neles ValvGuard SystemSeries VG800B

Installation, Maintenance andOperating Instructions

9 VG/B 70 enIssue 5/02

Table of Contents

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 31.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 Basic functionality . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.1 The safety circuit . . . . . . . . . . . 31.3.2 The diagnostic function . . . . . . . . 3

1.4 Communication . . . . . . . . . . . . . . . . . . . . . . . . . 31.5 Principle of operation . . . . . . . . . . . . . . . . . . . . 4

1.5.1 The remote communication interface (RCI) 41.5.2 The VG800B field device . . . . . . . 4

1.6 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.7 Technical specifications . . . . . . . . . . . . . . . . . . . 5

1.7.1 Electrical hazard protection . . . . . 51.7.2 Specifications . . . . . . . . . . . . . 5

1.8 Recycling and disposal of a rejectedVG800B field device . . . . . . . . . . . . . . . . . . . . . 6

1.9 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . 62 MOUNTING AND INSTALLATION . . . . . 7

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1.1 Mounting of VG800B field device . . 7

2.2 Mounting on Metso Automation actuatorswith VDI/VDE mounting bracket. . . . . . . . . . . 7

2.3 Mounting on linear actuators withMetso Automation or IEC60534 mounting face. 7

2.4 Mounting of the Remote CommunicationInterface (RCI) module . . . . . . . . . . . . . . . . . . . 8

2.5 Piping and air supply . . . . . . . . . . . . . . . . . . . . . 82.6 Electrical connections . . . . . . . . . . . . . . . . . . . . 82.7 Additional instrumentation . . . . . . . . . . . . . . . 11

3 COMMISSIONING AND OPERATION . . 113.1 Using Local user interface (LUI). . . . . . . . . . . 11

3.1.1 VG800B functions . . . . . . . . . 133.1.2 HART write protection . . . . . . 133.1.3 Configuration . . . . . . . . . . . . 143.1.4 Testing . . . . . . . . . . . . . . . 143.1.5 Safety protection . . . . . . . . . . 14

3.2 Using ValveManager software andHART communication . . . . . . . . . . . . . . . . . . 153.2.1 Monitoring . . . . . . . . . . . . . 153.2.2 Configuration . . . . . . . . . . . . 15

3.2.3 Test settings . . . . . . . . . . . . . 163.2.4 Alert configuration . . . . . . . . . . 173.2.5 Statistics alerts . . . . . . . . . . . . 173.2.6 Automatic travel calibration . . . . . 183.2.7 Alert handling . . . . . . . . . . . . 183.2.8 Decommissioning . . . . . . . . . . 18

4 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . 194.1 Prestage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.2 Spool valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.3 Circuit board (upper), ND800 . . . . . . . . . . . . 194.4 Circuit board (lower),

power supply board PSB . . . . . . . . . . . . . . . . . 204.5 Position sensor . . . . . . . . . . . . . . . . . . . . . . . . . 204.6 Pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . 214.7 RCI unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 SAFETY MANUAL . . . . . . . . . . . . . . . . . . . 216 TROUBLE SHOOTING . . . . . . . . . . . . . . . 227 ERROR CODES. . . . . . . . . . . . . . . . . . . . . . 238 TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 ORDERING SPARE PARTS. . . . . . . . . . . . 2310 DRAWINGS AND PARTS LISTS . . . . . . . 25

10.1 Exploded view and parts list, VG800B . . . . . 2510.2 Mounting parts for B1CU6-502 and

B1JU 8-322 actuators. . . . . . . . . . . . . . . . . . . . 2610.3 Mounting parts for Quadra-Powr®, ST,

SP and Valv-Powr® actuators . . . . . . . . . . . . . 2610.4 Mounting parts for D/R linear actuators . . . . 2710.5 Mounting parts for linear actuators

with IEC 60534 mounting face . . . . . . . . . . . . 2810.6 Mounting parts for limit switches

for EX i enclosure. . . . . . . . . . . . . . . . . . . . . . . 2911 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . 30

11.1 VG800B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.2 RCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

12 TYPE CODING. . . . . . . . . . . . . . . . . . . . . . 31

READ THESE INSTRUCTIONS FIRST!

These instructions provide information about safe handling and operation of the valve controllerIf you require additional assistance, please contact the manufacturer or manufacturer’s representative.Addresses and phone numbers are printed on the back cover.

SAVE THESE INSTRUCTIONS!

All trademarks are property of their respective owners.

Subject to change without notice.

2

1 INTRODUCTION

1.1 GeneralThese instructions describe the Metso Automation NelesValvGuard system for use in safety related on/off duty.

ValvGuard comprises two components, the Remote Communica-tion Interface (RCI), which is installed close to the control room andthe VG800B, ’a smart field device,’ which is mounted on the fieldlocated ESD valve actuator. The general arrangement is shown inFigure 1.

Valve Guard is a safety system, great care must be taken to properlyunderstand the final installation requirements before commencinginstallation of any component. Failure to do this may result in a faultyinstallation and improper operation.

1.2 CompatibilityValve Guard may be used with any cylinder or diaphragm springreturn actuator, but it is recommended for use with the MetsoAutomation range of actuators since full design applicability is knownand mounting parts are available. See Chapter 2.

1.3 Basic functionalityValve Guard operates at two independent levels, the safety leveland the diagnostic level.

1.3.1 The safety circuitThe 0/24 Vdc output signal from plant safety-PLC or equal safetysystem is connected to the RCI within the cross connection controlcabinet. The RCI output is wired to the VG800B in the field usingstandard cabling. Within the VG800B a spool valve controls the airsupply to the valve actuator. The spool valve is energized by the24 V supply (ESD valve open) and is de-energized (ESD valveclosed) at 0 V. The layout is shown in Figure 3.

1.3.2 The diagnostic functionProgramming and data collection functions are controlled by themicro controller (µC). The µC takes its power from the normalstate 24 Vdc supply. In the 0 V condition the µC is inactive. µCfunctionality is configured remotely by a software package calledValve Manager. Certain functions can also be controlled locally byuse of push buttons mounted within the VG800B casing. It isnecessary to remove the cover of the VG800B field unit to do this.Please refer to Figure 14.

1.4 CommunicationRemote communication from the control room with the VG800Bis possible via HART protocol and a PC fitted with a suitable modemwired to the RCI.

There is a second ’real-time’ communication system which enablesthe µC to send messages to the RCI and further on to the plantDCS system. This is described later.

SAFE AREACONTROL ROOM

ELECTRICAL ROOM

ALARM / OK

TESTINGDCS

SAFETY PLC

HARTCOMMUNICATION

RCI

Fig. 1. ValvGuard system

ND800

HART

HART

10 Hz PWM

CPU

Display

Pushbuttons

DigitalI/O

PSBTF

control

SFcontrol

ADC

Pneumaticblock

Positionsensor

Pressure sensor

PWMamplifier

RCI out0/24 Vdc

Fig. 2. VG800B hardware

3

1.5 Principle of operation

1.5.1 The remote communication inter-face (RCI)

The Remote Control Interface (RCI) is mounted in the controlcabinet of the plant safety PLC and connected to it’s output. Ifintrinsic safety is used for explosion protection an isolator or a barrieris fitted on the field side of the RCI as shown in Figure 1 (suitablemodels are specified in the Technical Specifications).

NOTE:The installation within the control cabinet must meet the coderequirements of intrinsic safety. The manual and Figure 1 arediagrammatic only and may not be taken as an instruction forthis purpose.

The nominal safety PLC output is 24 V but a 15 % variance on thisis acceptable.

The RCI has two functions:To transmit HART signals to and from the VG800B fielddevice. A suitable modem is connected between the PCand the RCI to facilitate this.To receive real-time signals from the VG800B field unit.These signals are displayed on three Light Emitting Diodes(LEDs) mounted on the RCI casing. The RCI also has relaypotential free contact outputs which correspond with theLED display. Three signals are given, refer to Fig. 3..Green = OKYellow = TestRed = Alarm

NOTE:When a test is running, and the yellow LED indicates a test,simultaneously the green LED is lit and the correspondingrelay indicates an OK status. After the test (if the test has failedor there is some other error) the red LED will light and thecorresponding relay indicate an alarm. See detailed functionfrom Fig. 8.

1.5.2 The VG800B field deviceIn service the 24 Vdc supply powers the prestage (PR) redundantcoils (A and B) which controls the air pressure on the spool valve(SV) in such a position that keeps the SV return spring compressed.The SV is arranged so that the actuator air supply is maintained onthe actuator piston in opposition to the actuator return springthereby keeping the ESD valve open or close. When an emergencyoccurs, the power at the control room is switched to zero, thisde-energises the both PR coils and vents the pressure on the SVcausing the SV return spring to change the SV position to shut offthe air supply and to vent the air above the actuator piston. Theactuator spring then closes the ESD valve. When power is restoredthe PR coils are energized and air pressure once more causes theSV to compress the SV return spring. Air supply pressure is againapplied to the actuator piston which opens the ESD valve.

It is also possible for the µC to operate the ESD valve. This is doneduring commissioning and diagnostic testing. The µC takes powerfrom the 24 Vdc supply which is applied to PR coil (B). During a testthe µC is able to isolate PR coil (B) from the power supply causingthe voltage to drop to zero. This causes the same valve closing actionas already described in respect of 0 V on PR coils (A and B) sincethese are in parallel. As the ESD valve begins to close the positionsensor monitors the valve position. When the valve reaches the preprogrammed travel point the µC once again energizes the PR coil(B), which causes the ESD valve to open or close again. During partialclosure testing the µP monitors the output from the position sensorand compares this with the actuator air pressure. If the relationshipbetween these parameters shows an error the test is aborted.

VG800B24 / 0 V

HART

10 Hz PWM

SAFE AREA HAZARDOUS AREA

6

5

4

1

2

3

RCI

Inputregulator

HARTfilter

PWMdemodulator

HART

Fig. 3. Remote Communication Interface (RCI)

A B

PR

SV

Controlcircuit

coilcoil

toactuator

0 / 24 Vdc

Fig. 4. Prestage (PR) and spool valve (SV) units

4

1.6 MarkingsThe VG800B field device is provided with an identification platesticker, see Fig. 5. Identification plate markings from top to bottomare:

Type designation of the field deviceEnclosure classInput signal (voltage range)Operational temperatureSupply pressure rangeCE markManufacturing series number

Alternative markings on the additional plate, Fig 6Filter regulator (-K)Conduit entry1/2NPT (-L)Manufacturing series number

1.7 Technical specifications1.7.1 General

ValvGuard may be used with any cylinder or diaphragm spring returnactuator, but it is recommended for use with the Metso Automationrange of actuators since full design applicability is known andmounting parts are available. See the Section on ’Mounting forFurther information or contact your local Metso Automation office.

1.7.1 Electrical hazard protectionIntrinsically Safe systems may be used with ValvGuard. Isolators maybe more attractive in retro-fit installations as there is no requirementto monitor the relative earth potential which will be needed withBarrier devices. Compatible unit is MTL Isolator 5042.

1.7.2 SpecificationsGeneral

The VG800B valve controller is suitable for rotary and sliding stemvalves.

Actuator connection: In accordance with VDI/VDE 3845standard (S1)

Action: Single acting

Turning angle: min 45°, max. 95°

Environmental influence

Operational temp.: -40 - +80 °C (-40 - +176 °F)

Shock requirements: according to IEC TC65B draft

Enclosure

Material: Anodized aluminium alloy

Protection class: IP65, NEMA 4 and 4XPneumatics ports: 1/4 NPTElectrical connection: Screw terminals internals for 2.5 mm2

Conduit entry: M20x1.51/2 NPT (with adapter)

Weight: 3.6 kg (7.9 lbs)

Pneumatics

Supply pressure: 3.5-7 bar (50-100 psi)(filter/regulator mandatory)

Air quality: As defined by ISA S7.3 standard

Capacity: Max 30 Nm3/h (18 scfm)at 4 bar (60 psi) supply

Electronics

Polarity protection: -30 Vdc

Voltage range: 16.5-30 Vdc

Maximum current: 100 mA (RCI-VG800B)

RCI module is located at electric cross connection room(safety area) where no explosion protection is needed.

No. 2001160001

NELES VALVE CONTROLLER

TYPE VG8568B1

Input 21-30 V DC, Imax 100 mA, Pmax 0,6 W

REV 1.0

EEX d IIC T6/5 LCIE 99.E6086 X

Ambient temperature: -40 C ... +70 C / -40 F ... +158 FSupply pressure: 350-700 kPa / 3,5-7 barg / 50-100 psig

WARNING: Do not open while energized!

BAR CODE (TYPE)

BAR CODE (SERIAL NO)

MADE BY METSO AUTOMATION

Fig. 5. Identification plate

Fig. 6. Optional plate

5

Local keypad functions

Calibration: Automatic / Manual

Mode Selection: Auto/Off

Testing: Partial valve test / pneumatic test

Power-up selection: Off /On / Cal

Normal position: Close / open

Rotation: Rot: clockwise / counterclockwise

Protect (HART write protection):Off / On

Actuator type: Rotary / linear

Approvals

Flame proofcode B1 CENELEC EEx d IIC T6

CENELEC (EN 50014, EN 50018)

Explosion proofcode B2 Class I, Div. 1 and 2, Groups B, C and D

Class II and Class III, Groups E, F and G,FM 3615

TÜV 968/EL 115.00/00

User interfaces

Local: 3 keys + LCD display

HART: PC with HART modems(RS 232 interface) together with Valve Manager program

Electromagnetic protection

Protection standards: EN50081-1 and EN50082-2IEC 801-2 ESD, level 4,IEC 801-3 electromagnetic field, level 3IEC 801-4 Fast Transients, level 4

CE marking

Electromagneticcompatibility: 89/336/EEC

1.8 Recycling and disposal of a rejectedVG800B field device

Most ValvGuard parts can be recycled if sorted according tomaterial. Most parts have material marking. A material list is suppliedwith the device. In addition, separate recycling and disposal instruc-tions are available from the manufacturer. A field device can also bereturned to the manufacturer for recycling and disposal against afee.

1.9 Safety precautions

CAUTION:Opening the cover of VG800B field device enclosure isallowed for authorized and trained persons only!Misuse of powered VG800B field device may cause a danger-ous situation.

CAUTION:Do not exceed the permitted values!Exceeding the permitted values marked on the valve control-ler may cause damage to the controller and to equipmentattached to the controller and could lead to uncontrolledpressure release in the worst case.Damage to the equipment and personal injury may result.

CAUTION:Do not open the enclosure when the controller isenergized!

CAUTION:Do not remove or dismantle a pressurized controller!Removing or dismantling a pressurized prestage, spool valveor pressure sensor of an VG800B leads to uncontrolledpressure release. Always shut off the supply air and releasethe pressure from the pipelines and equipment before re-moving or dismantling the controller.Otherwise personal injury and damage to equipment may result.

CAUTION:During automatic or manual calibration the valve oper-ates between open and closed positions. Make sure thatthe operation does not endanger people or processes!

NOTE:Avoid earthing a welding machine in close proximity to anVG800B valve controller.Damage to the equipment may result.

NOTE:The display may become unreadable in ambient temperaturesbelow -20 °C/-4 °F.Warming up the display, for instance with thumb, may benecessary in such conditions.

6

2 MOUNTING AND INSTALLATION

2.1 GeneralEach emergency valve will be equipped with an individual ValvGuardsystem including the VG800B field device and the Remote Com-munication Interface module (RCI).

The ValvGuard system comprises a full safety loop from the plantsafety system output module (cross connection control cabinet)down to the VG800B field device.

It must be taken into consideration that the whole safety loop ismounted and installed properly with a professional manner.

2.1.1 Mounting of VG800B field deviceWhen the VG800B field device is supplied with a valve and actuatorthe whole unit will be supplied as specified by the customer for hisinstallation. When Valve Guard is ordered separately the mountingparts must be ordered at the same time.

Example Order: (BJ 13)-Z-VG800B. (See type coding in latersection).

The VG800B field device has the new Metso Automation mountingface for connection in accordance with VDI/VDE 3845 (S1). Cou-pling piece is ’H-clip’.

When mounting VG800B field device to an other manufacturer’sactuator, special mounting brackets are needed. Metso Automationmay be able to help in this process. This must be specified intype-coding (Y).

2.2 Mounting on Metso Automation actuatorswith VDI/VDE mounting bracket

Allow the actuator spring to be in the ’extended’ position.Set the actuator’s position indication arrow on the indica-tor cover to indicate a ’closed’ valve for an ESD valve (or’open’ for a vent or blow-off valve). Attach the draughtpiece (2) to the indicator cover in the position shown inposition Fig 4. Secure the draught piece by tightening theretaining screw. The screw should be locked by the useof Loctite or similar thread locking compound.Attach bracket (1) to the VG800B field device.Attach Bracket (1) to the actuator. The coupling on theShaft of the VG800B (40) must be engaged with thedraught piece (2) shown in Fig 7. See also drawings inSection 9.2 and 9.3.

2.3 Mounting on linear actuators with MetsoAutomation or IEC60534 mounting face

See figures in Sections 9.4 and 9.5.Temporally fit an Filter/regulator air set to the actuatorport so that the valve can be stroked to any position. Setactuator to its mid stroke position. (See serial plate for theactuator/valve assembly stroke length.Assemble the feedback lever arm to the controller inputshaft. Make sure that the lettering on arm faces towardsthe VG800B.Assemble the controller mounting bracket loosely to theslotted leg of the actuator. Ensure that the mark on theshaft and the feedback lever arm operate in the quadrantshown.Ascertain dimension "A" for the stroke of the actuator asmentioned above. Now place a mark on the lever arm at

this distance from the centre of the VG800B input shaft.When assembled the actuator pin shown in Section 9.4and 9.5 must correspond with this mark.Mount VG800B loosely on to its mounting bracket.Adjust the VG800B mounting bracket and the and theVG800B itself so that it is "square" to the actuator in allplanes. At the same time the feedback lever must behorizontal (at 90° to the actuator centre line).Tighten bracket fixing screws.Adjust the VG800B on its bracket so that the distance "A"(as marked in earlier) is maintained between the VG800Bshaft centre and the actuator pin.Tighten all fixing screws/bolts, then re-check that theVG800B mounting complies with previous steps. Carefullystroke the valve and ensure that the actuator pin does notfoul the VG800B case. (It may be necessary to shorten thispin in the case of small actuator with a stroke of 1.25").Assemble the spring to the feedback arm as shown.Apply grease to the contact point of the pin and the leverarm.Finally stroke the actuator and check for proper functionof the assembly.

C2

S

C1 The mark on the shaftshould stay in this sector

Fig. 7. Mounting on Metso Automation actuator with VDI/VDE mounting face

40

Shaft

mark =yellow dot

7

2.4 Mounting of the Remote Communica-tion Interface (RCI) module

The Remote Communication Interface (RCI) module is a DIN railmountable device having approximately the following dimensions:104 mm (H) x 110 mm (D) x 16 mm (W) or (4.1" x 4.3" x 0.6").

The RCI module can be mounted in the same electrical crossconnection control cabinet, where the plant safety-PLC of othersafety system is mounted.

If the loop is intrinsically safe requiring Ex isolator it is practicable tomount RCI modules on the same rail as Ex isolators.

The RCI module must always be mounted on the plant safety systemside before the Ex isolator.

If there is not space enough in the control cabinet for the RCI modules(and Ex isolators) a separate cabinet is required to prevent any damages.

Note that the RCI modules must always be located on the safe sideof the plant (e.g. in non hazardous area).

A principle mounting arrangement of RCI module and VG800B fielddevice can be seen in Fig. 8.

NOTE:The RCI unit is not an isolator!

2.5 Piping and air supply

CAUTION:Do not exceed the permitted supply pressureof the VG800B!

Table 1 provides the recommended tube sizes in accordance withactuator sizes. Tube sizes are the minimum values allowed. Forsupply air choose a tube one size bigger. Operating times can betested by the Valve Manager program.

Connect the air supply to S (1/4 NPT).Connect C2 (1/4 NPT) to the actuator.

For the pipe threads liquid sealants, such as Loctite 577, arerecommended.

NOTE:Too much sealant may cause faulty operation of the controller.Sealing tape is not allowed.Ensure the cleanliness of the air piping.

The supply air must be clean, dry and oil-free instrument air, e.g.according to standard ISA S7.3-81.

2.6 Electrical connectionsThe VG800B is powered by a standard 24 Vdc.. HART is carriedover the supply voltage between the RCI and the VG800B. It isrecommended that the HART modem is connected to the RCI,where the connection is protected against short-circuiting.

The input signal cable is led through a M20x1.5 cable gland. Connectthe conductors to the terminal strip according to Fig. 9.

Check the wire polarity before connection. The controller has 30 Vpolarity protection. EMC requirements require earthing of the inputcable shield either at the DCS end or at the VG800B end, but neverat both ends.

NOTE:Without earthing the valve position measurement may haveinterference in a strong magnetic field.

Contacts of relays in the RCI unit:

OK 1-2 and 4-6Alarm 1-2 and 4-5Test 1-3 and 4-6

HARTMODEM

VG800B

HARTFILTERINPUT

REGULATOR

R

1MGND

PGND

RCI

OK

TEST

ERR

TESTING

OK/ALARM

6

5

4

3

2

1

14

15

8

9

12

11 +

–

+

–

Vin

1

310

Fig. 8. Connection diagram

86

57

42

13

HART-connection (ø2,3 mm)

24 Vdc from RCI

Earth connection

Fig. 9. Terminals in VG800B

8

Actuator PipingCu/SS (") Cu/SS (mm)

B1C Stroke vol.dm3/in3

NPT 1/4 3/8 1/2 6/4 10/8 12/10

6 0.3/18 1/4 x x9 0.6/37 1/4 x x11 1.1/67 3/8 x x13 2.3/140 3/8 x x1720

4.3/2625.4/330

1/2 xx

xx

2532

10.5/61021/1282

1/23/4

xx

(x)(x)

xx

(x)(x)

4050

43/262484/5126

3/41

(x)(x)

xx

xx

502 195/11900 1 x xB1J

B1JAStroke vol.

dm3/in3NPT 1/4 3/8 1/2 6/4 10/8 12/10

810

0.9/551.8/110

3/8 xx

xx

1216

3.6/2206.7/409

1/2 xx

xx

2025

13/79327/1648

3/4 xx

(x)(x)

xx

(x)(x)

32322

53/3234106/6468

1 (x) xx

xx

QP Stroke vol.dm3/in3

NPT 1/4 3/8 1/2 6/4 10/8 12/10

1 0.62/37 3/8 x x2 1.08/66 3/8 x x3 2.18/133 3/8 x x4 4.34/265 3/8 x x5 8.7/531 3/8 x x6 17.5/1068 3/4 x x

Table 1. Piping

9

SINGLE-ACTING ACTUATOR

SINGLE-ACTING ACTUATOR

1. Spring to close valve, e.g. B1J_

Default setting:ASt = OFFrot = cC (pressure relief rotation to clockwise)Pro = OFFnoP = OPEAct = rotdisplay = 0 %

3. Spring to open valve

Default setting:ASt = OFFrot = ccC (pressure relief rotation to counterclockwise)Pro = OFFnoP = CLOAct = rot

2.Spring to open valve, e.g. B1JA_

Setting:ASt = OFFrot = cC (pressure relief rotation to clockwise)Pro = OFFnoP = CLOAct = rot

CAUTION: Valve closes exceptionally counterclockwise.Unsuitable for Q-, R-, T5-, F- and L-series valves.

C1

C2

S

C1

C2

S

C1

C2

S

display = 100 %

display = 100 %

ASt: defines position of unit to which it remains after voltage failure, re-booting or when voltage is connected for the first time tothe unit.

rot: rotation direction is understood when pressure is relieved from cylinder or diaphragm actuator.

The commisioning modes are:OFFOn = AUTOCAL

Fig. 10. Operation directions and air connections

10

2.7 Additional instrumentationIf there is need to have information when a valve is fully open orfully closed, the actuator of ValvGuard can be equipped withelectro-mechanical or proximity sensor limit switches.

In case of emergency shut down there is need to close or open avalve very fast. The Figs. 11-13 illustrate accessories which areneeded to achieve fast action as well as to allow partial valve stroketest. The exhaust valve is normally high capacity valve.

A filter-regulator is mandatory and port size should be related totubing size between VG800B and actuators.

3 COMMISSIONING AND OPERATION

VG800B is commissioned and configured with the help of local userinterface (LUI) or graphical user interface Valve Manager forValvGuard by using their menu.

3.1 Using Local User interface (LUI)

NOTE:Please note that local operation with push buttons is notpossible when the VG800B is mounted in hazardous area andenergized. The operation must be performed from the safeside using HART communication and Valve Manager software.

The LUI consist of three push buttons and a LCD display. The statusof VG800B can be seen from the display. The keyboard and displayof the VG800B are shown in Fig.14. Operations and display arecontrolled by +, - and r keys.

Two setting functions are available: m or c. Both ofthese names refer to the function to be adjusted or changed. In thea or o mode the display indicates the valve travel inpercentage. Default value from factory is o. In case of someerror, the error code is displayed in the LCD display. By pushing rbutton the error code is cleared, and the mode and valve openingis displayed again. By pushing + and - for 5 seconds, the user entersthe menu described in the Fig.15. All the different options areblinking in the menu and + and - buttons scroll through the differentoptions. From the menu the user can change the operation modeof the device (a/ o), start a valve test or an actuatorpressure test, start an automatic or a manual calibration procedure,set auto start after re-booting or at power-up, select the rotationdirection of the valve and set the HART write protection On or OFF.By pushing the + and - shortly the user can safely return to theprevious level or abort a test or a calibration procedure.

The local user interface (LUI) keyboard can also be totally disabledwith a parameter setting.

If a function is not allowed a text ’Err’ is displayed in the LCD. Thiscould happen for instance if trying to start the calibration in theautomatic mode.

CLO

SE AIR SUPPLY

VG

C2

142

3

FROM RCI

1. VG800B2. spring-return actuator3. limit switch4. filter/regulator

Fig. 11. Standard operation

FROM RCI

AIR SUPPLYVG

CLO

SE

5

2

14

3

C2

1. VG800B2. spring-return actuator3. limit switch4. filter/regulator5. solenoid valve

Fig. 12. Operation with solenoid valve

AIR SUPPLY

FROM RCI

41

7

6

2

3

VG

C2

CLO

SE

1. VG800B2. spring-return actuator3. limit switch4. filter/regulator6. quick exhaust valve7. throttle valve

Fig. 13. Operation with quick exhaust valve

MODE:

CALIB

AUTO MAN OFF

Fig. 14. LCD-display and keyboard

11

& > 5 s

Push shortly to abort the calibration or test,or to return to the previous level.

&

> 5 s

> 5 s

Fig. 15. Keyboard operations

12

3.1.1 VG800B functionsSee keyboard operations Fig. 15

VG800B includes following keyboard functions:

Mode setting = mTesting = tSt

Calibration = cAuto Start = ASt

Normal Position = noP

Rotation = rot

Protection = Pro

Actuator type = Act

3.1.1.1 Mode setting

In the o mode calibration is allowed but not testing. RCI’s errorsignal is lit. In the a mode testing is allowed but not calibration.RCI’s OK signal is lit.

3.1.1.2 Testing

The VG800B has two kind of diagnostic tests: The pneumatic testPt checks the proper operation of the pneumatics of the field devicewhile a valve stroke test St checks the operability of the whole valveassembly by partial stroking the valve as configured from the normalposition.

3.1.1.3 Calibration

By pressing the r an automatic valve travel measurement calibrationis started. More detailed description of thi is given in section 3.1.3.

3.1.1.4 Automatic start-up function

The automatic start-up function ASt defines the field device actionafter the 24 V is switched on. OFF means that the field device willremain in o mode after start-up. On means that the field devicewill go to a mode and start the automatic diagnostics asconfigured. CAL means that after start-up the field device will performan automatic travel measurement calibration before going toa mode.

3.1.1.5 Normal position

The valve normal position selection noP defines the valve positionin normal energized condition. The two possibilities are OPE for fullyopen and CLO for fully closed.

3.1.1.6 Rotation

The rot defines actuator rotation direction when pressure isrelieved from a cylinder- or diaphragm actuator. The value cC meansclockwise rotation for closing and ccC means counterclockwise toclose.

3.1.1.7 Protection

The Pro defines HART write protection On or OFF. The VG800B isdelivered from factory with HART write protection OFF as defaultsetting. Reading and changing parameters with Valve Manager forValvGuard is thus allowed.

3.1.1.8 Rotary vs. linear valve selection

The act defines a style of valve. rot is for rotary valves and Li n is forlinear valves to compensate for nonlinearity of the position feedbackcaused by the actuator linkage mechanism of linear valves. Theappropriate selection must be made at Act display.

You can return to operation state from any setting by pressing +and - keys shortly simultaneously for less than 1 second, repeatingif necessary

3.1.2 HART write protectionThe VG800B is delivered from the factory with HART writeprotection OFF as the default setting. Reading and changing parame-ters is thus allowed. HART protection can be enabled with a switch(DIP1) located on the circuit board (Fig. 16). Changes which mayinfluence the valve position cannot be made using the ValveManager program when switch no. 1 (on the left-hand side of theswitch block) is ON. For detailed information see the Valve ManagerUser’s Guide.

1

DIP1

DIP1OFF

1 1 2

ON

1 2

ON

DIP1ON

1 1 2

ON

Fig. 16. DIP switch

13

3.1.3 ConfigurationThe VG800B position sensor operational range is factory adjustedto suit Metso Automation actuators. If VG800B is to be fitted intoanother manufacturer’s actuator, the sensor may need to bereadjusted as explained in Section 4.5. The basic factory setting ofthe VG800B assume spring to close the valve and a clockwise closingdirection for the position sensor when pressure is relieved from thecylinder or diaphragm actuator.

Connect the air supply and voltage from RCI unit. Makesure that the voltage is between 21 - 30 Vdc, measuredfrom the + and - terminals of VG800BSet the operation mode to o. Press the + and - for 5seconds and the m starts to blink.Press + key shortly as many times as ASt appears on thedisplay. Press r to change "power-up" position to corre-spond On by scrolling + or - keys. After selection press rkey, which returns you back to A5t mode.After selecting noP on the display, press r key and thecurrent parameter value will be shown on the display.Now you may select between two values by pressing +or - key. The value CLO signifies the pressure on theactuator to close the valve and OPE means the pressureto open the valve. Press the r key to finalize your selectionand return to noP mode. See default values in Fig. 10 andfunction in Fig. 15.The next setting is rot where you will select by pressingr key either clockwise- or counterclockwise rotation ofthe valve when pressure is relieved from cylinder- ordiaphragm actuator. After your choice with + or - keyspress r key which returns you back to rot mode.Press + key as many times as the letter Act appear on thedisplay and by pressing r key you can select by scrollingwith + or - key desired style of valve. The rot is for rotaryvalves and Li n is for linear valves. To conclude press r keywhen desired value is shown on the display.

3.1.3.1 Calibration

After the above-mentioned settings you can start calibration byscrolling with + or - key so far that display shows c, whichis blinking on the display. Press r to select a or Mcalibration, which are also blinking depending on which one youhave selected by scrolling with the + or - keys.

CAUTION:Automatic calibration drives the valve against themechanical open and closed travel limits of thevalve-actuator assembly and a self-tuning proce-dure is performed. Make sure that these proce-dures can be safely executed.

As a result of calibration the position sensor is fixed to correspondfully open and close position of a valve.

a calibration function:For safety reasons the r key needs to be pressed for 5seconds to activate the a calibration function. Dur-ing calibration the display shows the text CAL. Aftercalibration the VG800B returns automatically to thec function.At any time you may interrupt the calibration sequencesby pressing the + and - keys simultaneously.

After the a calibration sequence is finished press the+ and - keys simultaneously to get back to the operationstate. If this sequence has ended and an error message Err

appears on the display, see Chapter 6.

Now the VG800B will work with basic settings.

M calibration function:After selecting the M calibration function from thedisplay press the r key to activate the procedure.With the - key drive the valve to the closed (0 %) positionand then press the r key.Drive the valve into the open position (100 %) with the+ key and press the r key.If an error message Err appears on the display, seeChapter 6.Press the + and + keys simultaneously to return to theoperation state.

Now the VG800B will work with basic settings.

3.1.4 TestingAdditionally to the above mentioned functions, there are two localtests:Pneumatic test and a valve stroke test.

To be able to run the tests, the operation mode has to be a.Tests are not allowed in o mode. Scroll with + or - keys as faras display shows tSt. Press then r key and select with + or - desiredtest performance. By selecting Pt the unit will carry out internalpressure test and ensures that pneumatic portion is available. Duringthis operation the display shows 100 %. By selecting St you canmake partial valve stroke which will move the valve the configured(default value 20 %) amount from the normal energized position.

3.1.5 Safety protectionBefore going back to the operation mode of a valve the user canwrite protect the unit by using Pro setting. Once Pro is displayedpress r key and the current parameter value will be shown on thedisplay. Now you can select with two values by pressing + or - key.The value OFF means that user is able to make changes of settings,tests and read diagnostics by using Valve Manager. The value On

means that unit is write protected and user is only able to readdiagnostics but changes of settings and tests are not allowed

When all the parameters are correctly set, return to operation stateby pressing the + and - key simultaneously for short time. Thedisplay should show 100 % and a mode.

14

3.2 Using ValveManager software andHART communication

Commissioning and configuration of the VG800B can be made alsowith help of graphical user interface Valve Manager for ValvGuardby using its menu. Operational principle is illustrated in Fig. 17.Communication with the device is done with HART communica-tion protocol by connecting into terminals 8 and 9 of the RCI unitlocated in safe area. See Fig. 8.

3.2.1 Monitoring

There are four dynamic variables:Valve position graph displays the actual travel of theESD/ESV valve measured by the ValvGuard. Actual travelis shown as a percentage of calibrated valve travel.Leakage signal graph shows leakage through a valve whenit is closed. Optional leakage sensor is needed to install.See Fig.19.Actuator pressure graph can be used to check that thereis enough pressure to compress the spring. With the aidof pressure information, possible frictions and actuatorleakage can be discovered by comparing prevailing andprevious pressure curves.PCB temperature graph shows the temperature insidethe VG800B on the PCB (Printed Circuit Board)

3.2.2 ConfigurationAll the ValvGuard configuration settings are defined in Settingswindow, Fig. 20 which has two different pages. All the testing relatedparameters are set using this screen. In addition, testing related alertconfiguration is done via Settings | Alert conf. window.

If configuration settings have been read with the Read config buttonon the main window prior to issuing Settings command, parameterfields are automatically filled. Zero value fields are shown blank.Parameter value is read by double-clicking the text box or optionbutton of each parameter. A new setting parameter is sent to thefield device by clicking the Set button. A successful update isconfirmed by a Set successful window. If the sending procedure failsfor some reason, an error message window is shown.

Setting Device action NotesOff

Auto

Cal&Auto

The device remains inthe Off-mode

The device enters theAuto-mode

The device performs atravel sensor calibrationand enters the Auto-mode.

RCI’s Error-signal is lit.Calibration but not testingallowed. Default value.

RCI’s OK-signal lit.Testing but nocalibration allowed.

RCI’s OK and Testingsignals are lit duringcalibration.

Table 2. Valid Power-up settings

Control room (Safe area)(Hazardous area)

Factory floor

VG800B

HART-communication

(HHC)

ALARMTESTING

OK

SCS / DCS

RCI

Fig. 17. Connections

Fig. 18. Dynamic variables display

Fig. 19. Leakage signal

Fig. 20. Settings screen

15

3.2.2.1 Power-up selection

The Power-up selection option defines the field device action atpower-up, voltage failure or rebooting. Valid options are Off, Autoand Cal&Auto. Table 2 lists effects of settings.

3.2.2.2 Local user interface

The keyboard operation of the VG800B field device can be disabledwith this option. If the keyboard is disabled, push button operationsare ignored. Operation can be restored by sending Keyboardenabled command. The default setting is Keyboard enabled, thenew value is sent to the device by Set button.

3.2.2.3 Spring action direction

Spring action direction defines actuator rotation direction whenpressure is relieved from a cylinder. If configuration data is read,current action setting is indicated. If the setting is changed, the textturns into red until the Set button is clicked.

This setting must be changed only if the actuator type is changed.An incorrect setting will prevent the field device to operate properly.

3.2.2.4 Actuator type

Actuator type setting is used to define proper operation of the fielddevice for rotary and linear valves. This setting must be changed onlyif the actuator type is changed. An incorrect setting will prevent thefield device to operate properly. The default setting is Keyboardenabled, the new value is sent to the device by Set button.

3.2.2.5 Valve normal position

Valve normal position is the valve position when the cylinder ispressurized. If releasing pressure from the actuator cylinder closesthe valve the setting should be Normally open, otherwise the settingis Normally closed. This setting affects only on the position displayof the field device and normally needs not to be changed. The newvalue is sent to the device by Set button. The default setting isNormally open.

3.2.2.6 Device mode

The field device operating mode can be changed with Device modeoption. Change of the mode may be necessary to perform calibra-tions or run tests. Available settings are Off and Auto modes. Themode is changed by choosing the desired option and clicking Setbutton. A successful setting is confirmed by Set successful window.

Please note, that Set successful window only confirms commandexecution. After commanding the device into the Auto mode thedevice may still revert to previous state despite a successful com-mand. If, for example, there is an hardware error the device modewill not be changed.

A colored box of the device mode item indicates status of theVG800B device at the moment the parameter setting is read.Meaning of color codes is explained in Table 3.

3.2.3 Test settings

3.2.3.1 Pneumatics test interval

Pneumatics test interval can be given in days, hours or minutes. Timecount of a new test period is started at power-up, parameter updateand at the beginning of each test.

Default value of the test interval is 1 000 000 hours. Input valuerange of each field is limited to 0-41666. One decimal of minutefield is taken into account. Decimals of other fields are ignored.

3.2.3.2 Pneumatics test timer

With a pneumatics test timer the next pneumatics test executioncan be started after a pre-determined period. After that pneumaticstests are repeated at frequency defined with the pneumatics testinterval.

The pneumatics test timer dialogue is shown by clicking the checkbox. The value is set by Set button. A successful setting is confirmedby pop-up window. Also, the timer dialogue will be hidden.

3.2.3.3 Valve test stroke size

The valve test stroke size is the distance in percentage the valve ismoved during a valve test. It is relative to a valve position when anactuator cylinder is pressurized. Effect of an actuator type to actuatormovement is shown in Table 4.

3.2.3.4 Valve test interval

Valve test interval is used the same way and parameter range issame as that of pneumatics test interval.

Default value of the test interval is 1 000 000 hours. Input valuerange of each field is limited to 0-41666. One decimal of minutefield is taken into account. Decimals of other fields are ignored.

3.2.3.5 Valve test timer

Valve test timer operation is similar to the pneumatics test timer.

3.2.3.6 Pressure step

The pressure step parameter affects the pressure control of thespool valve prestage unit. This parameter can be used to adjust thevalve test duration. Higher values yield shorter test times. Defaultvalue is 0.05 and usable range is about 0.003...0.2 bar. Usually thisparameter needs not to be changed.

Colour ExplanationGreen

Yellow

Red

The device is in Auto mode. Automatic testingenabled.A test is running.

Off or fail safe mode. Automatic testing disabled

Table 3. Device mode color codes

Actuatortype

Test stroke Actuatormovement

LCD- display attest stroke

Spring toclose

Spring toopen

20 %

20 %

20 % to close fromopen position

20 % to open fromclosed position

80

20

Table 4. Actuator travel and test stroke

16

3.2.4 Alert configurationDevice alert configuration settings are available via the Settingwindow, Fig. 20, by alert configuration button. Configuration screenis shown in Fig. 21.

The current setting of a parameter can be retrieved by double-click-ing each text box. A new value is set by clicking the Set button.Statistics related settings are configured at Diagnostics screen, Fig. 22

3.2.4.1 Test timeout

The test timeout is a maximum time limit for a test to complete. Ifthis time is exceeded, test is aborted, error is generated and Errorsignal of the RCI unit is lit. Cause of the test failure can be, forexample, a faulty valve or field device, insufficient air supply orimproper parameter setting of the field device. The failure event islogged into involatile memory of the field unit.

The default value of the parameter is 90 seconds. If the actuatorcylinder is large and/or the pressure step setting has a small value, isit possible that the default is too short causing test failures. In thosecases extending the timeout will prevent unwanted alerts.

3.2.4.2 Position error tolerance

Valve position is constantly monitored by the field unit. If themeasured position change exceeds the tolerance and a valve test isnot running, a position error is generated. The error signal is lit andfuture automatic testing is disabled. Default value for the parameteris 15 %.

3.2.4.3 Supply pressure high and low limit

If the supply pressure is beyond it’s specified range, a deviceoperation failure can occur. Limit values can be adjusted with theseparameters. If the limits are exceeded, an error is generated andRCI’s Error signal is lit. If the pressure is restored, the device willresume normal operating mode

3.2.4.4 Valve test warning time

Before a valve test is started, the Test signal of the RCI-unit is lit.This pre-test signal duration can be adjusted by the parameter. Thedefault value is 2 seconds.

3.2.5 Statistics alertsStatistics alerts settings are available through Diagnostics screen ofthe main window, Fig. 22. The settings window is shown in Figure23. If the configuration data has been read from the field devicebefore opening this screen, fields are automatically filled.

Fig. 21. Alert configuration screenFig. 22. Diagnostics screen

Fig. 23. Statistics alerts setting window

Fig. 24. Leakage signal trend

17

3.2.5.1 Load factor high or low limit

A load factor of an actuator is calculated each time a valve test isperformed. The calculation is based on the supply and the break-away pressures. Too high load factor can impair position controlaccuracy or can be a sign of valve wear or damage. Also, a low loadfactor can indicate a valve damage.

The default values are 100 % for high and 0 % for low limit. Thesefigures should be adjusted to application.

3.2.5.2 Breakaway high and low limit

Each time a valve test is run, the cylinder pressure at which theactuator starts to turn is recorded. If the pressure is too low it canbe a sign of high actuator load. On the other hand, high Breakawaypressure value can indicate a device failure.

The default values are 2 bar for high and 0 bar for low limit

3.2.5.3 Number of tests

A number of valve and pneumatics test executions are logged. Theexecution numbers can be controlled by triggering an alert if a limitis reached. An alert will not affect normal operation of the unit butmay be helpful in scheduling maintenance actions

The default value for both tests is 100 000.

3.2.6 Automatic travel calibration

WARNING:Calibration will move the valve from the closedposition to the fully open position!Make sure you are allowed to perform calibration.

Selecting the command Calibration | Automatic Travel Calibrationopens a Calibration window, Fig. 25. The automatic valve travelcalibration runs a calibration routine in the VG800B valve controllerwhich calibrates the valve travel according to the mechanical limitsof the actuator. The calibration is started with the Start button.While the calibration is running, it can be stopped with the Stopbutton. The state of the calibration is shown at the bottom of thewindow and the user is informed of the success of the calibration.Calibration will require some time., Fig. 26.

Position Sensor, Pressure Sensor and Temperature Measure-ment Calibrations are only needed if the sensors are replaced. Seedetailed User’s Guide of Valve Manager for Neles ValvGuard

Database

The parameters are saved using Save to database option of theFile menu.

Monitoring, testing and diagnostics can be also made by using User’sGuide of Valve Manager for Neles ValvGuard.

All times shown in the database are in hours.

3.2.7 Alert handlingIf the Error signal of the RCI unit is lit, an error code is shown onthe LCD display. The same error code can be retrieved by usingthe Valve Manager software. To retrieve the error code connect aHART modem to the RCI unit, make a connection to the field deviceand read the diagnostics data by pressing the Read diag. button ofthe Valve Manager. The error code is shown in the Event Historywindow. Refer to the User’s Guide of the Valve Manager for NelesValvGuard if necessary. The error codes are explained in Table 5.

3.2.7.1 Error codes and recovery

See Chapter 7 and Table 5.

3.2.8 DecommissioningBefore de-commissioning ensure that you have the authority tomake the change to the safety instrumented system, and that thesafety instrumented functions still remain appropriate. It is alsorecommended that the configuration parameters of ValvGuard,such as the automatic start-up function, valve test stroke size andinterval are set to safe values to ensure a possible re-commissioningin a safe manner. Also to avoid unnecessary alarms after re-com-missioning, it is also recommended that the statistics (trends) andthe corresponding alarm limits are reset.

Fig. 25. Calibration menu

Fig. 26. Automatic Travel Calibration window

18

4 MAINTENANCE

The maintenance requirements of the VG800B depend on the serviceconditions, for instance, the quality of instrument air. In normal serviceconditions no regular maintenance is required. The best reliability isachieved by following these instructions.

In the following text the numbers in parenthesis ( ) correspond tothe part numbers on the exploded view in Chapter 10, unlessotherwise stated.

The VG800B field device includes the following interchangeablemodules: prestage (3), spool valve (4), two circuit boards (5, 400),position sensor (6), and differential pressure sensor (7).

The modules are located underneath a protective cover (46) whichis attached with M3 screws. If a module fails it must be changed. Themodule retrofit must be made in a clean, dry environment. Afterreplacement apply thread locking compound (for instance, Loctite243) and tighten the screws firmly.

4.1 Prestage

NOTE:The prestage must be handled very carefully. In particular themoving parts on both ends of the prestage should not betouched when the prestage is functioning and the protectivecover is not in place.

DisassemblyUnscrew the M4 screws and remove the prestage module.Unplug the prestage (3) wire connectors from the lowercircuit board (400). To do that you have first to removethe upper circuit board. Be careful not folding pressuresensor connectors when putting the upper board back inplace. For upper circuit board removing see 4.3.

ReassemblyPlace the O-rings in the respective grooves and press theprestage into place. Make sure that the nozzles are prop-erly guided on top of the O-rings.Push the prestage 2-pole wire connectors into the socketson the lower circuit board. Make sure that the wires donot cross each other. The wire connectors can only befitted in the correct way.The screws guide the prestagebody into the correct position.Tighten the screws evenly with a torque of approx.0.8 Nm (0.6 ft.lb). Set the protective cover (46) carefullyin place and tighten the screws.Remount the circuit board carefully. Do not let thefeedback shaft touch the circuit board. Locate the pins ofthe pressure sensor on the matching connections on theboard. Be careful not bending the pins.Tighten the board to its place with threaded spacers.Connect the wires to the terminal block as shown in Fig.28. Plug the prestage wire connectors into the board.Put the upper circuit board on its place following theinstructions in 4.3.

4.2 Spool valveDisassembly

Unscrew the M4 screws and remove the spool valveassembly.

The spool valve can be cleaned by following especially clean andcareful procedures. The seal (106), spring (100) and spring endstopper (101) are located at the end of the spool valve ( 103). Thespool (97)can also be removed for cleaning. When opening thespool valve assembly don’t let the spring eject the spool out of thebody.

NOTE:Each spool valve body has an individual matching spool whichcannot be replaced by any other spool. Never change theorientation of the spool.

ReassemblyIt is important that spool valve end (103) is evenly tight-ened.Place a new gasket (98) in the location determined by the fittingscrew holes. Fit the spool valve into its corresponding positionon top of the seal and tighten the M4 screws (99) evenly.The O-rings must be mounted first in their grooves located inthe spool valve unit. During mounting the O-rings must becompressed because the sealing is done radially. Make sure thatthe O-rings are evenly compressed and that they are fully insidethe grooves. The O-rings must be in perfect condition; nodefects are allowed. If a tool is used it must be blunt.

4.3 Circuit board (upper), ND800Disassembly

First unplug all wire connectors from the circuit board (5)and the signal wires from the terminal block. Remove theM3 screws.

NOTE:Ground yourself on the body of the device before touchingthe circuit board.

Take hold of the sides of circuit board and lift it directlyupwards and outwards. Handle the board carefully, touch-ing only the sides.

10097106108

107

103 104 105 96 109

Fig. 27. Spool valve

19

ReassemblyRemount the circuit board carefully. Do not let thefeedback shaft touch the circuit board.Locate the pins of the pressure sensor on the matchingconnections on the board. Be careful not bending the pins.All wirings from the lower circuit board should slidethrough split between upper circuit board and the pre-stage unit (3). Watch out that wirings don’t slide betweenpressure sensor pins.Tighten the M3 screws evenly.Connect the wires to the terminal block as shown in Fig. 26.Plug the prestage wire connectors into the board makingsure that the wires do not cross each other. Plug theposition sensor wire connector into the board.Mount the protective cover (46).

NOTE:Changing a new circuit board requires updating the moduleparameters using HART communication. See the instructionsprovided with the new circuit board.

4.4 Circuit board (lower),power supply board PSB

DisassemblyTo remove the lower circuit board (400) you have first toremove upper circuit board (5), see 4.3. After that removethreaded spacers (4 pcs.).Unplug prestage connectors from lower circuit board andsignal wires from connector block.

NOTE:Ground yourself on the body of the device before touchingthe circuit board.When lifting, take hold of the sides of circuit board.Handle the board carefully, touching only the sides.

ReassemblyRemount the circuit board carefully. Do not let thefeedback shaft touch the circuit board.Locate the pins of the pressure sensor on the matchingconnections on the board. Be careful not bending the pins.Tighten the board to its place with threaded spacers.Connect the wires to the terminal block as shown in Fig. 28.Plug the prestage wire connectors into the board.Put the upper circuit board on its place following theinstructions in 4.3

4.5 Position sensorBefore loosening the position sensor (6) first loosen the circuit boardaccording to 4.3.

The position sensor assembly (6) consists of the MR-sensor (114),which is fixed to the housing, and the spiral (117), which is fixed tothe main shaft. See Fig. 29.

DisassemblyFirst you have to remove pressure sensor (see 4.6) orprestage unit (see 4.1). After that, loosen the M3 screws(116, 2 pcs.) and lift the sensor out of the housing.Remove the lock ring (119) from the shaft and open thehexagonal socket screw (118, 2 pcs.). Mark the top of thespiral before removing it. Slide the spiral out of the shaft.

ReassemblyMount the new sensor and spiral together as a pair. Slidethe spiral back onto the shaft and replace the lock ring onthe shaft. Turn the spiral and the shaft to the positionshown in the Fig. 29, corresponding to a 45° valve opening.Tighten the M3 screws.Install a 0,1 mm (0.004 in) thick gauge strip between thesensor and the spiral. Press the sensor against the spiral,without using unnecessary force, and tighten the screws(116) evenly. Remove the strip.Mount the circuit board and the protective cover (46)according to Section 4.3.

NOTE:Changing the new position sensor requires updating of thecalibration values of the sensor using HART communication.See the instructions in the User’s Manual for the VG800BHART master software (e.g. Valve Manager for NelesValvGuard).

ND800

PSB

EOY

NDIN1

23

4

56

78

VA1

VA2

HART

FROM RCI

X8X6

X1 X2X3 X4

RX

X5

X7 (SF)

X6 (TF)

red

blue

8-way cable

positionsensorcable

differentialpressuresensor

cables ledthrough grommets

Fig. 28. Circuit board connections

119

118 117116114

40

40

45˚

40

90˚

45˚

Mark

Mark

Yellow

Yellow

Mark

Mark

Mark tothisposition

Fig. 29. Position sensor

20

4.6 Pressure sensorBefore removing the pressure sensor (7) you must loosen the circuitboard according to section 4.3.

DisassemblyLoosen the M3 screws (126, 2 pcs.) and lift out thepressure sensor (7) holding it from the both ends, Fig. 30.

ReassemblyMount the O-rings (123, 2 pcs.) in their grooves in the housing.Push the pressure sensor back into place, guided by the O-rings.The final location is shown in Fig. 30. Tighten the M3 screws evenly.Replace the circuit board and the protective cover accord-ing to Section 4.3.

NOTE:Changing the pressure sensor requires updating of the calibra-tion values of the sensor using HART communication. See theinstructions in the User’s Manual for the VG800B HARTmaster software (e.g. Valve Manager for Neles ValvGuard).

4.7 RCI unitBefore removing the RCI unit you must disconnect all the connec-tors or wires from the unit. See connections from Fig. 8.

Disassembly:Lift unit from one corner and pull RCI unit out from DIN rail.

Reassembly:Select correct rail width from selector. Place unit to DINrail from one side and then push it to it the place. Makesure the unit is locked and firmly on rail.Connect all connectors or wires and make sure they areon the right places, see Fig. 8.

NOTE:Changing the RCI unit will disconnect VG800B from operationand causes the valve to move to fail-safe position.

5 SAFETY MANUAL

ValvGuard is a safety related product. Extra attention is required tomake sure it is used in a way it is intended to be used and in a safemanner. The following checklist provides assistance to this. Everyitem mentioned in the checklist should be compared against theinstallation, and if any deviations exist the safety of the installationcannot be guaranteed.

De-energized is the safe state of the installation. Thismeans that no electronic or software fault within theValvGuard system can lead to a dangerous failure in caseof a demand.The required hardware fault tolerance of the installationis zero. If hardware fault tolerance of 1 is required (forexample in a furnace isolation application), then a dualredundant configuration should be used (see figure 30).

The ValvGuard system must be configured before commis-sioning. The parameters configured to the VG800 must beread back and verified using the Valve Manager for NelesValvGuard software package before commissioning. It isrecommended that the parameters are also stored in theValve Manager for Neles ValvGuard database in the com-puter (see Section 3.2.2).To obtain the best possible diagnostic coverage must theautomatic test intervals and the various alarm limits in theVG800 be set (see Sections 3.2.3, 3.2.4 and 3.2.5). Thediagnostic coverage factor for an ESD-valve (a fail to closevalve) can be assumed to be around 75 % (valve +actuator), and the diagnostic coverage factor of an ESV-valve (fail to open valve) around 90 % (valve + actuator).For more accurate estimates contact Metso Automation.The diagnostic coverage of the pneumatic unit withinValvGuard can be assumed to be > 90 % only if a pressureregulator is installed in the air supply to the VG800 (seeSections 2.5 and 2.7).Both relay outputs in the RCI unit must be used (con-nected to an external system, see Section 2.6). Anyinconsistencies (faults) in the relay outputs have to bedetected by the external system (e.g. a DCS or a PLC).For example if the "test" -relay output is not indicating atest according to the programmed automatic test intervaland the status of the valve is still "ok", then either the "test"-relay or the "ok/alarm" -relay output might have failed, i.e.there could be a critical alarm which is inhibiting automatictesting, but is not indicated because of a failed relay output.NOTE! The relay outputs are independent of the ValveManager for Neles ValvGuard software and HART com-munication.

Fig. 30. Pressure sensor

Fig. 31. RCI units

Fig. 32. Dual redundant configurations

21

The parameters programmed in the VG800 must be pro-tected. If the organizational procedures are established, thiscan be done using the user access levels in the Valve Managersoftware package (see "Valve Manager for Neles ValvGuardUser’s guide"). Otherwise the HART write protection in theVG800 has to be utilized (see Section 3.1.1.7).

6 TROUBLE SHOOTING

Mechanical/electrical defects

1. A change in the input voltage does not affect the position of theactuator

Supply pressure too lowSpool valve sticksTubes between controller and actuator are incorrect, seeFig. 10Actuator and/or valve jammedSignal wires incorrectly connected, no value on displayCircuit board is defectiveCalibration has not been carried outPrestage is defectivePosition sensor is defective

2. Inaccurate positioning Spool valve dirtyDirt in permanent air gapActuator too smallSupply pressure too smallPressure sensor is defectiveLoose in coupling between actuator and VG800BActuator and/or valve sticks

3. Positioning too slowSpool valve dirtySupply air tube too small or supply air filter dirtyValve and/or actuator sticksCheck leakages in tubes between VG800B and actuatorCheck leakages in mechanical stop screws

4. Err is shown during calibrationVG800B is in a modePosition sensor is out of range, see Section 4.5Mechanical actuator travel exceeds position sensor lineartravel, i.e. 110°. If it fails in fully closed position turn thespiral (117) 5 degrees counterclockwise. If it fails in thefully open position, turn the spiral (117) 5 degrees clock-wise.The parameter setting rot is incorrectly selected, seeSection 3.1.1.6 and Figs. 10 and 15The actuator did not move or was stuck during calibrationInput signal voltage is not according to the specificationVG800B - actuator mounting is incorrect, see Fig. 7 andSections 9.2 - 9.5Spool valve sticksPrestage is defective

5. RCI unit shows errorCalibration was not successfulThere is mechanical and/or electrical problem withVG800BVG800B has detect problem with valve, for more infor-mation see User’s guide for Valve Manager for NelesValvGuard

6. RCI unit does not show anythingCheck power supply connectionSupply voltage is not according to the specificationPower connector is not firmly in place

22

7 ERROR CODES

When the VG800B detects serious device failure (analogue inputs,analogue outputs or electronics) it enters fail-safe mode which drivesthe control valve into the safe position. Fail-safe mode is indicatedby the LCD as message Exx, where xx is a number between 1-99,or by the HART master software (e.g. Valve Manager). The errormessage is displayed until the cause of error is eliminated and theVG800B unit is cold-started, i.e. the input voltage is momentarilydisconnected

When the VG800B detects an error during travel calibration, theerror message Err is displayed. It disappears when any key is pressed.

The VG800B stores error messages in its non-volatile memory,which saves the 20 most recent error codes. The memory can beread out with HART communication by using Valve Manager.

Table 5 lists the error messages shown on the LCD display and theirexplanations.

8 TOOLS

No special tools needed.

9 ORDERING SPARE PARTS

Spare parts are delivered as modules. Available modules are shownin Section 10.1.

When ordering spare parts, always include the following information:controller type designation and serial number from the IDplatecode of this manual, part number, part name and quantityrequiredWhen ordering the circuit board, serial number of theposition sensor

*) Shown only by Valve Manager (Err shown on LCD display)

Error code Reason Action

E33 *Position sensor error in calibration Check device mode, device must be in OFF-mode.

Check position sensor, the mark on the shaft must stay in the right sector,see Fig. 7.

E34 *Calibration timed out Check the pressure supply.

Check actuator piping.

E39 *Reference test timed out Check test time out parameter.

Check the pressure supply.Check actuator piping.

E51

Position feedback ADC low limit failure. Check the mounting of controller; the mark on the shaft must stay in theright sector, see Fig. 7.Check wires, connector and position sensor rotation range or changecircuit board.Rotate the position feedback shaft 10 degrees counterclockwise andcold-start the device.

E52

Position feedback ADC low limit failure. Check the mounting of controller; the mark on the shaft must stay in theright sector, see Fig. 7.Check wires, connector and position sensor rotation range or changecircuit board.Rotate the position feedback shaft 10 degrees clockwise and cold-startthe device.

E56

Supply pressure level is low. Check pressure supply.Check actuator piping.Check pressure sensor.Check/adjust supply pressure alarm limit.

E57

Supply pressure level is high. Check pressure supply.Check pressure sensor.Check/adjust supply pressure alarm limit.

E58

Position error. Check filed device travel calibration.Check pressure supply.Check actuator piping. Check field device connection.Check prestage unit operation.Check spool valve unit operation. Check/adjust position error tolerance.

E61Memory (EEPROM) failure. Change circuit board.

E65Memory (EEPROM) failure. Change circuit board.

Table 5. Error messages shown on LCD display

23

Error code Reason Action

E72

Pneumatics test failure Check actuator piping.Check pressure sensor.Check prestage unit operation.Check spool valve unit operation.Check/adjust test time-out parameter.

E73Valve test counter limit Check/adjust test counter limit.

E74Pneumatics test counter limit Check/adjust test counter limit.

E75

Load factor high limit Check supply pressure.Check actuator piping. Check actuator operation.Check valve operation.Check/adjust load factor alert limit.

E76

Load factor low limit Check actuator operation.Check valve operation.Check/adjust load factor alert limit.Please note, that this error is generated, if load factor trend data has beenreset and alert limit value > 0. In this case, to override error message set thealert limit to 0 and readjust after 24 hours device operation.Error message will be removed automatically when some trend data has beenrecorded

E77

Breakaway pressure high limit Check actuator operation.Check valve operation. Check/adjust breakaway pressure alert limit

E78

Breakaway pressure low limit Check actuator piping. Check actuator operation.Check valve operation.Check/adjust breakaway pressure alert limit.Please note, that this error is generated, if breakaway pressure trend data hasbeen reset and alert limit value > 0. In this case, to override error message setthe alert limit to 0 and readjust after 24 hours device operation. Error message will be removed automatically when some trend data has beenrecorded.

E81Change circuit board.

E82Change circuit board.

E91Change circuit board.

Err

Travel calibration fails Check range of position sensor or mechanical limits of actuator.Check wires and connectors.Check leakage.Check that prestage is not defective.Check that field device is in Off modeCheck that the device is in AUTO mode when starting a test.

Table 5 Continued

24

10 DRAWINGS AND PARTS LISTS

10.1 Exploded view and parts list, VG800B

5

46

400

7

1

4013

63

2

44

98

401

Item Qty Description Available spare parts Recommended spare parts

1 1 Housing2 1 Cover3 1 Prestage unit x4 1 Spool valve assembly x x5 1 Circuit board, ND8006 1 Position sensor x7 1 Differential pressure sensor x13 1 Pneumatic block40 1 Shaft46 1 Protective cover98 1 Gasket x x400 1 Circuit board, PSB x401 1 Conduit block

25

10.2 Mounting parts for B1CU6-502 andB1JU 8-322 actuators

10.3 Mounting parts for Quadra-Powr®, ST,SP and Valv-Powr® actuators

Item Qty Description

1 1 Mounting bracket2 1 Draught piece3 4 Washer4 4 Screw13 2 Stud (BC6)14 2 Hexagon nut (BC)28 4 Screw29 1 Screw36 1 Coupling’s jacket

Item Qty Description

1 1 Mounting bracket2 1 Ear4 4 Screw28 4 Screw29 1 Screw30 4 Screw35 1 Adapter plug

(QP II 1/S- 6/S only)35 1 Adapter plate

(QP II 2B/K thr. 6_/K)36 1 Coupling jacket

Item Qty Description

1 1 Mounting bracket2 2 Coupling half3 1 Adapter4 4 Screw5 4 Hex nut6 1 Screw7 4 Screw8 4 Washer9 4 Screw10 4 Washer

26

10.4 Mounting parts for D/R linear actuators

4.00

5.00

70˚

35˚

2.87

3.57

3/4"

3/4"

1"

1-1/2"1-1/8"1"

1-1/8" 1-1/2"

2-1/4"

2-1/4"

3-1/2"

3-1/2" 3-1/2"

3-1/2"

3-1/2"

3-1/2" ININCHES

STROKE

1.00 1.13 1.502.25

3.50

60˚ROTATEFOR 3/4"

STROKE

0.75 STROKE

30˚

0.71

0.80

1.07

1.61

2.50

0.65FOR

3/4" STROKE

1.00" UP TO 5.00"STROKE @ 70˚ ROTATE

LEVER ARM IN MID-STROKE POSITIONDISTANCE FROM THE CENTER OF FEEDBACK ARM

TO THE CENTER OF ACTUATING PIN

9

10

11

8

25 4 3

1 7

6

12

13

14

LEVERARM SPRING POSITIONTO BE AGAINST ACTUATOR PIN

MAKE SURE THIS MARK ON THELEVER ARM IS IN THE SAME

QUADRANT AS THE MARK ONTHE FLAT OF THE SHAFT.

ACTUATOR

MID STROKE3/4"

1"1-1/8" 1-1/2" 2-1/4" 3-1/2"

3/4"

1"

1-1/8" 1-1/2" 2-1/4" 3-1/2"

4"

4"

5"

5"

IN INCHES

STROKE

90˚

4"

4"

1-1/8"

1-1/8"3/4"1"

3/4"

1"

1-1/2" 2-1/4" 3-1/2"

1-1/2" 2-1/4" 3-1/2"

5"

5"

IN INCHES

STROKE

Item Qty Description

1 1 Mounting bracket2 2 Screw3 2 Flat washer4 2 Lock washer5 2 Hex nut6 1 Positioner lever arm7 4 Linkage arm spring9 1 Positioner pin10 1 Screw11 2 Lock washer12 4 Screw13 4 Lock washer14 4 Flat washer

27

10.5 Mounting parts for linear actuatorswith IEC 60534 mounting face

56

1516

1718

19

84 2

1112

149 11 1

3

7

70˚

14.3

(20

mm

)

21.4

(30

mm

)

28.6

(40

mm

)

35.7

(50

mm

)

42.8

(60

mm

)

50 (

70 m

m)

57.1

(80

mm

)

64.3

(90

mm

)

71.4

(10

0 m

m)

Stroke

(20 - 100 mm)

Sca

le

Dis

tanc

e fr

om s

haft

cent

er to

car

rier

bolt

acco

rdin

g to

str

oke.

Feed

back

leve

r in

hor

izon

tal p

ositi

on a

t mid

trav

el o

fst

roke

.

The

mar

k on

the

shaf

t sho

uld

stay

in th

is s

ecto

r!

Str

oke

20 -

60

mm

Str

oke

60 -

100

mm

28

10.6 Mounting parts for limit switchesfor EX i enclosure

Item Qty Description

1 1 Console2 1 Driver3 2 Washer4 2 Hexagon nut5 4 Hexagon nut6 4 Stud8 4 Washer9 4 Hexagon screw10 1 Thread bar11 1 Cover12 2 Pin13 2 Hexagon nut14 1 Bracket support15 3 Washer16 3 Cross rec head screw28 4 Socket head screw43 2 Connection fork44 2 Haxagon nut45 2 Snap ring46 4 Washer47 1 Link48 1 Haxagon nut49 1 Socket head screw

29

11 DIMENSIONS

11.1 VG800B

11.2 RCI

99.53.92Ø40

Ø1.57

512.00

481.89

1646.45

40.16

25

0.98

M5 / 18

29

201.14

0.78M6 / 10

3x1/4 NPT

5/16 UNC / 13

OUTLET3/8 NPT

26 30

1.181.02

(35.4)

F05-ø50

(VDI/VDE 3845)

1.39

31 1.22

(35.

4)

(1.3

9)

3434

1.34

1.34

48.5

1.91

VG800B_A1

4 0.16

66

170

2.60

66.9

27 1.06

ND800/B1-L = 1/2 NPT

VG800B_A

7319 0.75

2.87

48

5.50.21

1.89

VG800B_S123

1412

4

0.55

0.90

4.88

177

6.97

83 3.27

1/4

NP

T

VG800B-K

532.08

682.68

Ø40

Ø1.

57

64

2.52B1: M20x1.5B2, B3: 1/2 NPT

30

12 TYPE CODING

VALVGUARD SYSTEM

1. 2. 3. 4. 5. 6. 7.

VG 8 5 68 B1 S1 A _ KL

1. sign PRODUCT GROUP

VG ValvGuard system for emergency shutdown valves,including the smart on/off valve controlller and theRemote Comminication Interface module (RCI)

2. sign SERIES CODE

8

3. sign INPUT SIGNAL RANGE

5 0/24 Vdc binary on/off signal

4. sign SPOOL VALVE CONNECTIONS(S, C2)

68 Single action 1/4 NPT

5. sign ELECTRICAL CLASSIFICATION

Flame / explosionproof constructions

B1 CENELEC EEx d IIC T6 certification according toEN 50014 and EN 50018.IP65 enclosure. Built-in display and local keypad. M20x1.5 conduit entry.Temperature range -40 ˚C…+80 ˚C / -40 ˚F…+176 ˚FVoltage range 16.5 - 30 Vdc

B2 FM-certification, Class I, Division 1 and 2, Groups B,C and D, Class II and Class III, Groups E, F and G,FM 3615.Nema 4X and IP 65 enclosure. Built-in display andlocal keypad.Temperature range -40 ˚C…+80 ˚C /-40 ˚F…+176 ˚FVoltage range 16.5 - 30 Vdc

6. sign ACTUATOR CONNECTION

S1 Rotary motion.Attachment face according to standardVDI/VDE 3845, equipped with an H-clip. When separate deliveries, VDI/VDE 3845 ear issupplied.

A1 Linear motion.Applicable to MetsoAutomation D/R-seriesdiaphragm actuator.Also applicable to linear actuators according toIEC 60534-6-1 with own linkage set.

YY Special construction, to be specified.

7. sign PRESSURE GAUGES ON THEON/OFF VALVE CONTROLLER

N No pressure gauges.

A Pressure gauges, scale bar/psi/kPa, basic materialbrass, nickel plated housing stainless steel.Glycerine filled.Temperature range for gauges -40 ˚C... +70 ˚C /-40 ˚F... +158 ˚F.

ACCESSORIES

K Filter regulator for supply air, type BELLOFRAM 51FR.Pressure gauge, scale bar/psi/kPa, basic materialbrass, nickel plated, housing stainless steel, glycerinefilled. Specified in the option sticker. Temperature range-18 ̊ C…+52 ̊ C / 0 ˚F ...+125 ˚F. Filter size 5 µm.Filter regulator with higher capacity needed forbigger actuators than BC40 and BJ32.

L M20x1.5 / 1/2 NPT (Ex d) conduit entry nipple.Will be specified in the option sticker of device.

HART MODEMS

HART 20 Valve Manager® for ValvGuard-software and modemwith RS232 interface for PC.

HART 21 Update Valve Manager® for ValvGuard.

31

Metso Automation Inc.Europe, Levytie 6, P.O. Box 310, 00811 Helsinki, Finland. Tel. +358 20 483 150. Fax +358 20 483 151

North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, MA 01545, USA. Tel. +1 508 852 0200. Fax +1 508 852 8172

Latin America, Av. Central, 181-ChÆcaras Reunidas,12238-430 Sªo JosØ dos Campos, SP Brazil. Tel. +55 123 935 3500. Fax +55 123 935 3535

Asia Pacific, 501 Orchard Road, #05-09 Wheelock Place, 238880 Singapore. Tel. +65 673 552 00. Fax +65 673 545 66Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai, United Arab Emirates.

Tel. +971 4 883 6974. Fax +971 4 883 6836www.metsoautomation.com