage 

Prestage is located under cover with following symbol: 

            

      

 
Removal 

WARNING: Risk of injury. Ensure that supply pressure is shut off and actuator pressure is released prior 

to removal of the prestage.  
WARNING: The prestage must be handled carefully. Never touch the moving parts on the prestage and 

never rotate the nozzle. If the moving parts of the prestage are damaged, that may lead to reduced 

control performance of the device. 
NOTE: It is recommended to replace both the prestage and the relay valve at the same time. 
NOTE: it is recommended to also replace the filter and seal below the prestage (included in the spare 

parts kit) 

 

- Disconnect power from the device  
- Shut off

 

supply pressure and make sure that the actuator pressure is released 

- Remove the device from the actuator mounting bracket if there is limited working space in front of the 

prestage cover (Disconnect the supply and actuator piping if device is needed to remove). 
 
- Loosen the prestage cover M4 screws (Torx T20, 4 pcs) and remove the prestage cover 
 

Fig. 74   NDX1510_ prestage location.

Fig. 75   NDX_511_ and NDX_512_ prestage location.

14.3.2 

Removal of prestage

 

WARNING

Risk of injury. Ensure that supply pressure is 

shut off and actuator pressure is released prior 

to removal of the prestage. 

14 MAINTENANCE

M

AINTENANCE

Summary of Contents for NELES NDX 511 Series

Page 1: ...For full information go to our website www metso com ndx 7 NDX 71 en 4 2019 Installation Maintenanceand OperatingInstructions NDX Intelligent valve controller ...

Page 2: ...NS 36 11 1 PRESSURE GAUGE BLOCK INSTALLATION 36 START UP 38 12 LOCAL USER INTERFACE LUI 38 12 1 OVERVIEW 38 12 2 LUI USER ACCESS CONTROL 38 12 3 CALIBRATION REQUIRED PRIORTO START 39 12 4 MONITORINGVIEWS 40 12 5 ACTIVE ALERTS 40 12 6 EXCEPTIONS 41 12 7 REMOTE ACTIONS 41 12 8 MENU 41 12 8 1 Guided start up 42 12 8 2 Calibration 43 12 8 3 Parameters 44 12 8 4 Linearization 49 12 8 5 Manual control 5...

Page 3: ...14 3 3 Installation of prestage 74 14 3 4 Relay valve 75 14 3 5 Removal of relay valve 75 14 3 6 Installation of relay valve 76 14 3 7 Local User Interface 77 14 3 8 Electronics module 77 14 4 REPLACING OPTIONS 79 14 4 1 Pressure Gauge Block 79 DIMENSIONS 80 15 DIMENSION DRAWINGS 80 15 1 NDX1510 80 15 2 NDX_511_ 81 15 3 NDX_512_ 82 15 4 POSITION FEEDBACK MAGNETS FOR LINEAR AND ROTARY ACTUATORS 83 ...

Page 4: ...e 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 See also www metso com valves for the latest documentation SAVE THESE INSTRUCTIONS Subject to change without notice All trademarks ...

Page 5: ...or manufac turer s representative Addressesandphonenumbersareprintedonthebackcover See also www metso com NDX for the latest documentation SAVETHESE INSTRUCTIONS FOR LATER USE 1 1 BEFOREYOU BEGIN Do not install operate or maintain intelligent valve con troller without being fully trained and qualified in valve actuator and accessory installation operation and main tenance To avoid personal injury ...

Page 6: ...ns and Class I Div 2 instal lations of NDX_ _ _2 have to be supplied by a Class 2 or Limited Energy Source in accordance with CSA 61010 1 12 UL 61010 1 Ex WARNING Electrostatic charge hazard The cover is non conductive Clean with a damp cloth only Spark hazard Protect the aluminum housing from impacts and friction Ex WARNING For use in the presence of combustible dust Ignition protection relies on...

Page 7: ...NG NDX Ex d version Ex d certified cable glands needs to be used Maximum of two cable glands installed into NDX 1 2 NPT ports are allowed Ex d WARNING NDX Ex d version If device is installed to Ex d area it can t be installed to Ex i area anymore and If device is installed to Ex i area it can t be installed to Ex d area anymore Ex d WARNING NDX Ex d version Cover and housing and their flange surfa...

Page 8: ...ts to all control valves small and big rotary and linear single and double acting Available for intrinsically safe and flameproof applications Minimized process variability Linearization of the valve flow characteristics Excellent dynamic and static control performance Fast response to control signal change Accurate internal measurements Fig 1 Easy installation and configuration Simple fast config...

Page 9: ...management software connected to the control loop After connections of electric signal and pneumatic supply the micro controller μC continuously reads measurements Input signal Valve position with contactless sensor α Actuator pressure I II Supply pressure S Device temperature Advanced self diagnostics guarantee that all measurements operate correctly Powerful microcontroller calculates a control ...

Page 10: ...ions Manufacturing serial number explained TT device and factory sign YY year of manufacturing WW week of manufacturing NNNN consecutive number Example PH15360001 controller year 2015 week 36 consecutive number 1 Approval and type code plate Approval and type code plate includes following markings Type code 15 signs C code CE mark Approvals max two Operational temperature Input resistance Fig 5 Id...

Page 11: ...CS MOUNTING START UP OPERATION MAINTENANCE DIMENSIONS HOW TO ORDER LOGISTICS 11 NDX VALVE CONTROLLER Warnings plate Warnings plate includes explosion hazard warnings Fig 7 Warnings plate 3 PRODUCT SUMMARY GENERAL INFO ...

Page 12: ...140 49 1 4 191 201 207 220 15 25 376 372 374 87 378 379 373 47 42 130 100 32 375 3 Fig 8 NDX1510_ exploded view 1 3 4 15 25 30 191 37 47 87 100 130 140 191 201 207 220 221 372 373 374 375 376 378 379 94 Fig 9 _NDX_511_exploded_view 3 PRODUCT SUMMARY ...

Page 13: ...Prestage bottom filter assem x 32 O ring x x 37 Cover assem relay x x x 42 Cover assem prestage x 47 Countersunk screw x x x TX20 49 Prestage channel filling piece x 87 Exhaust cover x x x 94 Check valve double act only x x 100 Prestage unit assem x x x 130 Pan head screw x x x TX20 140 Relay valve assem x x x 191 Electronics module x x x 201 Countersunk screw x TX20 201 Socket head screw x x HEX3...

Page 14: ...oduct installation and maintenance Fig 12 NOTE Other tools are dependent on the actuator which the NDX is installed upon PH2 TX 7 TX 8 TX 10 TX 20 3 mm 8 mm 3 mm 5 mm 6 mm 10 mm 13 mm and 21 22 mm with linear actuators 8 mm and 24 mm with rotary actuators 3 PRODUCT SUMMARY ...

Page 15: ...kg 4 4 lbs Compact 2 8 kg 6 2 lbs Standard 3 8 kg 8 4 lbs Explosion proof Gauge block 0 9 kg 2 0 lbs 4 5 Pneumatics Supply Pressure 1 4 8 bar 20 116 psi single acting 2 0 8 bar 29 116 psi double acting Pressure range up to 10 bar with limited life time Supply Media Air nitrogen sweet natural gas2 Effect of supply pressure on valve position 0 1 at 10 difference in inlet pressure Air quality Acc to ...

Page 16: ... IIIC T85 C T115 C Dc IECEx EESF 18 0008X IEC 60079 0 2017 IEC 60079 11 2011 IEC 60079 15 2010 Input Ui 28 V Ii 120 mA Pi 1 W Ci 22 nF Li 100 μH Output Ui 28 V Ii 120 mA Pi 1 W Ci 22 nF Li 100 μH external load resistance 0 690 Ω Digital output Ui 16 V Ii 25 mA Pi 100 mW Ci 22 nF Li 100 μH T4 40 C 85 C T5 40 C 65 C T6 40 C 50 C II 2GD Ex db IIC T6 T4 Gb Ex tb IIIC T85 C T113 C Db Sira 17ATEX1283X E...

Page 17: ...ice is delivered in IP67 packaging for storage and transportation 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 elsewh...

Page 18: ...NDX VALVE CONTROLLER Most valve controller parts can be recycled if sorted accord ing to material A valve controller may also be returned to manufacturer for recycling and disposal 6 RECYCLING AND DISPOSAL ...

Page 19: ...ot valid MODEL VD25 MODEL VD29 MODEL VD37 MODEL VD48 AND 55 Fig 13 7 1 1 Installation to Neles Globe VD29 1 Mount the magnet holder with magnet to the actuator coupler tighten the fixing screw Fig 14 2 Mount the bracket to the actuator leaving the screws loose Fig 15 5 mm 6 mm 13 mm or 21 22 mm Depends on actuator size NOTE Similar mounting steps apply also with other Neles Globe actuator sizes NO...

Page 20: ...cket screws from step 2 Remove the magnet alignment tool 5 Mount the NDX to the bracket Fig 17 Bracket OrientationTable Neles Globe Neles Actuator Size Stroke mm Bracket Model Orientation VD 25 20 29 40 37 20 40 48 40 50 60 55 80 90 7 LINEAR MOUNTING ...

Page 21: ...de an alignment tool which makes device installation very easy 1 Mount the IEC bracket to the actuator leaving the screws loose 2 Mount the magnet alignment tool magnetically to the magnet bracket 3 Mount the magnet bracket to the actuator coupler leaving the screws loose Fig 18 4 Attach the magnet alignment tool to the center holes on the IEC bracket 5 mm Fig 19 NOTE Other tools are dependent on ...

Page 22: ...ove 6 Tighten the magnet bracket screws 7 When the magnet moves smoothly in the magnet alignment tool that automatically defines the correct alignment and distance from the device position sensor Tighten the IEC bracket to the actuator and remove the magnet alignment tool Fig 20 8 Mount the device to the IEC bracket by four screws Fig 21 7 LINEAR MOUNTING ...

Page 23: ...odel make sure that the following tolerances are followed with magnet mounting 1 Magnet shall be centered within 3 mm tolerance as shown in the picture 2 Magnet center shall never exceed the magnet center travel limits shown in the picture NOTE Use only Metso original magnets Bracket and fixing bolt material should have low magnetic permeability e g AISI316 or aluminium NOTE Always ensure that the...

Page 24: ...xceeded Figure 24 shows the exclusion zone There is no material limitation outside the exclusion zone but to guarantee the optimal performance do not use any magnetic material inside the zone Inside the exclusion zone but close to the walls AISI 304 and any austenitic steel can be used Fig 25 4 5 3 mm Fig 23 Max 6 deg Max 1 mm Max 3 mm Max 4 deg Max 3 deg Max 2 mm Fig 24 7 LINEAR MOUNTING ...

Page 25: ... if there is no position indicator in the actuator Place position indicator plate to the correct position so that it correspond to the valve position Lock position indicator plate with screw driver so that it can t turn by bending locking tabs Mount magnet to the actuator There shall be use thread locking in magnet assembly to prevent magnet loosening under heavy vibration Thread locking should be...

Page 26: ...l should have low magnetic permeability e g AISI316 or aluminium Aim for small mechanical clearance but avoid contact there shall be max 5 mm gap between the magnet and NDX Tilt is not critical Aim for zero eccentricity Polarity of the magnet is irrelevant Figure 27 shows the exclusion zone There is no material limitation outside the exclusion zone but to guarantee the optimal performance do not u...

Page 27: ... 8 mm 6 mm Fig 29 NDX1510_ piping Actuator Exhaust 3 8 NPT Actuator Pressure 1 4 NPT Housing Exhaust 3 8 NPT Supply Pressure 1 4 8 bar 20 116 psi Media Air nitrogen or sweet natural gas 1 4 NPT 8 mm 6 mm Fig 30 NDX_511_ and NDX_512_ piping NOTE Remove all temporary transportation plugs with 8 mm flat head screwdriver NOTE When NDX251_ is used with single acting actuator one of the pneumatic ports ...

Page 28: ...k valve on supply pressure port S is used on double acting version of NDX NDX251_ only Check valve on supply pressure port S shall be used with double acting actuators only CAUTION If double acting version of NDX NDX251_ is installed on single acting actuator the check valve must be removed 9 PNEUMATICS PIPING ...

Page 29: ...ck is installed Fig 32 NOTE Placement and distances between exhaust and pressure channels are different than with out the pressure gauge block See Dimension drawings for details NOTE When NDX251_ is used with single acting actuator one of the pneumatic ports I or II needs to be plugged Install steel plug with 6 mm hexagon wrench 9 PNEUMATICS PIPING MOUNTING ...

Page 30: ... In double acting device either I or II pneu matics ports can be used with single acting actuator NOTE When mounting the pneumatic connectors the exhaust cover may need to be removed temporarily Mount the exhaust cover back when the pneumatic connectors are mounted Do not leave device without exhaust cover Water and dirt may get into the device NOTE If electrical input signal is lost the actuator ...

Page 31: ...e Double acting Positioner fail action Open Signal direction Falling Other parameters according to assembly SINGLE ACTING ACTUATOR SPRING TO CLOSE 5 Increasing input signal to open valve shown Actuator type Single acting Positioner fail action Close must be in the spring direction Signal direction Rising Other parameters according to assembly 6 Increasing input signal to close valve not recommende...

Page 32: ... below are trendsetting They are measured with 3 bar supply air pressure without a process pressure They may vary significant ly due to different factors such as but not limited to pressure difference of the valve the stiction of the actuator supply air pressure the capacity of the supply air system and the dimensions of the supply air piping Actuator NDX Model Size Stroke Stroke Volume NPT Stroki...

Page 33: ...y PressureTable ActuatorType Spring Range Supply Pressure MIN Suggested MAX Neles VD C 0 8 2 6 bar 11 37 psi 2 6 bar 38 psi 3 6 bar 52 psi 4 0 bar 58 psi Neles VD A 0 2 1 0 bar 3 15 psi 1 4 bar 20 psi 2 1 bar 30 psi Neles VD B 0 4 2 1 bar 6 30 psi 2 1 bar 30 psi 3 1 bar 45 psi Other 1 4 bar 20 psi 8 bar 116 psi 9 PNEUMATICS PIPING MOUNTING ...

Page 34: ...HART 4 20 mA Loop Power 3 8 mA 9 7 VDC 485 Ω at 20 mA OUT Position Transmitter External 12 30 VDC 780 Ω max 690 Ω for I S Fail safe output is 3 5 mA or 22 5 mA 4 20 mA OUT or NAMUR DO Optional 4 20 mA IN Namur DO Optional PH2 5 mm 10 mm 2 pc 1 2 NPT Standard M20X1 5 available with adapter Fig 38 Wiring of NDX_511_ and NDX_512_ NOTE Remove temporary cable gland plugs with 10 mm hexagon wrench 10 EL...

Page 35: ... of the input cable be carried out from one end only NOTE If device is installed to Ex d area it can t be installed to Ex i area anymore Recommended Wire Type Shielded twisted pair with a max conductor size of 2 5 mm2 14 AWG HAZARDOUS AREA NONHAZARDOUS AREA PositionTransmitter Li 100 μH Ci 22nF Imax 120 mA Umax 28 V Pmax 1 W DO values see below Setpoint Li 100 μH Ci 22nF Imax 120 mA Umax 28 V Pmax...

Page 36: ...TROLLER 11 1 Pressure Gauge Block installation PH2 5 mm 10 mm Fig 41 Pressure gauge installation of NDX1510_ PH2 5 mm 10 mm Fig 42 Pressure gauge installation of NDX_511_ and NDX_512_ 11 INSTALLATION OF DEVICE OPTIONS ...

Page 37: ...d tighten three screws 4 Install and tighten the exhaust covers into the exhaust ports I and II by hand NOTE Remove all temporary transportation plugs with 10 mm hexagon wrench just before installing the pressure gauge block During transportation and storage the plugs shall be mounted NOTE Exhaust covers are different for Exh I and Exh II and shall not be mixed Make sure that they are reinstalled ...

Page 38: ...ator Type Valve Type þ þ Valve Dead Angle þ þ Performance Level þ þ Safety Cut off Range þ þ Input Signal Direction þ þ Positioner Fail Action þ þ Language Selection Monitoring of valve position target position input signal supply and actuator pressure Local control of the valve NOTE NDX1510_ When installing the cover make sure that the cover button symbols are at the same position as the symbols ...

Page 39: ...e has Cover lock active and PIN lock non active Default PIN code is 1234 Enter the PIN using the up down buttons and then press Enter to select each value Entering invalid PIN gives Invalid PIN notification Different lock settings can be configured in DTM See detailed instructions in Operation chapter 13 5 2 4 All para meters Fig 44 12 3 Calibration required prior to start Device needs to be confi...

Page 40: ...4 Number of active events if any and their descrip tions listed Tag name is shown in all views in the upper left corner 12 5 Active alerts When an active alert appears it will be shown in the upper right corner of the all LUI views as long as there are active alerts Then user can check then active event detail from the event list as shown on previous page Tag Device tag is visible in all views Tag...

Page 41: ...or fails position indicator shows on the LUI 12 7 Remote actions When calibration or offline test is started remotely i e from DTM there is a warning on the LUI before the valve starts to move 12 8 Menu Press Enter o to open menu Guided start up Calibration Parameters Linearization Manual control User Guide About POS 999 or sensor broken 12 LOCAL USER INTERFACE LUI START UP ...

Page 42: ... displayed select manual 1 point or automatic calibration WARNING Device needs to be in fail safe position when 1 point calibration is used Start Manual Automatic 0 90 180 270 Closed Open Linear Rotary None Booster QEV Booster QEV Single Double If Valve type Linear 1 point calibration Start Calibration WARNING Make sure that the valve movement does not endager people or processes before running ca...

Page 43: ...h the device to manual control mode pressing enter Next drive valve manually into open or close end depends on installation After defining end position with enter there is a warning about automatically moving valve before tuning part will start If it is safe to continue press enter and arrow keys at the same time as shown in the display Display shows progress of the calibration After calibration t...

Page 44: ...r is single acting spring return or double acting þ þ Once Actuator type is selected press enter to edit the setting Change setting with arrow keys and confirm that with enter þ þ If single acting actuator is selected Pneumatics Connection parameter needs to be defined too Options are I or II I means that the port I is connected to the actuator and II means that the port II is connected to the act...

Page 45: ... Soft seated R valve 4 Low Cv Finetrol Positioner fail action þ þ Positioner fail action will take place in case of signal or supply pressure failure or when the controller software discovers a fatal device failure For single acting actuators set value in the spring direction This means that changing this parameter will not change actual fail action this parameter tells the device which is the act...

Page 46: ... Change value with arrow keys and confirm that with enter Cut off closed þ þ Cut off closed is used with valves that require great torque to be closed It is used to ensure that the valve is fully closed at a 4 mA input signal þ þ When this value is exceeded the valve is forced to a 0 position This is called the tight cut off feature If for example the value is 2 tight shut off starts when the inpu...

Page 47: ... pass valve fully þ þ Run Calibration see chapter 12 7 2 Calibration þ þ Check the valve performance þ þ If the performance is insufficient þ þ Adjust Performance Level parameter þ þ If needed adjust the by pass valve and recalibrate þ þ Adjust Symmetry parameter if the symmetry for the opening closing speed needs to be changed Configuration with Quick ExhaustValves þ þ Ensure that QEV by pass flo...

Page 48: ... HART 6 device þ þ Once HART revision is selected press enter to edit the parameter Select or change value with arrow keys and confirm that with enter þ þ Device needs to be rebooted after change Setpoint unit þ þ It is possible to define if setpoint unit will be in or in mA in one of the main views þ þ Once Setpoint unit is selected press enter to edit the parameter Select correct unit with arrow...

Page 49: ...ss enter to edit the setting Select Cancel or Reset with arrow keys and confirm with enter 12 8 4 Linearization Linearization can be used for linear valves when linkage geometry needs to be corrected by valve controller Lin earization can be done with 3 points and end points Linearization will be done in positions 25 50 and 75 NOTE There must be external position measurement in linear valve that y...

Page 50: ...ice starts to follow setpoint PWM control Control directly PWM signal to the prestage By pass position measurement Can be used for identifying if problem is in positioner or if the valve actuator is stuck Valve position may jump when going back to auto mode and device starts to follow setpoint 12 8 6 User Guide Here you find QR code for our product web pages and support material ScanQRcodewithQRsc...

Page 51: ... functions listed below These functions are realised in various ways in DeviceCare and in FDT Frame Applications User management and administration Device inventory management DTM management Automatic bus scanning Uploading or downloading of device configuration Loading of device specific views into the user interface Execution of device specific functions Parametrization of devices when DTM is co...

Page 52: ...nnected status shows if connection to the device is established or if the DTM is in disconnected offline mode 6 Green arrow icon is displayed when the DTM is sending or reading parameters from the device 7 Parameter set state Device parameters are stored to the device and also in the local database This icon shows iftheinformationshownintheDTMisupdated with the device only saved to the local datab...

Page 53: ...puter or local computer network for later use or as a backup file The Import function allows you to load previously saved configurations into the DTM for use in device configuration Exported configurations are saved in xml file format Location of the Import and Export functions depends on the FDT frame application used Usually there is a menu or context menu with right mouse click which provides a...

Page 54: ...Supply Pressure Sensor Failure Actuator Pressure Sensor Failure Reduced control performance Temperature Sensor Failure Detected Normal Info Maintenance required Off specification Function check Device failure Single statuses can be enabled disabled and classified to certain NAMUR class in DTM s Status Configuration view Relatedeventsintheeventlogarelistedinthesamechapter 13 5 2 2 Device Informatio...

Page 55: ...vailable statuses can be either disabled or classified to a certain NAMUR class in Status Configuration view Status limits and current value is shown in the same view when applicable Fig 60 Following table lists all statuses and related events in the event log that are available from the device Description proposed actions and default NAMUR classification are also described in the table Status con...

Page 56: ... will help to compensate changed operating conditions and check performance Check valve at next maintenance opportunity Disabled Hunting Detected Hunting detected Hunting recovery Improper selection of position control performance level If there are boosters the hunting may be caused by those Check position control performance level possibly change to less aggressive to stabi lize valve Try to ope...

Page 57: ...ce performance If perfor mance is adequate increase value of Total Operation Time Limit in DTM EDD Status Configuration view Maintenance Required Supply Pressure Sensor Failure Supply Pressure Sensor Failure Detected Supply pressure sensor recovered Supply pressure mea surement is faulty Control performance is reduced Change the printed circuit board module to a new one during next maintenance act...

Page 58: ...e Failsafe activated Failsafe activated Recovered from fail safe Linear magnet not detected Setpoint sensor or position sensor has failed Check position feedback magnet and recalibrate the device Replace printed circuit board module Follow instructions in User Guide Failure Actuator Diagnostics Status Related events in the event log Status description Proposed actions Default NAMUR classification ...

Page 59: ...ng conditions and check performance Maintenance Required Maximum Stiction Too High Maximum stiction high limit exceeded High maximum stiction recovered Maximum stiction is above high limit Valve or actuator static friction has increased This may cause accuracy prob lems and ultimately prevent valve from moving Review the device performance If perfor mance is adequate increase value of Maxi mum sti...

Page 60: ...ibration recom mended Previous calibration was cancelled Run position calibration Maintenance Required Single point calibration is used calibration recommended Single point calibra tion is used Run position calibration Assembly Related parameter was changed calibration recommended Assembly Related parameter was changed Run position calibration Device is unable to detect mag net in whole position r...

Page 61: ...re than 5 means that control performance is decreased 2 0 100 Positioner Diagnostics Limits Parameter name Description Default value Limits options Total Relay Valve Travel Limit Set the total relay valve travel alert limit 1000 000 0 10 0000 0000 Date For Total Operation Time Alert Select date for next alert 25 years after first start up 0 100 years Actuator Diagnostics Limits Parameter name Desc...

Page 62: ...enerated 120 20 120 Valve Position Below Low Limit Set valve position low alert limit If a measurement goes below the limit a status is activated for the device and an event is generated 20 20 120 Maximum Stiction Too High Limit Set maximum stiction high alert limit If a measurement exceeds the limit a status is activated for the device and an event is generated 16 bar 0 16 bar Maximum Stiction To...

Page 63: ...mum pressure rating Since the maximum pressure rating for the NDX positioner is 8 bars this should be the highest limit if the actuator has a higher rating If a measurement exceeds the limit a status is activated for the device and an event is generated 8 bar 1 4 8 bar Supply Pressure Below Low Limit For the supply pressure low limit the spring rating of a spring return actuator can be used For do...

Page 64: ...estart required Restart required after changing the HART protocol HART 6 HART 6 HART 7 Assembly Related Parameter name Description Default value Limits options Positioner Fail Action Set Positioner Fail Action according to actuator spring direction If you change the value of this parameter calibrate the device When there is linear actuator without mechanical limit in open closed end it is recommen...

Page 65: ...t signal Rising Setpoint to Open Rising Setpoint to Open Rising Setpoint to Close Valve Target Position Low Limit Sets the lower limit for the working range of the valve 0 0 100 Valve Target Position High Limit Sets the upper limit for the working range of the valve 100 0 100 Max Travel Speed To Close Describes the percentage of change per second in the setpoint as the valve changes from OPEN stat...

Page 66: ...terization Type Linear Flow Modification is not used Shape Factor Flow Modification is used If you select this option enter a Shape Factor value User Curve You can create a custom table If you select this option manually edit the Values as necessary Not Used Linear Not Used Linear Shape Factor User Curve Shape Factor Shape Factor describes the nearest approximate or the exact shape of the valve ch...

Page 67: ...ime for triggering the device temperature status and event in case device temperature high or low limit is exceeded 0 s 0 36000 s Valve Position Latch Time Set wait time for triggering the valve position status and event in case valve position high or low limit is exceeded 30 s 0 36000 s Access Permissions Parameter name Description Default value Limits options Local User Interface Lock Select Loc...

Page 68: ...s It can operate as NAMUR limit switch or any any status information shown in the list Always Off Always Off Limit Switch Closed Limit Switch Open Any device status NAMUR Output Function Defines digital output normal state Normally Closed Normally Open Normally Closed Note These parameters may not be available It depends on the device hardware configuration Dynamic Variables Parameter name Descrip...

Page 69: ...ed To view the data in the DTM read the data from the device The graph shows opening and closing pressures When the data has been read from the device DTM auto matically saves the graph to the database Advanced diagnostics Comparison of two selected online valve signatures based on the time stamp is available in advanced diagnostics version of NDX Select wanted days and read your selection Monitor...

Page 70: ... and Partial StrokeTest User can use the Template menu to select either default values or some predefined set of values for the execution of a test Test parameter grid allows entering test specific parameters for the selected test For example for Multipoint Step Test user can enter up to 20 test steps by expanding the gird by clickingtheroundplussignatthetop rightcornerofthegrid Offline test proce...

Page 71: ...on of the setpoint changes HART Diagnostics Parameter name Description Total Messages In Total HART messages received Total Messages Out Total HART messages sent HART Com munication Error Rate during last hour HART communication error rate in percentage during last hour HART Com munication Error Rate during last day HART communication error rate in percentage during last day 13 5 3 7 Trends Steady...

Page 72: ...valve position and the last three months If the valve operation point has recently changed it can be seen in three months histogram Valve position histogram trend is especially useful when optimizing plant operation or replacing old control valves If valve operation point is 80 90 most of the time then the valve could be too small for current application If valve operation point is 10 30 most of t...

Page 73: ...X1_ Partnumber 140 H149515RELAYVALVEASSEMBLYforNDX2_ Partnumber 140 H149508 PRESTAGE UNIT ASSEMBLY Part number 100 H149509 MAIN COVER ASSEMBLY Part number 15 H149512 SILENCERS IP COVER 3 8 NPTWITH O RING Part number 87 H149518 LUI MODULE Part number 207 H149527 PNEUMATIC SET for NDX1512_ includes H149508 and H137059 assembly H149528 PNEUMATIC SET for NDX2512_ includes H149508 and H149515 assembly ...

Page 74: ...T20 4 pcs and remove the prestage cover Fig 76 Compact version NDX1510_ TX20 Pliers Disconnect power from the device Shut off supply pressure and make sure that the actuator pressure is released Remove the device from the actuator mounting bracket if there is limited working space in front of the prestage cover Disconnect the supply and actuator piping if device is needed to remove Loosen the pres...

Page 75: ...calibration Standard and explosion proof version NDX_511_ and NDX_512_ TX20 TX7 TX8 PH2 NDX_511_ or HEX6 NDX_512_ Press the prestage into place Press in the marked positions mildly by hand Do not use excessive force as this may indicate the prestage shaft is misaligned or the o ring is not lubed Tighten the screws holding the prestage in place Push the prestage 2 wire connector into the socket on ...

Page 76: ...oved relay valve see picture Installation NOTE make sure there is no debris in the small shaft hole eg from the o ring of the removed relay valve see picture WARNING Do not use any tools to install the relay valve It can be pushed on its place just by using hands Fig 85 WARNING Do not use any tools to install the relay valve It can be pushed in place by hand Align the small and large shaft in corr...

Page 77: ...tion Note that there might be other regulations which prevents opening cover when process is running or power is connected Mount new display and tighten the screws Mount main cover and tighten the screws WARNING Flameproof Explosion Proof version Tightening torque for the housing cover screws is 15Nm 14 3 8 Electronics module Tools for NDX1510_ PH2 TX7 TX20 60 mm 2 5 inch reach required Tools for ...

Page 78: ...10_ Fig 91 NDX_511_ and NDX_512_ þ þ Loosen the display screws and remove display Fig 91 Fig 92 Fig 92 NDX1510_ Fig 93 NDX_511_ and NDX_512_ þ þ Loosen the prestage cover screws and remove the prestage cover Fig 93 applies to NDX1510_ only þ þ Unplug the prestage wire connector from the prestage Fig 94 NDX_510_ þ þ Loosen the electronics module screws and grounding screws NDX_511_ NDX_512_ then re...

Page 79: ...ater in supply air this gasket prevents water access to the electronics þ þ Mount new electronics module and tighten the electronics module screws and grounding screws NDX_511_ NDX_512_ þ þ Plug the prestage wire connector to the prestage þ þ Reinstall the prestage cover and tighten the screws þ þ Mount new display and tighten the screws þ þ Mount main cover and tighten the screws WARNING Flamepro...

Page 80: ...80 NDX VALVE CONTROLLER 15 1 NDX1510 LINEAR APPLICATION ROTARY APPLICATION Fig 98 15 DIMENSION DRAWINGS ...

Page 81: ...GENERAL INFO SPECS MOUNTING START UP OPERATION MAINTENANCE DIMENSIONS HOW TO ORDER LOGISTICS 81 NDX VALVE CONTROLLER 15 2 NDX_511_ Fig 99 15 DIMENSION DRAWINGS DIMENSIONS ...

Page 82: ...82 NDX VALVE CONTROLLER 15 3 NDX_512_ Tightening torque 15 Nm 48 Fig 100 15 DIMENSION DRAWINGS ...

Page 83: ...RATION MAINTENANCE DIMENSIONS HOW TO ORDER LOGISTICS 83 NDX VALVE CONTROLLER 15 4 POSITION FEEDBACK MAGNETS FOR LINEAR AND ROTARY ACTUATORS Fig 101 NDX1510_ 15 5 PRESSURE GAUGE BLOCK NDX1510_ Fig 102 NDX1510_ 15 DIMENSION DRAWINGS DIMENSIONS ...

Page 84: ...84 NDX VALVE CONTROLLER Fig 103 NDX_511_ Fig 104 NDX_512_ 15 DIMENSION DRAWINGS ...

Page 85: ...clared in conformity with the provisions of the Machinery Directive TheproductaboveismanufacturedincompliancewiththeapplicableEuropeandirectivesandtechnicalspecifications 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 a...

Page 86: ... channel NAMUR Internal 2 wire passive position transmitter Analog position feedback signal output 4 20 mA supply voltage 12 30 V DC Applicable to 5 sign 1 or 2 7 sign TEMPERATURE RANGE G General 40 85 C 40 185 F 8 sign SHALL ALWAYS BE HYPHEN OR SLASH Standard for 5 sign 0 or 2 If 5 sign 1 is selected select hyphen for Ex i or I O extension pending Select slash for 5 sign 1 and 9 and 10 sign N Not...

Page 87: ...0 C to 65 C T6 40 C to 50 C Applicable to 5 sign 0 or 2 D NEPSI China certifications Ex d Ex d IIC T4 T5 T6 Gb Ex d tD A21 IP66 T85 C T95 C T4 or T113 40 C 85 C T5 or T95 40 C 72 C T6 or T85 40 C 57 C Applicable to 5 sign 2 J Japan certifications Ex d IIC T6 T4 Gb Ex tb IIIC T85 C T113 C Db T4 40 C to 85 C T5 40 C to 72 C T6 40 C to 57 C Applicable to 5 sign 2 K KOSHA Korea certifications Ex d IIC...

Page 88: ...orocaba São Paulo Brazil Tel 55 15 2102 9700 Fax 55 15 2102 9748 Asia Pacific Haw Par Centre 06 01 180 Clemenceau Avenue Singapore 239922 Tel 65 6511 1011 Fax 65 6250 0830 China 11 F China Youth Plaza No 19 North Rd of East 3rd Ring Rd Chaoyang District Beijing 100020 China Tel 86 10 6566 6600 Fax 86 10 6566 2583 Middle East Roundabout 8 Unit AB 07 P O Box 17175 Jebel Ali Freezone Dubai United Ara...

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