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INTELLIGENT
VALVE CONTROLLER

ND9200F

Rev. 2.2

Installation, Maintenance and
Operating Instructions

7 ND92

F 70 e

n

• 1/20

09

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2
3
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Содержание ND9200F

Страница 1: ...INTELLIGENT VALVE CONTROLLER ND9200F Rev 2 2 Installation Maintenance and Operating Instructions 7 ND92F 70 en 1 2009 ...

Страница 2: ...ode 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 20 6 3 Flame arrestor assembly 20 6 4 Diaphragms 20 6 5 Communication circuit board 20 7 ERROR MESSAGES 21 7 1 Failsafe errors 21 7 2 Alarms 21 7 3 Errors 22 7 4 Warnings 22 7 5 Notifications 23 8 TROUBLE SHOOTING 23 9 ND92_F K...

Страница 3: ...ofile 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 modules for a...

Страница 4: ...ssure 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 t...

Страница 5: ...si supply in steady state position 0 6Nm3 h 0 35scfm spoolvalves2 3 1 0 Nm3 h 0 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 condi...

Страница 6: ...flow ports and cable glands plugged until installing Follow instructions elsewhere in this manual 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 Dam age to the equipment and personal injury may res...

Страница 7: ...r so that the pointer 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 locking compound to the screw 48 and tighten firmly Remove the protective plastic plugs from pneu matic connections C2 S and C1 Leave the metal plugs 54 in the unu...

Страница 8: ... the unused connections at the bot tom of the controller Single acting actuators install a metal plug 53 with sealant to the C1 connection 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 approximatel...

Страница 9: ...ecommended 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 ND9200F 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 th...

Страница 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...

Страница 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 ...

Страница 12: ...arth connection screw The shield can be 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 indica...

Страница 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 ND9200F controller actuator and valve configuration After verifying the parameters th...

Страница 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 activated In order to change the manual setpoint return to the measurement monitoring view and go to targe...

Страница 15: ...d 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 1 A using the and keys The value 2 A i...

Страница 16: ...it high cut off and high limit If the input signal is smaller than low cut off TRANSDUCER_BLOCK FINAL_VALUE_CUTOFF_LO the valve will be fully closed If the input signal is smaller than low limit TRANSDUCER_BLOCK FINAL_VALUE_RANGE LO the valve stays in the low limit If the input signal is greater than high cut off TRANSDUCER_BLOCK FINAL_VALUE_CUTOFF_HI the valve will be fully opened If the input si...

Страница 17: ...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 to run the normal ...

Страница 18: ...e position and 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 ND9200F unit is restarted i e the power loop is momentarily disconnected 5 7 5 Reduced Performance When...

Страница 19: ...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 6 1 1 Removal Loosen the M8 stop screw 110 in the position indicator 109 and turn the positio...

Страница 20: ...r 171 This assembly can not be disassembled and should be replaced if clogged To remove the flame arrestor assembly unscrew the screws 173 4 pcs and remove the dia phragm 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 Installa tion is the reversal of removal Place the O rings carefully 6 4 Diaphragms The diaphragms 169...

Страница 21: ...y message Description POSITION SENSOR FAILURE Position sensor measurement failed Change the ND9000 device to a new one PRESTAGE SHORTCUT ERROR Shortcut in the prestage unit FAE nnn Fatal malfunction in the device nnn is a number between 001 004 Change the ND9000 device to a new one Display message Description DEVIATION ALARM Valve deviation out of limits STICTION LOW ALARM Stiction has exceeded th...

Страница 22: ... valve unit SPOOL SENSOR RANGE ERROR Spool sensor range failed during position calibration Check the configuration parameters Check the prestage and spool valve unit Display message Description TOTAL OPERATION TIME WARNING Operating time exceeded limit VALVE FULL STROKES WARNING Valve stroke counter limit reached VALVE REVERSALS WARNING Valve reversals counter limit reached ACTUATOR FULL STROKES W...

Страница 23: ...icks 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 incor rectly selected The actuator or valve did not move or was stuck during calibration Supply pressure too low Spool valve dirty ...

Страница 24: ...nduit entry Manufacturing serial number The type designation is described in Chapter 14 9 1 3 Technical specifications 9 1 3 1 ND92_F K_ 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 100mA 30VDC 125VAC K06 Switch accuracy 2 Number of switches 2 K05 or K06 Protection class of cover IP66 DIN 4005...

Страница 25: ...ce with screw 326 Install the base plate 324 with the limit switches and con nector 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 con duit entries which will not be used Mount the pointer 109 on the shaft 311 Adjust the limit swit...

Страница 26: ... switch according to 9 2 and check the adjustment according to 9 4 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 neces sary 10 TOOLS No special tools required 11 ORDERING SPARE PARTS Spare parts are delivered as modules The modules available are indicate...

Страница 27: ...12 1 Exploded view and parts list ND9200F 107 110 109 228 223 39 215 220 210 19 18 104 182 221 2 197 196 181 200 177 176 170 184 169 171 173 14 174 193 63 61 47 15 16 12 100 42 222 173 167 165 166 120 139 164 162 163 217 218 219 199 57 183 140 36 ...

Страница 28: ... Spring guide 165 1 O ring 166 1 Spring 167 1 Diaphgram cover 169 1 Pilot pressure diaphgram x 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 x 196 1 Bushing 197 1 Flame arrester assembly x 199 1 O ring 200 1 Flame arrester plunger 210 1 Controller circuit board 215 1 ...

Страница 29: ...en 29 12 2 Exploded view and parts list ND92_F K_ ND92_F I__ ND92_F B__ 107 110 109 308 223 104 100 311 312 301 313 315 346 349 348 347 314 350 351 305 304 I_ _ 324 300 307 306 325 326 302 358 357 355 K0_ 111 111 ...

Страница 30: ... 301 1 O ring 302 1 Screw 304 1 Bracket 305 2 Screw 306 1 Bracket 307 3 Screw 308 2 Screw 311 1 Extension shaft 312 2 Screw 313 2 or 4 Cam disc 314 2 or 4 Screw 315 1 Terminal block 324 1 Base plate 325 2 Screw 326 1 Screw 346 1 Bearing bushing 347 2 Proximity switch 348 1 Fixing plate 349 2 Screw 350 1 Washer 351 1 Screw 355 2 or 4 Microswitch 357 2 Spring washer 358 2 Screw ...

Страница 31: ...5 4 Screw 66 4 Screw 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 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 actuators only Note See 12 5 f...

Страница 32: ...hole drilled ø5 5 through Note Old series B actuators Note Different mounting position 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 Item Qty Description 1 1 Mounting bracket 2 2 Coupling half 3 1 Adapter 4 4 Screw...

Страница 33: ...4 31 28 48 47 16 38 53 39 38 65 64 54 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 64 1 Mounting plate 65 4 Screw Set conical plug to the scale according to the stroke ...

Страница 34: ...this position with feedback lever 54 Maximum stroke 120 mm Maximum stroke 80 mm Allowed travel range 45 90 45 45 45 45 Item Qty Description 1 1 Bracket 2 1 Feedback lever 3 1 Filling piece 4 1 Clearance remove spring 5 4 Cross rec head screw 6 4 Washer 7 4 Hexagon screw 8 4 Washer 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...

Страница 35: ...OSED 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 blue OMRON D2VW 01 gold plated contacts K06 100 mA 30 V DC 125 V AC Ambient temperature 40 80 C 40 176 F ...

Страница 36: ...itch Supply voltage 8 V DC Ri 1 kΩ Current consumption active face free 3 mA active face covered 1 mA Intrinsically safe II 2 G EEx ia IIC T6 According to CENELEC EN50014 and EN50020 Voltage Umax current Imax inductance Li and capacitance Ci according to certificate of switch see table PROXIMITY SWITCH blue brown OPEN CLOSED Type of proximity switch Electrical values Umax Imax Li Ci V mA µH nF Ex ...

Страница 37: ... 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 PROXIMITY 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 A...

Страница 38: ...38 7 ND92F 70 en ND92_F B06 1 LS1 open 2 LS2 closed 3 GND 12 13 15 16 O C 1 2 3 LS2 LS1 Bus powered switches no external connections ...

Страница 39: ... 30 39 1 54 52 2 05 1 4 NPT 35 4 1 39 M6 35 4 1 39 M6 x 12 4 0 16 25 0 98 25 0 98 3 0 12 14 0 55 15 0 59 ND9200 1 4 NPT 39 1 54 52 2 05 33 1 30 33 1 30 14 0 55 26 8 1 05 ø6 ø0 23 35 4 1 39 35 4 1 39 F05 ø50 VDI VDE 3845 M6 10 5 0 41 6 0 23 13 0 51 101 2 3 98 162 6 37 63 2 48 161 6 33 ...

Страница 40: ...40 7 ND92F 70 en 14 EC DECLARATION OF CONFORMITY ...

Страница 41: ... 1 and 2 Groups A B C D E F Group A FM only ND92_FE2 Ui 32 V Temperature range T4 40 to 85 C 40 to 185 F T5 75 C 167 F T6 60 C 140 F 7 OPTIONS OF VALVE CONTROLLER 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 Spe...

Страница 42: ...42 7 ND92F 70 en ...

Страница 43: ...7 ND92F 70 en 43 ...

Страница 44: ...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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