Metso NelesAce User manual

NelesAce™
BASIS WEIGHT CONTROL UNIT
Installation, Maintenance and
Operating Instructions
8 ACE 71 en • 8/2017

28 ACE 71 en
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about safe handling and operation of the control unit.
If you require additional assistance, please contact Metso’s Automation business or your authorized
distributor or representative.
SAVE THESE INSTRUCTIONS!
Subject to change without notice.
All trademarks or registered trademarks are property of their respective owners.
IPCOMM © by Phytron-Elektronik GmbH.
Table of Contents
1 GENERAL ..............................................................3
1.1 General view ...........................................................3
1.2 Operating principle of the control unit ........3
1.3 Markings ..................................................................3
1.4 Technical specifications .....................................3
1.5 Recycling and disposal .......................................5
1.6 Safety precautions ...............................................5
2 MOUNTING ..........................................................5
2.1 Valve mounting .....................................................5
2.2 Actuator mounting ..............................................5
2.3 Control unit mounting .......................................5
3 COMMISSIONING .................................................6
4 MODIFYING THE PARAMETERS ..........................7
4.1 Hardware requirements to use IPCOMM .....7
4.2 Getting started ...................................................... 7
4.3 Basic functions........................................................7
4.4 Limitation of the motor current ...................... 8
4.5 Option inputs and PLC commands ................8
5 OPERATING ........................................................10
5.1 General ................................................................... 10
5.2 Keyboard functions .......................................... 10
5.3 LEDs in the control panel ................................ 10
6 MAINTENANCE ..................................................10
6.1 General .................................................................. 10
6.2 Calibration of the display ................................ 10
6.3 Replacement and calibration of
potentiometer and R/I modulator ............... 11
6.4 Removal and reinstallation of
the actuator ......................................................... 11
6.5 Trouble shooting ............................................... 11
6.6 Recommended preventive maintenance. 11
7 ASSEMBLY DRAWINGS AND PART LISTS .........15
7.1 Actuator ................................................................ 15
7.2 Control unit .......................................................... 16
8 DIMENSIONS AND WEIGHTS ............................17
9 TYPE CODE .........................................................18

8 ACE 71 en 3
1 GENERAL
1.1 General view
Metso NelesAce®basis weight control system comprises a V-
port segment valve, an actuator and a control unit.
The valve is a standard R-series V-port segment valve.
A stepping motor is used in the actuator to reach the best
possible degree of regulation. The actuator is equipped
with both open and close position limit switches and with a
position transmitter.
The process control system transmits a digital signal to the
control unit which in turn automatically controls the actua-
tor. Manual operation is also possible.
1.2 Operating principle of the control unit
The step motor controller is in command of the four-wire
connected step motor in the valve actuator. The controller's
protection class is IP65. Input signals are transmitted to the
controller through six digital input channels. Alternatives
are pulse duration interface or time duration interface.
There are also optional input channels (Option 1 and
Option 2). When option inputs are in use, it is possible to
change the step size and time duration frequencies
remotely. The process control system (DCS) transmits a
pulse mode. The pulse mode then drives the step motor to
either the open or close directions depending on the chan-
nel which DCS is using (open or close). The movement
stops if the pulses end or the actuator reaches the limit
switch. In time duration mode the step motor starts to
move from the pulse leading edge and stops from the pulse
trailing edge or when the actuator reaches the limit switch.
The opening angle of the actuator is 0 to 90º. The default
factory value for the step setting is 1/2 step per pulse where
14100 pulses equals to 90 degree movement. The accuracy
of regulation can be changed. In this case the step setting
must be changed by programming it to 1/1 step (7050
pulses). The control unit is also equipped with inputs for
two limit switch signals and feedback potentiometer signal.
RS232/485 interface compatible IPCOMM software is deliv-
ered with the control unit. This software allows parameter
changes to the control unit.
1.3 Markings
The valve controller is equipped with an identification plate
sticker, see Fig. 2. Identification plate markings from top to
bottom are:
Type code of the actuator and control unit
Nominal voltage
Nominal current
Supply voltage frequency
Protection class
Manufacturer number
Serial number
Gear ID
Control unit ID
Step motor ID
Max. step motor current
Ambient temperature
1.4 Technical specifications
1.4.1 Valve
See Installation, Maintenance and Operating instructions 3
R 74 for valve installation instructions.
Recommendation: Installation of the valve: 7 x DN down-
stream side and 10 x DN upstream side distance of the pip-
ing curve. Installing the valve into pipeline. See figure 3.
1.4.2 Actuator
Stepping motor:
Motor type ZSH87/3.200.5
Number of steps 200
Step angle 1.8° in full step mode
Compatible with ministep-mode
Protection class IP68
Insulation class F
EMC and CE approved (EN 60034-1)
Gear:
Gear ratio 1:141
Limit switches:
Contacts normally closed (NC)
Position transmitter:
Output signal 4–20 mA
External load 1 kΩ
Fig. 1 Pulse and time duration modes
Fig. 2 Example of the identification label
0 V
24 VDC/10,5mA
t
t
0 V
24 VDC/10,5mA
Pulse duration mode
Time duration mode
input pulse
pulse to stepping motor
input pulse
pulse to stepping motor

48 ACE 71 en
Fig. 3 Installing the valve into pipeline
Fig. 4 Connection diagram
DN x 10 distance after the curve
DN x 10 distance after the curve
X2
X3
X4
X5
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
8x0.5
4
3
2
1
4
3
2
1
1
2
4
5
1
2
3
4
5
1
2
1
2
2x0.5
8x0.5
4x0.5
TIME DURATION CLOSE
TIME DURATION OPEN
PULSE GND
24 VDC
LIMIT OPEN
LIMIT CLOSE
POS 4-20 mA +
POS 4-20 mA -
*) POS 4-20 mA +
*) ACTIVE POS 4-20 mA -
1
2
3
4
1
2
3
4
3
2
1
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
4
3
2
1
1
2
3
4
5
6
I
R
1
1
OPTION 2
OPTION 1
TIME DURATION GND
TIME DURATION CLOSE
TIME DURATION OPEN
PULSE GND
ERROR
ERROR
MAN-MODE
MAN-MODE
POS 4-20 mA -
POS 4-20 mA +
GREEN
YELLOW
BROWN
GRAY
WHITE
LIMIT OPEN
LIMIT CLOSE
X17
3
4
2
PASSIVE POS 4-20 mA -
5
CONTROL
24 VDC
ALARM
MAX 50 mA, 24 VDC
LIMIT SWITCHES
FEEDBACK POTENTIOMETER
DCS
TWISTED AND SHIELD
INSTRUMENT
CABLE
TWISTED AND SHIELD
INSTRUMENT
CABLE
TWISTED AND SHIELD
INSTRUMENT
CABLE
TWISTED AND SHIELD
INSTRUMENT
CABLE
PULSE OPEN
PULSE CLOSE
TIME DURATION GND
PULSE OPEN
PULSE CLOSE
2
PE (EARTH)
PE (EARTH)
X1
PELN
123
123
3x1.5S
1
23
123
PE
LN
POWER SUPPLY
230 VAC, 50/60 Hz
X6
12345
12345
5x1.5S
PE
2345
2468
PE
24 VDC OUTPUT, MAX 30 mA
0 VDC
12
X8
STEP MOTOR
PE
*) WHEN BECH TESTING BASIS WEIGHT VALVE, CONNECT A JUMPER BETWEEN PIN 3 AND 4
ON CONNECTOR X5 TO COMPLETE THE CIRCUIT AND TO SEE ACTUAL VALVE TRAVEL ON DISPLAY.
CONNECTOR PANEL
1
6
PE
(EARTH)

8 ACE 71 en 5
1.4.3 Control unit
Step motor controller type GSP 92-70
Nominal power 200 W max. motor power
Un 230 V AC (option 110 V AC)
In 2 A, fuse T 2.5 A
(110 V: 4.2 A, fuse T 5 A)
Output power max. 9 A, when 70 V input
to motor In 6.3 A
Steps 1/1 step 7050 pulses 0–90°
1/2 step 14100 pulses 0–90°
1/4 step 28200 pulses 0–90°
Factory settings 1/2 step, 14100 pulses / 0–90°
local control mode 200 Hz
time duration mode 150 Hz
Operational temp. 0°...50 °C
storage and transportation
-20°...+60 °C
Protection class IP65
I/O alarm contact, opening contact
24 V DC, max. 50 mA
manual operation,
closing contact 24 V DC,
max. 50 mA
Control signals pulse, time duration and option
inputs: 24 V DC / 10 mA
optocoupled
1.5 Recycling and disposal
Most control system parts can be recycled if sorted according to
material. Most parts have material marking. A material list is sup-
plied with the system. In addition, separate recycling and dis-
posal instructions are available from the manufacturer. A control
system can also be returned to the manufacturer for recycling
and disposal against a fee.
1.6 Safety precautions
2 MOUNTING
2.1 Valve mounting
See Installation, Maintenance and Operating Instructions 3
R 71 for valve installation instructions.
2.2 Actuator mounting
Actuator is mounted to valve at the factory.
The actuator is mounted to the valve with either two or four
bolts. Actuator is connected to the valve shaft with a back-
lash-free joint.
2.3 Control unit mounting
2.3.1 General
Dimensions for control unit are: length 400 mm,
width 355 mm and height 150 mm.
The cable between the control unit and the actuator
may be up to 120 m.
The control unit may not be installed above a radiant.
Operating ambient temperature range of control
unit is 0° to 50 °C.
Heat sink (215) must have enough space to ensure
cooling.
Control unit must not be mounted on a vibrating base.
Mount control unit on an even base using the
attachment points of the control unit box.
2.3.2 Control unit connections
Control unit receives maximum of six cables, one or three
from the control system, two from the actuator and one
supply voltage cable. They are connected to the connector
card of controller according to Fig. 3. The cable shields
should be connected to the lead-ins to avoid any interfer-
ence. Leading the cable from the DCS through a ferrite is
recommended.
The internal connections of the control unit between the
step motor controller, display card and connector card are
made using cables with connectors. All cables must be con-
nected to ensure the proper operation of the controller.
Connector card, Fig. 4, connectors X1...X12, and step motor
controller, Fig. 5, connectors X1...X6, are connected as fol-
lows:
Connector card Step motor controller
X7 — X1
X9 — X5
X10 — X2
X11 — X6
X12 — display card
CAUTION:
Follow all marked cautions in Installation, mainte-
nance and operating instructions when handling the
valve.
CAUTION:
Do not exceed the permitted values!
Exceeding the permitted values marked on the control
unit may cause damage to the control unit and to the
equipment attached to it. Damage to the equipment and
personal injury may result.
CAUTION:
Finger covers (170) must be on during operation!
Finger covers may only be removed from the bracket dur-
ing maintenance and when power is switched off.
CAUTION:
The hand wheel (108) handle of actuator must be bent
during operation.
The handle can only be used when power is switched off.
NOTE:
Only authorized persons are permitted to carry out the
electrical connections for the device.
NOTE:
Install the valve with shaft in upright position.
Consult factory for other positions.
ELECTRICAL SAFETY NOTE:
The control unit does not have a main switch. The electrical
installation must provide a main switch or a circuit breaker.

68 ACE 71 en
2.3.3 Error signal connections
Error signal is available at connector X3, pins 3 and 4.
The following errors are indicated:
no supply voltage to limit switches.
overheating of controller, >85 °C.
shot circuit in motor winding.
blow out of controller fuse.
2.3.4 Cable connections for actuator
Two cables are connected to the actuator. The first is con-
nected to the connector cover of actuator which has the
connections of the limit switch and the feedback potenti-
ometer, Fig. 6. The second cable is connected to the step
motor, Fig. 7. The cables are connected as shown in Fig. 3.
3 COMMISSIONING
Check the following proceedings at commissioning:
Check connections.
Check grounding.
Connect power supply.
Check that LED 11 is lit (HW Enable), see Fig. 5.
Move valve to open and close limits in manual mode.
Check functioning of limit switches and position display.
Connect control unit to automatic mode and check
that the valve is also operable with the signal from
control system.
Fig. 5 Connector card
Fig. 6 Connectors and LEDs for step motor controller
Fig. 7 Connector cover
S1
LED
LED
X6
X2
X3
F1 X1
LED
X5
X4
T1
13 12
5
6
7
8
1
2
3
4
A
B
C
D
10 9
11
1
1
1
Fuse Mains
L
N
1
– Limit switch + Limit switch
10 9
HW Enable
11
51
Outputs OK Outputs OK
READY
62
ERROR
Reset GSP
73
SW Enable
84
Reset error
Strobe
1213
STATUS
POWER
LEDs
14
14
Option
Fig. 8 Connection for step motor
NOTE:
When replacing the existing basis weight valve with
NelesAce it is recommended to you verify and, if neces-
sary, tune DCS parameters.
NOTE:
It is recommended that the valve position signal is used
only for informative purposes and feedback for control is
taken from other measures, e.g. flow.
2468
12345
5x1.5S
34
56
78
12

8 ACE 71 en 7
4 MODIFYING THE PARAMETERS
IPCOMM program is a setup program for the controller.
With the program the user can change every necessary
parameter. Every controller is programmed with factory set-
tings before sending to customer. The customer can modify
the settings in accordance with the processes that they use.
This chapter will concern only basics of the program. Use
the online help (F1-button) file to get more information.
4.1 Hardware requirements to use IPCOMM
To use IPCOMM on your PC the following requirements
should be fulfilled:
Any modern PC with Windows® operation system.
A free serial port (COM), or a suitable USB to serial
port adapter (consult factory for suitability).
4.2 Getting started
When the customer has to modify parameters it is possible
to do this with the PC and RS232 serial link cable (a laptop
computer is recommended).
Install the IPCOMM program to your PC.
Connect the serial link cable to controller (connector
X4) Fig. 5.
Supply voltage for controller must be switched on.
Start the IPCOMM program.
In login window (Fig.8) set the interface and baud-
rate (COM1, 28800 Baud)
Choose Axis 0.
Push the Ø button from the toolbar.
Now connection between the PC and the controller
should be active.
4.3 Basic functions
Once a connection has been established between the com-
puter and the controller, the user can carry out the configu-
ration. The basic window (Fig. 9) includes several functions
and information.
There are a few things that the user should check before
any modifications are carried out.
Check the general parameters. The OP-Mode must
be PLC-Mode.
The Type of Axis must be Linear.
Offset from Limit Switch must be 0
Check the possible errors before modifying the PLC
commands
Errors, program version and other information are
indicated in Status window, Fig. 10.
If any errors appear, reset those in reset windows
before changing the PLC parameters.
NOTE:
Most of the IPCOMM functions can also be started by
using a keyboard input, but not all of them. Therefore, a
mouse is necessary.
NOTE:
IPCOMM can only be used, if a controller is connected to
your PC.
Fig. 9 Login window
Fig. 10 Basic window
Fig. 11 Status window

88 ACE 71 en
4.4 Limitation of the motor current
Current settings are preset in the factory in accordance with
the valve size. Settings can be modified in Current Selection
window, Fig.11. In normal conditions there is no need to
modify these settings, but in case the customer changes
the actuator size and keep the same controller the settings
can be modified.
Use IPCOMM software for motor current setting.
Remember to push Actual Parameters button after current
value changes, otherwise changes will not be valid!
4.5 Option inputs and PLC commands
The Option inputs and PLC commands are preset in the fac-
tory. The settings can be modified to meet the process
requirements, for instance changing the time duration
speeds. Changes can be carried out in the PLC-code window,
Fig. 12 and Fig. 13. With the NelesAce delivery there is param-
eter list which includes program listing. The user may also
print the parameter list in start window by pressing the
printer button in the toolbar.
Factory settings and option input functions are indicated in
Table 2. When option inputs are in use, it's possible to
change the step size and time duration frequencies via DCS.
The customer can make the control logarithmic instead of a
linear control. The advantage of logarithmic control is that
controlling grade changes is much faster and more accu-
rate. Parameter changes can be done in following way:
Check the possible errors before modifying the PLC
commands.
Push PLC>> button to open PLC-code window.
Select parameter which you want to change.
To continue, follow instructions in Sections 4.5.1,
4.5.2 and 4.5.3.
The following is a description of the application of NelesAce
for the control system (DCS) vendor as the best available
method to control basis weight through use of the features
included in NelesAce.
The control method depends on the capabilities of the con-
trol system (DCS). In addition to the normal binary drive
open, drive closed output card a pulse train output card is
also needed to provide pulses to open and close the valve
in discrete steps.
In normal automatic mode the DCS uses pulses to control
NelesAce position. In this case DCS must have an appropri-
ate pulse output card which can send pulses at the correct
frequency (recommended time 25 ms per pulse). One pulse
from the control system (DCS) moves the NelesAce by one
pulse. Each pulse can equal 1/4 step, 1/2 step, 1 step, or 2
steps depending on which option or options are energized
and how the NelesAce is programmed, see table 2.
Normal movement is 1/2 step per pulse. Connection 7 (see
Fig. 3, Control 24 V DC) energized gives 1 step per pulse (=
option 1). Correspondingly connection 8 energized gives 2
steps per pulse (= option 2). Both connections 7 and 8 ener-
gized gives 1/4 step per pulse (= option 1&2).
When using 1/4 step mode the valve takes 28200 pulses for
full 0–100 % stroke, correspondingly 1/2 step takes 14100
pulses etc. Flow is controlled depending on the error
between actual and desired flow rate. The decision for step
size is made based on the magnitude of the error.
Fig. 12 Current selection window
NOTE:
Do not exceed the current setting of corresponding valve
size, Table 1.
Overload current may damage the valve shaft.
Table 1 Motor current limiting for different valve sizes
Valve Stop current
(A)
Run current
(A)
Boost current
(A)
DN 50-65 0.8 1.2 1.2
DN 80-100 1.2 1.5 1.5
DN 150 2.0 3.8 3.8
DN 200 2.0 3.8 3.8
DN 250 2.4 4.6 4.6
DN 300 2.8 5.1 5.1
DN 350 2.8 5.1 5.1
DN 400 2.8 5.1 5.1
DN 500 2.8 5.1 5.1
NOTE:
If error condition is on, while PLC commands are modified
all PLC parameters will be erased!
NOTE:
Don’t change ramp parameters!
Table 2 Factory settings and option inputs
Pulse duration
Option input 1 0 V DC 24 V DC 0 V DC 24 V DC
Option input 2 0 V DC 0 V DC 24 V DC 24 V DC
Step size 1/2 step 1/1 step 2/1 step 1/4 step
max. step input frequency 400 Hz except 2/1-step 200 Hz
Time duration
Option input 1 0 V DC 24 V DC 0 V DC 24 V DC
Option input 2 0 V DC 0 V DC 24 V DC 24 V DC
Time duration
speed
150 Hz 300 Hz 600 Hz 1200 Hz
min. time duration frequency is 50 Hz and max. 2 kHz

8 ACE 71 en 9
4.5.1 Changing pulse duration mode
settings
To change the step size, scroll the command (Prog.)
line selection slider to 0 (or up to 3, see Table 3).
Set the new value, step size is indicated in 1/8 steps,
so 4 is same as 1/2-step.
Push Program it! button, that saves the new settings.
Close PLC-code window.
Now pulse duration mode change is finished.
4.5.2 Changing time duration mode settings
To change the open speed, scroll the command
(Prog.) line selection slider to 32 (or up to 35, see
Table 4).
Change the Offsetfreq. and Run. Freq. values as
required and press Program it! button, that saves the
new settings.
On command (Prog.) line 48 (or up to 51, see Table 4)
the close speed can be changed correspondingly.
Close PLC-code window.
Now time duration mode change is done.
See Table 2 for different option configurations.
4.5.3 Changing local control mode settings
To change new speed for opening in the local control
mode, scroll the command (Prog.) line selection slider
to 40 (or up to 47, see Table 5).
On command (Prog.) line 56 (or up to 63, see Table 5)
the close speed can be changed correspondingly.
Close PLC-code window.
NOTE:
In pulse duration command lines (move relative), don't
change the Offset and Run frequencies!
Fig. 13 PLC-code window, pulse duration mode
Table 3 Pulse duration mode
Prog. line
(shown in PLC code window)
Step size and direction
0 1/2 step open
1 1 step open
2 2 steps open
3 1/4 step open
16 1/2 step close
17 1 step close
18 2 steps close
19 1/4 step close
NOTE:
In time duration command lines (Free run), notice that off-
set frequency (Offsetfreq.) must be smaller or equal than
run frequency (Run. Freq.), otherwise the function of the
time duration is not correct.
Fig. 14 PLC-code window, time duration mode
Table 4 Time duration mode
Prog. line
(shown in PLC code window)
Speed and direction
(factory settings)
32 150 Hz open
33 300 Hz open
34 600 Hz open
35 1200 Hz open
48 150 Hz close
49 300 Hz close
50 600 Hz close
51 1200 Hz close
Table 5 Local control mode
Prog. line
(shown in PLC code window)
Action
(factory settings)
40 200 Hz open
41 200 Hz open
42 200 Hz open
43 200 Hz open
44 200 Hz open
45 200 Hz open
46 200 Hz open
47 200 Hz open
56 200 Hz close
57 200 Hz close
58 200 Hz close
59 200 Hz close
60 200 Hz close
61 200 Hz close
62 200 Hz close
63 200 Hz close

10 8 ACE 71 en
5 OPERATING
5.1 General
Step motor controller has two modes: automatic (AUTO)
and local (MAN).
In automatic mode the control panel is disabled and step
motor is controlled by the control system. In local control
mode the step motor can be driven to both directions by
using the control panel push buttons, Fig. 14. Automatic/
local mode selection is done by AUTO/MAN push buttons.
When selecting local control mode the MAN push button
must be pressed for more than one (1) second. The lit LED
indicates that local control mode (MAN) has been selected.
Control unit receives position information from the actua-
tor's potentiometer. This position information is shown as
percentage in the panel's LCD display. Control panel has
LEDs to indicate limit switch status (open or close).
In the control panel display, 0 % indicates a closed valve
and 100 % indicates an open valve.
5.2 Keyboard functions
Arrow push buttons < or > :
Arrow push buttons are only active in local control (MAN)
mode. The valve closes with the arrow push button < and
opens with the arrow push button >. The actuator moves as
long as the button is pressed down or it reaches the limit
switch.
AUTO/MAN selection:
AUTO and MAN modes are selected with corresponding
keys.
5.3 LEDs in the control panel
AUTO/MAN (green):
LED indicates the operation mode of control unit. When
LED is lit the control unit is in manual mode.
OPEN (red):
LED is lit when the actuator is in its opening position limit.
CLOSE (red):
LED is lit when the actuator is in its closing position limit.
6 MAINTENANCE
6.1 General
NelesAce is a digital and modular device. This facilitates
maintenance. The smallest step motor movements are
impossible to distinguish from the movements of valve or
shafts without special measuring instruments. For this rea-
son the functioning of control unit/actuator/valve-combi-
nation must be evaluated from the hand wheel (108)
movements or lack of movements. The hand wheel is
attached to motor shaft. The hand wheel's handle must
be pressed down during operation.
6.2 Calibration of the display
The output current of the actuator's position transmitter is
4 mA when the valve is closed. When the valve is fully open
the output current is 20 mA. Calibration to R/I modulator is
carried out at the factory according to these output values.
The display card has two potentiometers (R9 and R14)
which are used to calibrate display readings to equal to the
readings of current output.
Fig. 15 Control panel
Fig. 16 Calibration potentiometers in display card
X14
N1
D1
ZERO
SPAN
R14
R9
V3
S5
S7
V5
S8
S6
V4

8 ACE 71 en 11
The display is calibrated with the trimmer potentiometers
of display card (216), Fig. 15. Potentiometers are marked as
"SPAN" (R9) and "ZERO" (R14). When the valve is in the clos-
ing position and the current is 4 mA the display is adjusted
with ZERO-potentiometer to 00.0 %. Current value is meas-
ured from the pins 2 and 3 in connector X5 in connector
card. When the valve is in the open position the display
reading is adjusted with SPAN-potentiometer to 100.0 %.
If the display shows - % continuosly, the current loop is
open. This can be the case if NelesAce is tested on the
bench before connecting to DCS. In order to obtain the cor-
rect figures during the bench test connect a jumper
between pins 3 and 4 on connector X5 to complete the cir-
cuit. Remove the jumper when connecting to DCS.
6.3 Replacement and calibration of
potentiometer and R/I modulator
Move valve to CLOSE position.
Remove connector cover in actuator (143).
Unfasten gear cover screws (126), 6 pieces.
Disconnect modulator's (50) connections.
Unfasten potentiometer's locking screws.
Remove potentiometer and replace it with new one.
Measure resistance from the potentiometer and adjust it
to 50 Ωby turning the potentiometer's shaft.
Tighten potentiometer's bracket (58).
Tighten potentiometer's locking screw (6).
Attach gear cover.
Measure current (4-20 mA) from connector X5 (2 and 3).
When valve is in CLOSE position, current is 4 mA
(potentiometer "4 mA" in R/I modulator).
When valve is in OPEN position, current is 20 mA
(potentiometer "20 mA" in R/I modulator).
Attach connector cover in actuator.
6.4 Removal and reinstallation of the
actuator
Actuator can be disengaged from the valve as follows:
Move valve to CLOSE position.
Switch off the power.
Remove finger covers (170) e.g. by prying with a
screwdriver from the gap between cover and
bracket.
Unfasten valve attachment bolts (173).
Unfasten shaft's locking screws (27).
Remove actuator carefully without causing damage.
Reinstalling is made in reverse order. Note, that valve and
actuator must be in CLOSE position before reinstallation.
While installing the valve check the gap between
segment and seat. The gap must be 0.20 mm in
every part of segment. If the segment has moved,
the gap may be smaller. In this case the segment
must be centred before tightening the locking
screws (27). Centring is made with a copper hammer
or with another soft tool so as not to cause damage
to the segment while hitting it. While the gap is of
equal size in every part of segment, locking screws
can be tightened.
Install finger covers (170) by pressing them back in
place. Check also the condition and stability of covers. If
the covers do not stay properly, adjust them by bend-
ing the bracket. Never use the actuator without
properly mounted finger covers!
6.5 Trouble shooting
In the following charts, Fig. 16 and Fig. 17, some failure situ-
ations have been presented. The charts refer to label (228)
inside the controller and the LEDs of the controller, Fig. 5.
IPCOMM communication program and instructions file can
be also used in trouble shooting. The instructions file clari-
fies the functioning of application software. These charts
are only applicable to correctly mounted and connected
device. Installation and connection instructions are pre-
sented in Section 2.
6.6 Recommended preventive maintenance.
Recommended preventive maintenance for NelesAce, the
part list and the service actions, see table 6.

12 8 ACE 71 en
Table 6 Recommended preventive maintenance for NelesAce
Part Id-code Part No Part
Description Picture Actions in one year interval Actions in two years interval
Estimated
service
hours / h
1. H025874 50, 61 Potentiometer +
R/I modulator
Calibration Component change 2
1.1. H092865 44,45, 60 Belt roller set for
NelesAce
---------------------- Checking the bearing condition 1
2. H015565 47 Potentiometer
belt
Checking: condition and tightness Checking: condition and tightness 2
3. H016030 80 Limit switches
(Micro switches)
---------------------- Checking: condition 2
4. H015545 107 Coupling
element
Component change Component change 1
5. H015502 30 Spring pin ---------------------- Checking: condition 1
6. H015501 Coupling (gear)
Aluminum piece
---------------------- Checking: condition 2
7. H015542 102 Coupling
(motor)
Aluminum piece
---------------------- Checking: condition 2
8. H027332 216 Display card ---------------------- ---------------------- 1
9. H025875 100 Step motor Optional Spare part Optional Spare part 2
10. 2 Gear Checking: leakages Checking: leakages, lubrication 1
10.1 H084903 Gear lubrication
set
---------------------- Component change 2
11. Valve Visual checking of valve:
• Clean valve surface of unwanted
material (pulp, process medium
etc.) covering it.
• Check that the operation of the
valve is smooth (no oscillation/
clap between parts detected).
• Check that no leakage in valve
body/shaft clamping is detected.
Visual checking of valve:
• Clean valve surface of unwanted
material (pulp, process medium
etc.) covering it.
• Check that the operation of the
valve is smooth (no oscillation/
clap between parts detected).
• Check that no leakage in valve
body/shaft clamping is detected.

8 ACE 71 en 13
Fig. 17 Trouble shooting chart 1
The valve doesn't move
acc. to automatic control
Yes
No Can valve be operated
in MAN mode?
Is control signal
available at
connector X2?
Yes
No
Failure before control unit.
Check the DCS
connections.
Is LED 6 lit and
does it turn off when
valve is operated?
Yes
No
Connector card is faulty.
Replace the connector
card.
Control unit is faulty.
Replace control unit.
Fuse is faulty.
Replace the fuse.
Check power supply.
Is LED 11 lit?
No
Yes
No
Yes
Is LED 6 lit and
does it turn off when
MAN- close or MAN- open
key is pushed?
Are LEDs 9 and 10
for limit switches lit?
No
Yes
Connector card is faulty.
Replace the connector
card.
Limit switches are faulty.
Replace the limit switches.
No
Yes
No
Yes
Is motor supply
voltage 70 VDC.
Check motor coils
(2 pcs).
Resistance R=0,7 Ω
Control unit is faulty.
Replace control unit.
Control unit is faulty.
Replace control unit.
Step motor is faulty.
Replace step motor.

14 8 ACE 71 en
Fig. 18 Trouble shooting chart 2
No
Yes
No No
Yes
Yes
Yes
No
Position display doesn't match
with actual valve position .
Does current from position
transmitter match with
actual valve position?
Is position transmitter
supply voltage 24VDC?
Connector card is faulty.
Replace connector card.
Potentiometer is faulty.
Replace potentiometer.
Actuator is faulty.
Does potentiometer
operate awless?
R/I modulator is faulty.
Replace R/I modulator.
Position display is
in working order.
Does re-calibration of
position display
x the problem?
Display card is faulty.
Replace display card.

8 ACE 71 en 15
7 ASSEMBLY DRAWINGS AND PART LISTS
7.1 Actuator
*) Delivered as a set
Part Qty Description Available spare parts Recommended spare parts
1 1 Mounting bracket
21Gear
23 1 Flange
27 2 Locking screw
28 2 Locking washer
29 1 Coupling
44 1 Potentiometer belt roller
47 1 Potentiometer belt
50 1 Potentiometer X *)
61 1 R/I modulator X *)
63 1 Pointer
80 2 Limit switch X
83 2 Release device
100 1 Step motor X X
102 1 Coupling
107 1 Coupling element
108 1 Hand wheel X
110 1 Motor cable
120 1 Gear cover
121 1 Identification plate
123 1 Window
126 6 Hexagon socket screw
140 1 Circuit board X
143 1 Connector cover
146 1 Limit switch and position feedback cable
160 1 Limiter
170 2 Finger cover
173 2/4 Hexagon screw
174 2/4 Spring washer
173 174
100 108 110
140
143
123 63
29 102 107
120
121
80 83
126
160
1
28 27 23
2
170
146
44 47 50 61
126

16 8 ACE 71 en
7.2 Control unit
Part Qty Description Available spare parts Recommended spare parts
210 1 HST housing
211 1 HST housing cover
212 1 Bottom plate
213 1 Side plate
214 6 Lead in socket
215 1 Heat sink
216 1 Display card X
217 1 Connector card X
218 1 Controller X X
228 1 Adhesive label
X14
N1
D1
ZERO
SPAN
R14
R9
V3
S5
S7
V5
S8
S6
V4
216 211 210 217
215
218
213
214
212
228

8 ACE 71 en 17
8 DIMENSIONS AND WEIGHTS
190
7.50
A
DN
160 200
6.25 4.00
H
D
C
300
12.00
HAND WHEEL
355
150
400
180
ø8
430
DN Actuator Dimensions, mm Weight, kg
RA RE
ACDHACDHRARE
50 NC4L-50 75 95 530 625 124 91 610 705 35 40
65 NC4L-65 75 100 540 640 145 97 615 715 38 42
80 NC4L-80 100 110 555 665 165 108 645 755 40 45
100 NC4L-100 115 120 565 685 194 120 655 775 42 50
150 NC4L-150 160 175 610 785 229 174 700 875 59 72
200 NC4L-200 200 200 645 845 243 201 755 960 83 131
250 NC4L-250 240 250 720 970 297 251 830 1085 115 156
300 NC4L-300 - - - - 338 269 855 1125 - 220
350 NC4L-350 - - - - 400 311 950 1265 - 300
400 NC4L-400 - - - - 400 353 1015 1370 - 380
500 NC4L-500 - - - - 508 420 1110 1530 - 740
Size Actuator Dimensions, inch Weight, lb
RA RE
ACDHACDHRARE
2 NC4L-50 2.95 3.74 20.87 24.61 4.88 3.58 24.02 27.76 78 89
2 1/2 NC4L-65 2.95 3.94 21.26 25.20 5.71 3.82 24.21 28.15 84 93
3 NC4L-80 3.94 4.33 21.85 26.18 6.50 4.25 25.39 29.72 89 100
4 NC4L-100 4.53 4.72 22.24 26.97 7.64 4.72 25.79 30.51 93 111
6 NC4L-150 6.30 6.89 24.02 30.91 9.02 6.85 27.56 34.45 131 160
8 NC4L-200 7.87 7.87 25.39 33.27 9.57 7.91 29.72 37.80 184 291
10 NC4L-250 9.45 9.84 28.35 38.19 11.69 9.88 32.68 42.72 256 347
12 NC4L-300 - - - - 13.31 10.59 33.66 44.29 - 489
14 NC4L-350 - - - - 15.75 12.24 37.40 49.80 - 667
16 NC4L-400 - - - - 15.75 13.90 39.96 53.94 - 844
20 NC4L-500 - - - - 20.00 16.54 43.70 60.24 - 1644

18 8 ACE 71 en
9TYPECODE
SEGMENT VALVE RA AND RE FOR nelesACE
* According to DIN standard , flange dimensions in some sizes and pressure classes are same
Gland packing: PTFE V-ring type
Blind flange: PTFE
1. 2. 3. 4. 5. 6. 7. 8. 9.
RA - W 100 A W - / -
RE M W 100 A W A / -
1. sign CV-CODE
-Standard CV, without sign
2. sign PRODUCT SERIES / DESIGN
RA Wafer, reduced bore, Neles face-to-face lenght, Body PN50 / ANSI Class 300*
RE Flanged, reduced bore, ISA S 75.04 and DIN/IEC 534 Part 3-2
3. sign RA
PRESSURE RATING
RE
PRESSURE RATING
-Body PN40 / ASME class 300 -
J- Body PN 10, flanged
K- Body PN 16, flanged
L- Body PN 25, flanged
M- Body PN 40, flanged
C- Body ANSI class 150, flanged
D- Body ANSI class 300, flanged
R- JIS 10K flanges
S- JIS 16K flanges
ASpecial, to be specified
4. sign CONSTRUCTION
WStandard, drive shaft with keyway for nelesACE.
Shaft/segment connection pinned and welded.
5. sign
SIZE
Max shut-off
pressure DIN/ISO PN10 DIN/ISO PN16 DIN/ISO PN25 DIN/ISO PN40
050* 50 bar use PN40 use PN40 use PN40 M
065* 50 bar use PN16 K use PN40 M
080* 50 bar use PN40 use PN40 use PN40 M
100* 40 bar use PN16 K use PN40 M
150* 40 bar use PN16 K use PN40 M
200 35 bar J K L M
250 35 bar J K L M
300 30 bar J K L M
350 30 bar J K L M
400 30 bar J K L M
500 30 bar J K L M
6. sign BODY SEGMENT SCREWS SHAFT, PINS / BEARINGS
ACF8M Type AISI 329 + HCr A2-70 Type AISI 329 / PTFE
CCG8M CG8M + HCr B8M XM-19 / PTFE
7. sign SEAT MATERIAL AND CONSTRUCTION
W
Seat: Stainless steel + cobalt based hard facing.
Seat welded away from segment.
Service: Basis weight service, unidirectional non tight.
8. sign MODEL CODE
-Version 0
AVersion A is used only with DN50, DN80-DN250 (Only for RE, NOT RA)
9. sign FLANGE FACING
-
EN 1092-1 Type B1 (Ra 3.2 - 12.5), standard
Cover:
ASME B16.5 Ra 3.2 - 6.3 (Smooth finish, RMS 125 - 250).
DIN 2525 Form E (Ra 4)

8 ACE 71 en 19
STEP MOTOR ACTUATOR nelesACE FOR BASIS WEIGHT CONTROL
CONTROL UNIT FOR nelesACE FOR BASIS WEIGHT CONTROL
Exemble:
RAW050AW-NC4L050-ND4KS22
Sign: 050, 065, 080, 100, 150, 200, 250.(size).
REJW200AW-NC4M200-ND4KS22
Sign: J/K/L/M/C/R/S (flange drilling)
Sign: 050, 065, 080, 100, 150, 200, 250, 300, 350, 400, 500. (size)
1. 2.
NC4L 400 - ND4KS2 2
1. sign PRODUCT SERIES / DESIGN
NC4L
Step motor actuator.
Ambient temperature 0...+50 °C / +32...+122 °F, IP65 enclosure
Applicable only with RA_W -serie valves.
NC4M
Step motor actuator.
Ambient temperature 0...+50 °C / +32...+122 °F, IP65 enclosure
Applicable only with RE_W -serie valves.
2. sign ACCORDING TO THE SIZE OF
THE SEGMENT VALVE
Available for sizes: 050, 065, 080, 100, 150, 200, 250, 300, 350, 400, 500.
RA_W series available for sizes: DN050 ... DN250
RE_W series available for sizes: DN050 ... DN500
1. 2.
NC4L 400 - ND4KS2 2
1. sign PRODUCT SERIES / DESIGN
ND4KS2
Control unit for pulse or time duration signals, includes push buttons for manual
operations and IPCOMM software for serial communication protocol of the RS232 or
RS485 interface. ½ step mode as a default. Position indication LCD. IP65 enclosure
2. sign SUPPLY VOLTAGE
1 110 VAC
2 230 VAC

Metso Flow Control Inc.
Europe, Vanha Porvoontie 229, P.O. Box 304, FI-01301 Vantaa, Finland. Tel. [phone]. Fax [phone]
North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, M A 01545, USA. Tel. [phone]. Fax [phone]
South America, Av. Independéncia, 2500-Iporanga, 18087-101, Sorocaba-São Paulo, Brazil. Tel. [phone]. Fax [phone]
Asia Pacic, 238B Thomson Road, #17-01 Novena Square Tower B, Singapore 307685. Tel. [phone]. Fax [phone]
China, 11/F, China Youth Plaza, No.19 North Rd of East 3rd Ring Rd, Chaoyang District, Beijing 100020, China. Tel. [phone]. Fax [phone]
Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai, United Arab Emirates. Tel. [phone]. Fax [phone]
www.metso.com/valves
20 8 ACE 71 en