Metso NELES NDX Series Operating and maintenance manual

For full information go to our website:

www.metso.com/ndx

7 NDX 71 en - 4/2019

Installation,

Maintenance and

Operating Instructions

NDX

Intelligent valve controller

TABLE OF CONTENTS

GENERAL 2

1 FOR YOUR SAFETY 5

1.1 BEFORE YOU BEGIN 5

2 SAFETY PRECAUTIONS 6

3 PRODUCT SUMMARY 8

3.1 INTRODUCTION TO NELES®

NDX INTELLIGENTVALVE CONTROLLER 8

3.2 KEY FEATURES 8

3.3 OPERATION PRINCIPLE 9

3.4 OPTIONS 9

3.4.1 Internal position transmitter 9

3.4.2 Digital output (namur) 10

3.4.3 Gauge block 10

3.5 MARKINGS 10

3.6 EXPLODED VIEW 12

3.7 TOOLS 14

SPECIFICATIONS 15

4 TECHNICAL DESCRIPTION 15

4.1 GENERAL 15

4.2 ENVIRONMENTAL INFLUENCE 15

4.3 ELECTROMAGNETIC PROTECTION 15

4.4 ENCLOSURE 15

4.5 PNEUMATICS 15

4.6 ELECTRONICS 15

4.7 APPROVALS 16

LOGISTICS 17

5 TRANSPORTATION AND STORAGE 17

6 RECYCLING AND DISPOSAL 18

MOUNTING 19

7 LINEAR MOUNTING 19

7.1 INSTALLATION TO NELES GLOBE 19

7.1.1 Installation to Neles Globe (VD29) 19

7.2 INSTALLATION TO IEC MOUNTING FACE 21

7.3 INSTALLATION TO ANY LINEAR ACTUATOR 23

8 ROTARY MOUNTING 25

8.1 INSTALLATION TO NELES BSERIES

ACTUATORS  MAGNET MOUNTING 25

8.2 INSTALLATION TO NELES BSERIES

ACTUATORS  BRACKET MOUNTING 25

8.3 INSTALLATION TO ANY ROTARY ACTUATOR 26

9 PNEUMATICS PIPING 27

10 ELECTRICAL INSTALLATION 34

11 INSTALLATION OF DEVICE OPTIONS 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 PRIOR TO START 39

12.4 MONITORING VIEWS 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 50

12.8.6 User Guide 50

12.8.7 About 50

OPERATION 51

13 DEVICE TYPE MANAGER (DTM) 51

13.1 INTRODUCTION TO DTM 51

13.1.1 Field Device Tool 51

13.1.2 FDT Functions 51

13.1.3 For More Information on the FDT Standard 51

13.2 GETTING STARTED 51

13.2.1 Software requirements 51

13.2.2 Installing DTM 51

13.2.3 Updating DTM installation 51

13.3 USER INTERFACE INFORMATION 52

13.4 USING DTM 53

13.4.1 DTM settings 53

13.4.2 Frame application functions 53

13.4.3 Import/Export 53

13.4.4 Printing 53

13.5 NDX DTM 53

13.5.1 Parameterize Oine 53

13.5.2 Parameterize Online 54

13.5.2.1 Performance 54

13.5.2.2 Device Information 54

13.5.2.3 Commissioning 55

13.5.2.4 Status Conguration 55

13.5.3 Diagnosis 69

13.5.3.1 Performance 69

13.5.3.2 Online Valve Signature 69

13.5.3.3 Event log 69

13.5.3.4 Oine Testing 70

13.5.3.5 Oine Test Results 70

13.5.3.6 Counters 71

13.5.3.7 Trends 71

13.5.3.8 Valve Position Histogram 72

GENERAL INFOSPECSMOUNTINGSTART UPOPERATIONMAINTENANCEDIMENSIONSHOW TO ORDER LOGISTICS

GENERAL INFO

SPECIFICATIONS

LOGISTICS

MOUNTING

START UP

OPERATION

MAINTENANCE

DIMENSIONS

HOW TO ORDER

GENERAL INFO

MAINTENANCE 73

14 MAINTENANCE 73

14.1 GENERAL 73

14.2 ORDERING SPARE PARTS 73

14.3 REPLACING PARTS 73

14.3.1 Prestage 73

14.3.2 Removal of prestage 73

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

15.5 PRESSURE GAUGE BLOCK 83

EC DECLARATION OF CONFORMITY 85

16 EC DECLARATION OF CONFORMITY 85

HOW TO ORDER 86

17 HOW TO ORDER INTELLIGENT VALVE CONTROLLER NDX 86

WARNING

Showing information about

possible hazards (etc.)

NOTE

Comments about how to get most out

of the product (etc.)

CAUTION

Information about being careful when

using the products in dierent scenes (etc.)

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.

See also www.metso.com/valves for the latest documentation.

SAVE THESE INSTRUCTIONS!

Subject to change without notice.

All trademarks are property of their respective owners.

GENERAL INFOSPECSMOUNTINGSTART UPOPERATIONMAINTENANCEDIMENSIONSHOW TO ORDER LOGISTICS

NDX VALVE CONTROLLER

READ THESE INSTRUCTIONS FIRST!

These instructions provide information about the safe hand-

ling, installation, commissioning, operation, troubleshoot-

ing, maintenance and replacement of the intelligent valve

controller. These instructions do not contain all detailed

information on every possible aspect of installation, oper-

ation or maintenance.

If you are uncertain about the use of the controller or its

suitability for your intended use or if you require additional

assistance, please contact the manufacturer or manufac-

turer’s representative.

Addresses and phone numbers are printed on the back cover.

See also www.metso.com/NDX for the latest

documentation.

SAVE THESE INSTRUCTIONS FOR LATER USE!

1.1 BEFORE YOU BEGIN

Do not install, operate or maintain intelligent valve con-

troller without being fully trained and qualied in valve,

actuator and accessory installation, operation and main-

tenance. To avoid personal injury or property damage, it

is important to carefully read, understand, and follow all

contents of this user guide, including all safety cautions and

warning. It is also important to be authorized by the plant

operator before operating the intelligent valve controller.

Note, that there are additional safety regulations which

are plant and/or hazardous area related. Those are not

covered in this manual.

1 FOR YOUR SAFETY

GENERAL INFO

NDX VALVE CONTROLLER

NOTE

Avoid grounding a welding machine in close

proximity to a valve controller. Damage to

the equipment may result.

CAUTION

Do not exceed the permitted values!

Exceeding the permitted values marked on

the valve controller maycause damage to the

controller and to equipment attached to the

controller and could lead to uncontrolled pres-

sure 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 pressurized pneu-

matic components of a valve controller leads to

uncontrolled pressure release. Always shut o

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 the

valve operates between open and closed po-

sitions. Make sure that the operation does not

endanger people or processes!

WARNING

Do not operate the device with cover removed!

- Environmental inuence (water, dust etc.)

Ex NOTE

Follow the standards EN/IEC 60079-14 when

installing the equipment and EN/IEC 60079-25

when connecting Ex i interfaces.

Ex Note

For ordinary locations 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 the enclosure.

Protect the cover of the valve controller from

impacts.

· When temperature is higher than 70 °C /

158°F the temperature rating of the cable

shall be higher than the ambient temperature.

· Device shall not be subjected to a prolic

charge generating mechanism.

· Accumulation of dust shall be avoided!

Intrinsic Safety (Ex i) WARNING

· Ensure that the complete installation and

wiring is intrinsically safe before operating

the device!

· The equipment must be connected via a

certied Zener barrier placed outside the

hazardous area.

· Temperature rating of selected connection

cable shall be greater than 83 °C.

Ex n WARNING

At an ambient temperature ≥ +70 °C / 158 °F,

the temperature rating of selected connection

cable shall be in accordance with the maximum

ambient temperature range. Selected cable

gland shall not invalidate the type of protection.

Ex d WARNING (NDX Ex d version)

Do not open the device when energized!

Explosion protection is lost.

Ex d WARNING (NDX Ex d version)

After de-energizing, delay one minute

before opening!

2 SAFETY PRECAUTIONS

GENERAL INFOSPECSMOUNTINGSTART UPOPERATIONMAINTENANCEDIMENSIONSHOW TO ORDER LOGISTICS

NDX VALVE CONTROLLER

Ex d WARNING (NDX Ex d version)

Tightening torque for the housing cover screws

is 15Nm.

Ex d WARNING (NDX Ex d version)

Use a cable gland and blind plug with suitable

Ex d certication.

For ambient temperature over 70 °C / 158 °F

use a heat resistant cable and cable gland

suitable for at least 92 °C / 196 °F.

Ex d WARNING (NDX Ex d version)

Ex d certied 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 ange surfaces

are Ex d critical parts. Extra caution needs to be

taken when handling them. If there are scratches

in ange surfaces or if the cover is dropped, the

cover and/or device needs to be changed.

2 SAFETY PRECAUTIONS

GENERAL INFO

NDX VALVE CONTROLLER

3.1 INTRODUCTION TO NELES® NDX INTELLIGENT

VALVE CONTROLLER

Metso’s Neles NDX is the next generation intelligent valve

controller working on all type of control valves and in all

industry areas. It guarantees end product quality in all

operating conditions with incomparable performance,

unique diagnostics, and years of reliable service. The NDX

is a future-proof investment with life-time support for

asset management.

3.2 KEY FEATURES

• Reliable and robust design

• Industry leading pneumatic capacity

• Benchmark control performance

• Simple and fast installation and commissioning

• Local / remote operation

• Wide language support

• Expandable architecture

• HART 6/7 communication as standard

• Advanced device diagnostics including

 Self-diagnostics

 Online diagnostics

 Performance diagnostics

 Communication diagnostics

 Extended o-line tests

 Performance view

 Online Valve Signature

• Extended o-line test capabilities

• Worldwide support for hazardous area approvals

Total cost of ownership

• Fast and reliable installation process

• Low energy and air consumption

• Easy to use diagnostics simplify determining when

valve maintenance is required

• Inherent high air capacity eliminates additional

instrumentation

• One positioner that ts to all control valves; small

and big, rotary and linear, single and double acting

• Available for intrinsically safe and ameproof

applications

Minimized process variability

• Linearization of the valve ow characteristics

• Excellent dynamic and static control performance

• Fast response to control signal change

• Accurate internal measurements

Fig.1

Easy installation and conguration

• Simple / fast conguration and calibration using one

of the following:

 Standard Local User Interface (LUI) accessible

without opening the device cover

 LUI can be rotated according to mounting

position

 Distributed Control System (DCS) asset

management program

• Backwards compatible with retrot kits for easy

replacement of Metso NE700 and ND9000 positioners.

• Easy retro-t to an extensive list of 3rd party valves

• Installation to all common control systems

Open solution

• Metso is committed to delivering products that

freely interface with software and hardware from a

variety of manufacturers; NDX is no exception. This

open architecture allows the NDX to be integrated

with other eld devices to give an unprecedented

level of controllability.

• FDT and EDD based multi-vendor support

conguration

• Support les for NDX are available for free download

from www.metso.com/ndx

NDX mounting on actuators and valves

• Supports all single and double acting pneumatic

actuators

• Both rotary and linear valves

• Guided startup and automatic/manual/1-point

calibration

3 PRODUCT SUMMARY

GENERAL INFOSPECSMOUNTINGSTART UPOPERATIONMAINTENANCEDIMENSIONSHOW TO ORDER LOGISTICS

NDX VALVE CONTROLLER

Product reliability

• Designed to operate in harsh environmental

conditions

• Rugged modular design

• Excellent temperature characteristics

• Vibration and impact tolerant

• IP66/NEMA4X enclosure

• Protected against humidity

• Resistant to dirty air

• Wear resistant and sealed components

• Fully contactless position measurement

• Fully encapsulated electronics

Predictive maintenance

• Easy access to collected data with any FDT/DTM

software and drivers

• Intelligent diagnostics analysis to visualize control

valve health and performance

• Patented on-line valve signature

• Historical trend and histogram collection

• Diagnostics collected continuously while the

process is running

• Extensive set of o-line tests with accurate key

gure calculations

• Clear notications with on-line alarms

• Condition monitoring tools available

3.3 OPERATION PRINCIPLE

The NDX is a 4–20 mA powered microcontroller based

intelligent valve controller. The device contains a local user

interface enabling conguration and operation without

opening the device cover. Conguration and operation

can also be made remotely by PC with asset management

software connected to the control loop.

After connections of electric signal and pneumatic supply,

the micro controller (C) 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 signal for I/P

converter (prestage). I/P converter controls the operating

pressure to the pneumatic relay (output stage). Pneumatic

relay moves and actuator pressure changes accordingly. The

changing actuator pressure moves the control valve. The

position sensor measures the valve movement.The control

algorithm modulates the I/P converter control signal until

the control valve position matches the input signal.

Service

Port mA

HART DO

µC

Pos 50.2

Pos

EXH1

EXH2

PCB

LUI

Prestage

Output stage

Pneumatic actuator

PT/DO

Fig. 2 Operating principle of double acting valve controller (NDX2512_).

3.4 OPTIONS

Following options are available for NDX valve controller:

• Internal position transmitter

• Digital output (namur)

• Gauge block

3.4.1 Internal position transmitter

Optional position transmitter connection is part of the

electronics module. Position transmitter is connected to

the 2-pole OUT terminal as shown in gure 4. Position

transmitter requires an external power supply.

Fig. 3

3 PRODUCT SUMMARY

GENERAL INFO

NDX VALVE CONTROLLER

3.4.2 Digital output (namur)

There are up to two congurable namur type digital outputs

(DO). They can be congured to activate based on valve

position measurement (as a limit switch) or any device status.

Configuration can be done via HART by using Valve

Manager (DTM) or EDD.

Output options can be following:

• One PT and one DO

• Two DOs

3.4.3 Gauge block

Fig. 4

Optional gauge block is available in the following three

options:

1/4 NPT with gauges (block with 1/4NPT threads + gauges)

G1/4 without gauges (block with G1/4 threads)

G1/4 with gauges (block with G1/4 threads + gauges)

3.5 MARKINGS

The valve controller is equipped with three identication

plates.

Identication plate

Identication plate includes following markings

• Contact details of the manufacturer

• Input signal (voltage range)

• Transmitter input signal (voltage range)

• Supply pressure range

• Output

• Enclosure type

• Manufacturing serial number*

• Build number

• H/C-code

• Type code (7 signs)

• Gauge block options

*) 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 Identication plate Fig. 6 Approval and type code

plate

EESF 18 ATEX 014X / IECEx EESF 18.0007X

[ ] II 1 G Ex ia IIC T6...T4 Ga

[ ] II 1 D Ex ia IIIC T85°C...T115°C Da

Tamb T6: -40...+50 °C, T5: +65 °C, T4: +80 °C

EESF 18 ATEX 015X / IECEx EESF 18.0008X

[ ] II 3 G Ex nA IIC T6...T4 Gc

[ ] II 3 G Ex ic IIC T6...T4 Gc

[ ] II 3 D Ex ic IIIC T85°C...T115°C Dc

Tamb T6: -40...+50 °C, T5: +65 °C, T4: +85 °C

See certicate for connection values

Class I, Div 1, Gps A, B, C, D; T4/T5/T6

Ex ia IIC T4/T5/T6 Ga

Class I, Zone 0 AEx ia IIC T4/T5/T6 Ga

Class I, Div 2, Gps A, B, C, D; T4/T5/T6

Ex ic IIC T4/T5/T6 Gc/Ex nA IIC T4/T5/T6 Gc

Class I, Zone 2 AEx ic IIC T4/T5/T6 Gc

AEx nA IIC T4/T5/T6 Gc

INSTALL PER DRAWING / INSTALLER

SUIVANT PLAN F82699 NDX

CONTROL WIRING DIAGRAM

TYPE: NDX2512TG-XU0N0000-000Y

ID: C0000001

Gauge block: [ ] 0 [ ] 1 [ ] 2 [ ] 3

3 PRODUCT SUMMARY

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