valve manager for hart modems user’s...

Valve Manager® 2.4for HART Modems

User’s Guide

Published by

METSO AUTOMATIONP.O.Box 310FIN-00811 HELSINKIFINLAND

Copyright 2002 by Metso Automation and the authors. All rights reserved. No part of this publicationmay be reproduced, stored in a retrieval system, or transmitted, in any form or by any meanselectronic, mechanical, photocopying, recording or otherwise, without the prior permission of thepublisher.

While this information is presented in good faith and believed to be accurate, Metso Automationdoes not guarantee satisfactory results from reliance upon such information. Nothing containedherein is to be construed as a warranty or guarantee, express or implied, regarding the performance,merchantability, fitness or any other matter with respect to the products, nor as a recommendationto use any product or process in conflict with any patent. Metso Automation reserves the right,without notice, to alter or improve the designs or specifications of the products and methodsdescribed herein.

Produced and printed in Finland by Mediaviisi Oy, Espoo 2002

Valve Manager for HART Modems User’s Guide 1

Table of contents

1. Safety considerations 4

2. Introduction 5

2.1 About Valve Manager 5

2.2 Hardware requirements 5

2.3 HART communication 5

3. Getting started 6

3.1 Installing Valve Manager 6

3.2 Starting the program 6

3.3 Using the keyboard 8

3.4 Connecting Valve Manager to the ND800 9

3.5 Data management 10

4. Read/Write device information 11

4.1 Read Configuration 11

4.2 Send Configuration 11

4.3 Changed Configuration 11

4.4 Read Diagnostics 12

5. Connection (F2) 13

5.1 Search 13

5.2 Compare 13

5.3 Device-Specific Information 14

5.4 HART Configuration 15

6. Monitoring (F3) 17

6.1 Graphs 17

6.2 Starting / Stopping monitoring 18

6.3 Holding graphs 18

6.4 Scaling graphs 18

6.5 Resetting graphs 18

6.6 Printing graphs 18

6.7 Saving to log file 18

7. Diagnostics (F4) 19

7.1 Statistics 19

7.2 Alerts 21

7.3 Event history 23

7.4 Reset diagnostics 23


7.5 Online diagnostics history 24

8. Testing (F5) 25

8.1 Start test 25

8.2 Printing the test curve 27

8.3 Saving the test data 27

8.4 Saving the test to a text file 27

8.5 Test result explanations 27

9. Settings (F6) 28

9.1 Position Control 28

9.2 Split Range 28

9.3 a0 Adjustment 29

9.4 Cut-off Safety Range 29

9.5 Position Sensor Rotation 29

9.6 Input Signal Direction 29

9.7 Valve Acting Type 30

9.8 Position Transmitter Direction 30

10. Characterization (F7) 31

10.1 Show mA vs. Travel 32

11. File Menu 33

11.1 New Database 33

11.2 Open Database 33

11.3 Save To Database 33

11.4 Import Database 33

11.5 Export Database Structure 33

11.6 Compact Database 33

11.7 Program setup 34

11.8 Print 34

11.9 Print Setup 34

11.10 Exit 34

12. Edit menu 35

12.1 Create a new plant area 35

12.2 Create a new tag 36

13. View menu 37

13.1 Users 38

13.2 Configuration 38

13.3 Process data 39

13.4 Diagnostics 39


13.5 Tests 40

13.6 Changing general information 41

13.7 Changing process data 41

13.8 Changing plant area 41

13.9 Changing alert limits 42

13.10 General diagnostics limits 42

14. Calibration menu 43

14.1 Automatic travel calibration 43

14.2 Prestage Trim 43

14.3 Position sensor calibration 44

14.4 Pressure sensor calibration 46

14.5 Input signal measurement calibration 47

14.6 Temperature measurement calibration 47

14.7 Position transmitter output calibration 48

14.8 Changing circuit board module 48

15. Flowmeter menu 49

15.1 Monitoring 52

15.2 Configuration 5315.2.1 Valve selection 5315.2.2 Medium 5315.2.3 Channel settings 5515.2.4 Transmitter location 5615.2.5 Status bar in configuration window 5715.2.6 Dropdown menu in configuration window 57

15.3 Calibration 5815.3.1 Dropdown menus in the calibration window 62

16. Security menu 64

16.1 Change Password 64

16.2 Edit Users 64

17. Troubleshooting 65

18. Remotely Accessible Information (HART) 66

18.1 Identification and Communication 66

18.2 Settings and characterization 67

18.3 Monitor 68

18.4 Diagnostics and Testing 68

18.5 Others 68


1. Safety considerationsThe ND800 valve controller is delivered from the factory with circuit board write protection OFF asdefault. This protection can be switched ON with a DIP switch located on the circuit board (for moreinformation see ND800 Installation, Maintenance and Operating Instructions 7 ND 70). Since ValveManager enables direct operation of the control valve, the HART write protect function in the ND800is an extension of the traditional write protect function in HART transmitters. This means that ValveManager can not change the ND800 configuration nor can it change the control valve position whilethe HART write protect switch is set to the ON position. Operating security can be maintained withthree level user privileges in the Valve Manager software (for more information on user privilegessee the chapter 16). Read the User’s Guide carefully before using Valve Manager.


2. IntroductionThis manual describes the operation and functions of Valve Manager 2.4 for HART Modemssoftware.

2.1 About Valve ManagerValve Manager is a Windows-based graphical user interface for the ND800 valve controller andNelflow. With Valve Manager the following functions included in the ND800 can be accessed:

• Identification• Configuration• On-line monitoring• Diagnostics: trends and alerts• Control valve testing• Calibration

The ND800 is a microprocessor-based valve controller (for more information see the ND800Installation, Maintenance and Operating Instructions 7 ND 70).The Nelflow is a ND800 based controller to transmit flow rate signal from control valve equippedwith connection to transmitters. Nelflow calculates the flow rate based on pressure differential overthe valve and capacity coefficient at measured opening angle (for more information see the NelflowInstallation, Maintenance and Operating Instructions 8 NDQ 70).Valve Manager version 2.4 is applicable to ND800 revisions 1 to 5.02 and Nelflow revision 5.

2.2 Hardware requirementsValve Manager requires the Windows1 98, Windows Me, Windows NT 4.0 or Windows 2000operating system on your PC.The hardware requirements are as follows:• Intel Pentium based CPU• 32 MB of RAM• 20 MB of free hard disk space• 1200-baud FSK modem for HART communication installed in the serial port (COM).

2.3 HART communicationHART2 is an open (nonproprietary), digital communication protocol used by smart field deviceswhich operate on the 4-20-mA current loop. The physical HART signal is based on FSK (FrequencyShift Keying) technology and the modulation frequencies are on the American Bell 202 modemcommunication standard. The 1200/2200-Hz frequency is superimposed on the 4-20-mA loopcurrent, but the average value of this signal is zero. HART thus does not affect existing analogueinstrumentation based on the 4-20-mA technology. The digital communication rate is 1200 bits/s.More technical information can be found in the booklet HART Field Communications Protocol, ATechnical Overview published by the HART Communications Foundation.

1 Windows is a trademark of Microsoft Corporation.2 HART is a registered trademark of HART communications foundation.


3. Getting started

3.1 Installing Valve ManagerValve Manager must be installed from CD-ROM to the hard disk. Windows must be installed beforeyou install Valve Manager. To begin, insert Valve Manager CD-ROM in the CD-drive, select Runcommand from Start menu and enter:

Z:\SETUP\SETUP.EXE,and click OK. Substitute the letter ‘Z’ with the appropriate drive letter if required.The Valve Manager Setup screen appears. Follow the instructions in the Setup program to finish thesetup. The setup program automatically installs all files needed for Valve Manager and creates anicon and a program group for it.

3.2 Starting the programValve Manager is started from Windows Start menu. Click Start button, point to Programs point toValve Manager, and then click Valve Manager 2.4.If Valve Manager has not been registered, Valve Manager informs the user and suggests that thisstep be performed. Clicking Register Now button starts Registration program (Figure 1) by whichregistration can be performed. Registration program can also be started, by selecting the RegisterValve Manager 2.4 icon in the Valve Manager start menu.

Figure 1 . Registeration program.

During start-up, Valve Manager asks for the user’s name and password (Figure 2).


Figure 2 . Login window.

The default user is ‘admin’ and the default password is also ‘admin’ (lower-case letters). Create anew user with ‘Administrator’ user access and delete the ‘admin’ user; Valve Manager cannotnow be started with the default user (see Chapter 16.2 for more details on adding/deleting users).After login the main window is displayed Figure 3).


Figure 3. Main window.

3.3 Using the keyboard

Moving between the interface controls

Moving from one control (e.g. button or text field) to another is done with the tabulator key (Tab),and moving in the reverse direction with the Shift+Tab combination.

Using keyboard commandsAll the controls in which the text includes an underlined letter can be chosen by the combinationAlt+’underlined letter’ (e.g. the Send button can be chosen by the Alt+N combination).

Closing windows and frames

All the pop-up windows and frames displayed in the working area can be closed with the Esc key.This performs the same operation as clicking the Cancel or Close buttons.

Exiting the program

Valve Manager can be closed via File|Exit or with the Alt+F4 combination.

Help system

Information on how to use Valve Manager is always available on-line by pressing function key F1 orby the menu command Help|Contents.


Full-screen graphsAll the graphs in Valve Manager can be displayed full-screen by double-clicking the graph or bypressing the Ctrl+F keys. Full-screen graphs can be closed with the mouse or the Enter or Esckeys.

3.4 Connecting Valve Manager to the ND800Communication between Valve Manager and the ND800 requires a 1200-baud FSK modemconnected to a serial port (RS232). The FSK modem can be connected either directly to the ND800current loop terminal strip (Figure 4) or across the 4-20-mA current loop wires (Figure 5). For moreinformation see your modem’s Users’ Manual.

Figure 4. HART connection to the terminal strip.

In intrinsically safe applications make sure that the isolator or barrier used is compatible with theHART communication when connecting the FSK modem between the 4-20-mA analogue output ofyour control system and the isolator or barrier. If the analogue output is not designed to conform toHART specifications, disturbances may occur in the 4-20-mA analogue output during HARTcommunication or the HART communication will not work properly. Check the HART conformity ofthe analogue output from your control system supplier before using HART communication duringprocess control. If problems occur in HART communication, they can be eliminated by a HARTisolator installed between the analogue output and the ND800. Contact your nearest MetsoAutomation representative to obtain HART isolators.

Operatorconsole

ValveManager

Controlsystem

1200 baudmodem

RS232 orPCMCIA

Cross connection room

4-20 mA input signal

ND800 ND800

Figure 5. HART connection.


3.5 Data managementAll the information read from the device can be saved in a database. The database is structuredaccording to the ‘Plant area - Tag’ hierarchy (Figure 6). This hierarchy makes it easier to managelarge numbers of devices. The database opened stays as a default database even the program isclosed, as long before the new database is opened.

PLANT AREA 1

PLANT AREA 2

TAG 1

TAG 2

TAG 3

TAG 4

TAG 5

DIAGNOSTICS,SETTINGS, ...

Figure 6. Hierarchy of the database.

When Valve Manager is started for the first time there is no database in the system. The user mustcreate a new database with the File|New Database command, after which all savings are directedto that database.The database structure can be created in the office with no prior connection to the devices. This isdone with the Edit menu commands. Another possibility is to create the database structure whenconnections to the devices are made for the first time. If the user tries to save information on adevice that is not found in the database, Valve Manager adds the device into the database. The plantarea for the new tag must be also chosen or added.If a tag is found in the database when the connection is made, all the savings in the database areautomatically directed to that tag. The tag information need be added only once.The user can examine the database with the View|View Database command.


4. Read/Write device information

4.1 Read ConfigurationThe Read Config. command reads all the configuration data for the selected tag. If the user haschanged the configuration data but has not yet sent it to the selected tag, the original informationcan be resumed by pressing the Read Config. button. Due to the slow data transfer rate of HARTcommunication the reading will require some time. Indication of ongoing communication can beseen in the status bar at the base of the main window.If the user has made some changes to the configuration that he has not yet sent to the device andtries to read configuration, Valve Manager shows a warning that asks the user to confirm overwritingof the changed values.

4.2 Send ConfigurationWith the Send Config. command the user can change the configuration of the selected tagprovided that HART write protection is turned off (to set the HART write protect switch see ND800Installation, Maintenance and Operating Instructions 7 ND 70). Any configuration data on thescreen that have been changed by the user, but not sent to the selected tag are indicated with a redcolour. After pressing the Send Config. button the user obtains a list of configuration data whichwill be sent to the selected tag (Figure 7). Pressing the Send button in this window will save the newconfiguration data into the ND800’s memory. The changed configuration data indicated in red willnow turn black, indicating that the new configuration data have been successfully sent to theselected tag. Again, sending all changed configuration data will require some time.

Figure 7. Sending new values window.

4.3 Changed ConfigurationBy pressing the Changed Config. button the user obtains a list of configuration data that have beenchanged but not yet sent to the selected tag, and which resembles the list in the Sending NewValues window (Figure 7).


4.4 Read DiagnosticsThe Read Diag. command reads all the diagnostics information available in the ND800. Due to theslow data transfer rate of HART communication the reading will require some time. Indication ofongoing communication can be followed from the status bar at the base of the main window.After the diagnostics is read Valve Manager checks if any of the user-set alarm limits have beenexceeded3.

3 Applicable to ND800 revisions 1-5.01 and Nelflow revision 5.


5. Connection (F2)

Figure 8. Connection frame.

Communication connection to a desired device is created in this window. After clicking theConnection button or pressing the F2 key the Connection frame is displayed (Figure 8).

5.1 SearchBy clicking the Search button Valve Manager begins to look for devices in the HART network andshows the tags found in the Tags found list. By clicking the tag label in the list the user can create aconnection to the corresponding device and read some general information (e.g. Tag andDescription) of the device. If only one device is found during the search operation it is automaticallyselected by Valve Manager. The database information of the selected tag is displayed beside the list.If the device is connected for the first time, the database information will be: Selected tag cannotbe found in the database!. In this case the tag can be added to the database by the Edit|CreateNew Tag command (see Chapter 12.2) or by the File|Save To Database command (see Chapter11.3).

5.2 CompareThe Compare button lets the user compare the configuration information in the memory of theselected device with the corresponding configuration information in the database (Figure 9). Theuser can copy information from the selected tag to the database and vice versa. If any informationdiffers between the selected tag and the database, it is shown with a red colour and two arrowsappear beside the particular information. By pressing the arrow on the left side the value is copiedfrom the selected tag to the database. Pressing the arrow on the right side causes the value in the


database to be sent to the device configuration memory of the selected tag. These operations areinitiated immediately.

Figure 9. Compare window.

5.3 Device-Specific InformationDevice-Specific Information shows more details about the chosen tag (Figure 10). Writableinformation can be changed and sent to the device configuration memory of the selected tag.Sending is done with the Send Config. button of the main window (see Chapter 4.2). Read-onlyinformation cannot be changed.More information on the different parameters can be found in Chapter 18.


Figure 10. Device-Specific Information window.

5.4 HART Configuration

HART Configuration shows configuration information about HART communication (Figure 11).Writable configuration information can be changed and sent to the device configuration memory ofthe selected tag. Sending is done with the Send Config. button of the main window (see Chapter4.2). Read-only information cannot be changed. The parameters in the HART Configuration windowshould not be changed under normal conditions. The HART parameters should be changed in thefollowing conditions:

Two or more ND800s in the same current loop - In the normal condition the polling address ofND800 should be 0. But, for example in the split range application the HART polling addresses ofND800s should be different. The polling address of each ND800 can be changed by setting thePolling address field value and sending it to ND800. The allowed polling address values arebetween 0-15, but the recommended range is 1-15. Note that there may exist some HARTmasters which do not poll all HART field devices if the polling address of one device is 0.

HART master is not able to communicate with ND800 - If the HART master application can notcommunicate with ND800, the value of Number of response preambles field should be increased.The allowed number of response preambles is between 5-20.

HART master does not understand the dynamic variables of ND800 - If the HART mastermaps the dynamic variables differently from ND800 variable mapping, you can rearrange thedynamic variables of ND800 according to the dynamic variable order of HART master. This can bedone by changing the field values of 1st, 2nd, 3rd, 4th dynamic variable code and 1st, 2nd, 3rd,4th dynamic variable unit code. The available dynamic variables and units with the correspondingcodes are shown in the dynamic variable tables in Chapter 18.1.

Changing the order of burst mode variables - If the order of burst mode variables need to bechanged, it can be done similarly as the reordering of the dynamic variables. The code of therequired dynamic variable is written in the corresponding burst variable field labeled as 1st, 2nd, 3rdor 4th burst variable code. To activate the burst mode, check Burst mode control On/Offcheckbox. You can also select which HART command should be burst by ND800 by setting thevalue in the Burst mode command field. The value depends on the burst command requirements


of the HART master application/device. The allowed burst mode commands are listed in Chapter18.1.More information on the different HART parameters can be found in Chapter 18.

Figure 11. HART Configuration window.


6. Monitoring (F3)

Figure 12. Monitoring frame.

With the monitoring function the user can observe five different variables indicating control valveoperation: Input Signal, Actual Travel, Travel Setpoint, Actuator Pressure and PCBTemperature. All the variables are on-line information, and the user obtains real-time informationon the condition of the control valve. With the monitored information the user can be assured thatthe control valves are working correctly.

6.1 GraphsSix different graphs can be viewed in the Monitoring frame. All of them are displayed as a functionof time. The desired graph is selected from the Monitored variable list in the top right corner.• The Input Signal graph displays the input signal (4 - 20-mA loop current) measured by the

ND800 valve controller which comes from the process controller. This information is useful indiagnosing loop cabling and ND800 operation.

• The Actual Travel graph displays the actual travel of the control valve measured by the ND800valve controller. Actual travel is shown as a percentage of calibrated valve travel. In addition tothe Travel Setpoint graph it shows possible differences in the desired and actual travel of thevalve. The user can monitor on-line how the valve responds to the input signal changes. Slowresponses or possible oscillation indicate incorrect position control settings or problems incontrol valve operation.

• The Travel Setpoint graph shows the valve travel setpoint according to which the ND800 valvecontroller controls the valve travel. The travel setpoint is the result of positioner input signalmodification, e.g. signal direction, a0 adjustment and characterization. By comparing thisinformation with input signal information errors in the valve controller configuration or problemsin valve controller operation can be detected.


• The Actuator Pressure graph can be used to check that the control valve is working properly.With the aid of pressure information, possible friction and actuator leakages can be discoveredby comparing prevailing and previous pressure curves. Actuator pressure is the pressuredifference in double-acting actuators and the pressure opposed to the spring in single-actingactuators.

• The PCB Temperature graph shows the temperature inside the ND800 valve controller on thePCB (Printed Circuit Board). The temperature information can be used for checking that theenvironmental temperature is within specified ambient temperature limits. This ensuresreliability of the ND800 valve controller.

• The Travel Setpoint and Actual Travel graph contains travel setpoint and actual travel in thesame curve.

The latest numerical values are shown in the text box below the Monitored variable list. Somevalues can be displayed in different units; e.g. pressure in bar or psi. The unit used can be selectedin the Program Setup window (see Chapter 11.7).

6.2 Starting / Stopping monitoringMonitoring is started with the Start button. The sampling rate of the monitoring can be typed in theSampling Rate text box. If no sampling rate is given, Valve Manager uses the default value (2 s).Monitoring can be stopped with the Stop button.

6.3 Holding graphsDrawing of the displayed graph can be stopped for closer examination at the end of the horizontalaxis by selecting the Hold Graph check box. All new information measured for the present variablewill be lost until drawing is resumed.

6.4 Scaling graphsThe displayed time scale of the graph can be changed by pressing the Scaling button. Thehorizontal axis of the displayed graph can be scaled by changing the value of Time scale in the textbox. If the Change scaling for all the curves check box is checked the scale is changed for all ofthe graphs.The scaling of the vertical axis can be done manually or automatically. If automatic scaling is usedthe time scale should not be very long due to the heavy update routines needed for automaticscaling.

6.5 Resetting graphsThe monitoring graph can be reset by the Reset button. The present graph is cleared from thedisplay and monitoring is started at the beginning of the horizontal time axis.

6.6 Printing graphsPrinting of the graphs is done via the Print button, which prints the currently displayed graph.

6.7 Saving to log fileAll monitored variables can be saved in a log file. Saving is started by pressing the Start Loggingbutton. When the button is pressed a window is displayed where the user is asked whether hewants to log all variables or just the displayed variable. When logging proceeds, pressing the buttonagain stops the process.The file created can be read e.g. into Microsoft Excel to form a curve of the saved values.


7. Diagnostics (F4)

Figure 13. Diagnostics frame.

The ND800 valve controller continuously monitors control valve behavior. It records valve traveltrends, histograms and possible alerts which can be seen in the Diagnostics frame (Figure 13).Trends and histograms show how the valve has operated over a long time period. Alerts tell aboutthe latest problems in control valve operation including control behavior and ND800 valve controllerfaults. Valve and actuator travel distances and reversals are also counted to inform the user of theneed for maintenance. User-set maximum values of travel distances and reversal numbers causealerts, for which the limits are set in Alert Settings window (see Chapter 7.2).All the Diagnostics information is very important for the process control and maintenance needs.Diagnostics information is on-line data which allows the process automation people to check thecondition of the control valves anytime needed. This checking is done in real-time and it does notdisturb the process. With these trends, histograms, travel distance and reversal counters and alertreports user can schedule the maintenance needs for the control valves. This is highly importantpredictive maintenance and it allows control valves and therefore the whole process to work moreaccurate and more reliably.

7.1 StatisticsFor ND800 revisions 1 to 5.01 the travel deviation trend and the load factor trend, described below,are not updated when the travel setpoint is under 10% or over 90%.For ND800 revision 5.02 the trends are not updated when the valve is intentionally fully open orclosed.


Travel deviation trendThis trend shows the deviation between the setpoint and actual travel during total valve operationtime. The travel deviation trend can be used to analyse present and predict future behaviour of thecontrol valve. (Figure 14)

Figure 14. Valve travel deviation trend.

Valve travel vs. timeThe histogram illustrates the valve’s opening history as percentages of total valve operation time.Valve opening is on the horizontal axis and percentages of operation time on the vertical axis. Thishistogram can be used to check valve sizing. If the valve operates mostly in small openings, thisindicates that the valve is oversized for the application. (Figure 15)

Figure 15. Valve travel vs time histogram.

Load factor trendThis trend shows the load factor of the actuator as a percentage4 (Figure 16). In the case of a singleacting actuator, the load factor shows the actuator load with respect to the present spring force, i.e.,a load factor of 100% indicates that the actual load may exceed the spring force5. For double actingactuators, the load factor shows the actuator load with respect to the user-given supply pressurelevel, i.e., a load factor of 100% indicates that the actual load may exceed maximum attainablepressure difference being equal to the supply pressure. Actuator type can be seen in the windowDevice-specific Information. When drawing the curve the user must type the actual supplypressure in Valve Manager if it is different from the value read from the database. The trend can beused for analysing the condition of the control valve. A high load factor indicates the presence ofhigh friction or an undersized actuator if the given supply pressure is equal to actual supply pressurelevel. 4 Does not apply to ND800 SW revision 15 Does not apply to ND800 SW revisions 1,2 and 3


Figure 16. Actuator load factor trend.

Elapsed trend timeThis is the time during which the data for the statistics displayed have been collected, and isdisplayed in hours. See above for collection principles for trends.

Total operation timeThis comprises the total time during which the valve controller has been operating, and is displayedin hours. Resetting the statistics does not affect the total time.

Valve number of full strokesThe distance the valve has travelled in full strokes. One full stroke means valve movement from 0 to100%. E.g. if valve moves from 40% to 50% full strokes increases by 0.1.

Valve number of reversalsThe number of changes in valve movement direction.

Actuator number of full strokesThe distance the actuator has travelled in full strokes.

Actuator number of reversalsThe number of changes in actuator movement direction.

7.2 Alerts

Alert SettingsThe alert settings (Figure 17 and Figure 18) are used to set limits for different diagnosticsinformation to warn the user when the limits are exceeded. The limits should first be set to highvalues such that no unnecessary warnings are given. After gaining experience, the user can tunethe limits to more accurate levels. The limits are saved in the database.When a particular limit is exceeded, Valve Manager opens a message box with a warning.Warnings are also displayed in the alert list.If no device specific alert limits are set, Valve Manager uses general limits if available (see 13.9).For ND800 revisions 1 to 5.01 the limits are stored only in the database. From revision 5.02 thelimits are stored in the ND800. If the values are changed they are sent to the device when the OKbutton is pressed.The alert limits can be set for the following diagnostic information:• Number of full strokes for the valve.• Number of reversals for the valve.• Number of full strokes for the actuator.


• Number of reversals for the actuator.• Travel deviation.• Actuator load factor.With the revision 5.02 device the window contains also text box for supply pressure which is used tocalculate the load factor in the ND800. Use fixed diagnostics limits check box defines whetherthe fixed limits stored in the ND800 is used to generate alerts. Fixed limits are available for thedeviation and load factor. Fixed warning limit for deviation is 5 % and fixed alarm limit 10 %. For loadfactor the fixed warning limit is 85 % and fixed alarm limit 90 %. Using the fixed limits do not disablethe user limit alerts, fixed limits are onlyused parallel with user limits.

Figure 17. Alert Setting for ND800 revision 1 to 5.01.

Figure 18. Alert settings for ND800 revision 5.02.


Possible alertsThe table below lists the explanations associated with each of the alerts given for ND800 revision 1to 5.01.

Table 1. Alert list for ND800 revisions 1 to 5.01.

ALERT EXPLANATION

Travel deviation Deviation between travel setpoint and actual valve travelexceeds set limit in travel deviation trend.

Load factor Load factor exceeds set limit in load factor trend.

Valve strokes Number of full valve strokes exceeds set limit.

Valve reversals Number of valve reversals exceeds set limit.

Actuator strokes Number of full actuator strokes exceeds set limit.

Actuator reversals Number of actuator reversals exceeds set limit.

In ND800 revision 5.02 the generation of the alerts is done in the device itself. Valve Manager asksthe status of the device connected every 15th seconds. If the status is different from the normal it isdisplayed in the alert list. The Table 2 lists the possible alerts for ND800 revision 5.02.

Table 2. Alert list for ND800 revision 5.02.

ALERT EXPLANATION

Online: Pneumatics problem Signal changes but actuator pressure does not.

Online: Friction problem Signal and actuator pressure change but the valve does notmove.

Online: Deviation alert User set limit for travel deviation exceeded.

Online: Load factor alert User set limit for load factor exceeded.

Valve full strokes limit exceeded Number of full valve strokes exceeds set limit.

Valve reversals limit exceeded Number of valve reversals exceeds set limit.

Actuator full strokes limit exceeded Number of full actuator strokes exceeds set limit.

Actuator reversals limit exceeded Number of actuator reversals exceeds set limit.

Deviation user limit exceeded User set limit for travel deviation exceeded.

Deviation fixed limit warning Default warning limit (5 %) for travel deviation exceeded.

Deviation fixed limit alarm Default alarm limit (10 %) for travel deviation exceeded.

Load factor user limit exceeded User set limit for load factor exceeded.

Load factor fixed limit warning Default warning limit (85 %) for load factor exceeded.

Load factor fixed limit alarm Default alarm limit (90 %) for load factor exceeded.

Factory settings in ND800 rev. 5.02 are 5 % for travel deviation user limit, 85 %for load factor user limit and fixed limits are enabled.

7.3 Event historyPressing the Event History button opens a window with a list of the 20 latest events and failuresstored in the ND800 memory.

7.4 Reset diagnosticsBy pressing the Reset diagnostics button, the user is asked which diagnostic information to reset.Checking the boxes for the desired diagnostics and pressing the OK button resets the selected data.Old data will be deleted permanently.


Figure 19. Reset Diagnostics window.

7.5 Online diagnostics historyPressing the Online Diagnostics History button opens a window containing the statistics of theonline diagnostic alerts (Figure 20). The information inlcudes alert count, the time when the alertfirst occurred, the time when the alert last occurred and the total time the alert has been active.Online diagnostics history is applicable to ND800 revision 5.02.

Figure 20. Online diagnostics history.


8. Testing (F5)

Figure 21. Testing frame.

To ensure that the control valves are working properly they can be tested with the Testing function(Figure 21). Two control valve performance tests, the Hysteresis loop and Step response, can berun with the device. The Step response test tells how rapidly the valve reacts to the input signal,while the Hysteresis loop test tells how large is the dynamic hysteresis + dead band, whichindicates friction quantity. The control valve test results can be used to diagnose the condition of thecontrol valve, thus showing the need for possible future maintenance work. Running control valvetests is, therefore, very important predictive maintenance work and ensures optimal performance ofthe control valve in every situation. Tests cannot be run if HART write protection is ON. Note thatcontrol valve testing affects process control by driving the control valve independently ofthe input signal from the control system!

8.1 Start testThe test is started with the Start Test button. The user is asked to select the desired test and givethe three parameters for the selected test in the Test Settings window (Figure 22); pressing theOK button starts the test.When starting hysteresis loop, Valve Manager also automatically starts dynamic variable monitoring.Valve Manager uses dynamic variables Travel Setpoint and Actual Travel to get more information onvalve operation.Control valve testing is recommended with the minimum input signal of 8 mA! When input signal is4 mA, ND800 is in the energy saving mode and performance is not optimal.Hysteresis loop parameters:• Loop time (100-1000 s); the default value is 500 s.

This is the total time used to run the hysteresis loop. Minimum time allowed is dependent of the


loop size. The time must be more than 50 seconds for each 10 % (i.e. 50 s for 10 % loop and500 s for 100 % loop.

• Loop size (10-100%);. the default value is 100%.This is the size of the loop.

• Starting point (0-90%); the default value is 0%.This is the opening where the test is started.

Step response parameters:• Testing time (2-500 seconds); the default value is 10 seconds.

This is the time period in which the valve opening is measured. The step is made at t = 0seconds.

• Step size (0.1-100 %); the default value is 10 %.This is the size of the setpoint step.

• Starting point (0-100 %); the default value is 45 %.This is the initial opening of the valve prior to the step.

Note! Remote testing and calibration should be done at the minimum input signal of 8 mAbecause of the energy saving mode of ND800.

Warning! Running a test changes the position of the valve. Make sure you are allowed torun a test.

Figure 22. Test Settings window..


8.2 Printing the test curveThe test data can be printed by pressing the Print Test button.

8.3 Saving the test dataThe test data can be saved in the database by pressing the Save Test button.

8.4 Saving the test to a text fileThe test data can be saved to a text file by pressing the Save Test As Text button. The text file canbe used to transfer the test data to e.g. an analysing system.

8.5 Test result explanationsPressing the Test Explanations button opens a help file describing how different problems can beseen from the test results and suggestions how the problem could be fixed (Figure 23).

Figure 23. Test Result Explanations window.


9. Settings (F6)

Figure 24. Settings frame.

The positioner functionality parameters in the ND800 valve controller can be determined in theSettings frame (Figure 24). These parameters affect control valve position behaviour duringoperation.

9.1 Position ControlThe Position Control parameters affect control valve accuracy, response rate and stability. SeeND800 Installation, Maintenance and Operating Instructions 7 ND 70 for setting the parameters.• Gain: The relative gain factor of the position control. The higher the gain the faster is the

response of the control valve. On the other hand, too high a gain may cause unstable behavioror overshooting. The value of the displayed gain factor is read from the device configurationmemory. See ND800 Installation, Maintenance and Operating Instructions 7 ND 70 for settingthe gain for various actuator types and sizes. In general a larger actuator or lower supplypressure requires a higher gain.

• Feedback parameters D and B: Position control feedback parameters D and B are related tothe actuator type. See ND800 Installation, Maintenance and Operating Instructions 7 ND 70 forsetting the values.

9.2 Split RangeSplit Range configuration sets the input signal range for full valve travel range. Split range low andhigh values are given as a percentage of input signal range. The user can choose between twostandard split range configurations, 4 - 12 mA (0 - 50 %) and 12 - 20 mA (50 - 100 %) and Customsplit range configuration, in which the user gives the split range low and high values as percentageof the input signal range.


Note! In split range applications check always the maximum allowed load of the powersupply. If the total load of two ND800s connected in series (two times the load of a singleND800) is greater than the maximum allowed load of the power supply, you must use anadditional power supply or a signal amplifier.

9.3 a0 Adjustmenta0 Adjustment is used to change the valve travel from fully closed to a desired travel with a smallchange in input signal near the 0% value of the input signal range (4 - 20 mA). This can be used tocompensate dead angle in a ball or segment valve such that it is equal to the a0 adjustment inconventional Metso Automation positioners. The a0 adjustment is used especially with small ballvalves which require a turn of several degrees from the closed position before any flow through thevalve is perceptible.Percentage is a desired valve travel setpoint as a percentage of calibrated travel during a0

adjustment. When the input signal range is 0-100%, a small change in input signal from 0% willthus cause a quick change in valve travel equal to the percentage of the calibrated valve travel range(see Figure 25). Suitable a0 values for Metso Automation segment and ball valves can be found inND800 Installation, Maintenance and Operating Instructions 7 ND 70.

9.4 Cut-off Safety RangeCut-off Safety Range is used with valves that require great torque to be closed. It is used to ensurethat the valve is fully closed at a 4-mA input signal (see Figure 25).Percentage is the increase required in the input signal with respect to the input signal range (4 - 20mA) before it affects the valve travel. The standard default value for cut-off safety range of theND800 valve controller is 2%.

9.5 Position Sensor RotationNote that this parameter is valve assembly related; you should thus check that the controlvalve assembly conforms to the setting of this parameter! If the position sensor rotatesclockwise when the valve closes, set Standard: clockwise to close. With inverse rotation setNonstandard: counter-clockwise to close. See ND800 Installation, Maintenance and OperatingInstructions 7 ND 70 for more information of operation directions and air connections.

9.6 Input Signal DirectionNote that this parameter is valve assembly related; you should thus check that the controlvalve assembly conforms to the setting of this parameter! Input signal direction (Figure 25)determines the travel direction of the control valve with respect to the input signal. See ND800Installation, Maintenance and Operating Instructions 7 ND 70 for more information of operationdirections and air connections.


a0 a0

cut-off safety range INPUT SIGNAL %

POSITION %

0

20

100

40

60

80

0 20 40 60 80 100

rising signal to close rising signal to open

= Basic setting = a0-setting

Figure 25. Principle of settings (no split range).

9.7 Valve Acting TypeNote that this parameter is valve assembly related; you should thus check that the controlvalve assembly conforms to the setting of this parameter! Valve Acting type determines thetype of the valve closing element. The type can be rotary or linear.

9.8 Position Transmitter DirectionPosition transmitter direction defines the direction of the position transmitter output. Thedirection can be direct or reverse. This parameter is valid only for the ND800 with positiontransmitter function.


10. Characterization (F7)

Figure 26. Characterization frame.

Note that flow characterization changes the linear relationship between input signal andvalve travel into a nonlinear one. If the relationship is markedly nonlinear, the ND800position control gain needs to be decreased, especially in the split range configuration inorder to avoid unstable behavior of the control valve.When optimizing process control loop performance a linear relationship between the flow and inputsignal should be established. This can be achieved by a flow modification curve sent to the ND800valve controller.The user can choose a modification curve by using preset curves (Preset), a curve based oninstalled flow characteristics calculated with Nelprof6 valve sizing and selection software (FromNelprof) or by making his/her own curve with the customized function (Customized). In thecharacterization picture (Figure 26) the Installed flow characteristics curve shows installedcontrol valve flow characteristics with no modification. The Modification curve shows the modifiedvalve travel setpoint with respect to the unmodified valve travel setpoint. Modified flowcharacteristics curve shows what the actual flow characteristics will be after modification.• The Preset button contains 3 different modification curves:

Linear � Equal percentage modifies the linear flow characteristics to equalpercentage flow characteristics.Equal percentage � Linear modifies the equal percentage flow characteristics tolinear flow characteristics.Linear � Quick opening modifies the linear flow characteristics to quick openingflow characteristics.

• The From Nelprof button allows the user to import installed flow characteristics of the valvecalculated and exported by Nelprof. Valve manager automatically displays the required

6 Nelprof is a registered trademark of Metso Automation.


modification curve according to the desired flow characteristics of the valve. The desired flowcharacteristics can be selected with the radio buttons: Linear, Equal Percentage or Quickopening.

• The Customized button allows the user to create a modification curve in any shape. The usercan also first choose preset modification curves or modification curves calculated according tothe imported flow characteristics curve by Nelprof and edit these.

• The Linear button makes the modification curve linear.Nelprof, Metso Automation’s valve sizing program, can be used to calculate the installed flowcharacteristics for each control valve when the process conditions are known. In Nelprof theinstalled flow characteristics are saved to file with the Export to Valve Manager command;selection must be made before the command can be used (see Nelprof User’s Guide for moreinformation). The installed flow characteristics should be calculated with Nelprof only if your processcondition information is accurate.When the flow modification curve has been created, it must be sent to the device by pressing theSend Config. button. If the modification curve is not sent, the old flow modification curve can beacquired from the configuration memory of the ND800 valve controller by pressing the ReadConfig. button.The flow modification curve must be rising. Valve Manager cannot send a curve that is not rising.

10.1 Show mA vs. TravelBy pressing the Show mA vs. Travel button the user can see the relation between the input signaland valve travel (Figure 27). Because the modification curve shows the relation between travelsetpoint and valve travel, settings like quick action and operating direction do not affect themodification curve. In mA vs. Travel window the user can see how these settings affect theoperation when concerning the relation between input signal and valve travel.

Figure 27. mA vs. Travel window.


11. File Menu

11.1 New DatabaseCreates a new empty database for which the user is asked the filename. The name of the databaseis saved in the registry file of the operating system. Next time Valve Manager is started the databaseis opened automatically.

11.2 Open DatabaseOpens an existing database for which the user is asked the filename. The name of the database issaved in the registry file. Next time Valve Manager is started the database is opened automatically.

11.3 Save To DatabaseSaves the device information into a database. Information read from the ND800 valve controller isnot automatically saved into the database. The user is asked what information to save in the SaveData window (Figure 28).If the tag is not found in the database it is added and the user is asked for some specific information(Figure 32). A plant area for the new tag is also chosen or created.

Figure 28. Save Data window.

11.4 Import DatabaseImports a database into the one opened in the Valve Manager. The whole contents of the databaseis copied. If a conflict occurs between two tags (belong to different plant areas) the user is askedhow to proceed. This function is useful if the user has read the valve information with a differentcomputer (e.g. laptop) and wants to import these to the one where the main database exists (e.g.desktop computer).

11.5 Export Database StructureSaves the structure (i.e. plant areas and tags) of the database opened in the Valve Manager into anew database. No data such as diagnostics are copied. This function can be useful when testing thevalves with a different computer from the one normally used. In this case it is good to have the samedatabase structure in both computers. When the tests have been made the database can beimported back to the main database by the File|Import command.

11.6 Compact DatabaseCompacts and repairs an existing database. If a database has been used for a long time, it canbecome fragmented. Compacting the database will remove fragmentation. The compacted databasefile is usually smaller and often provides better performance. Compacting can require some time.


11.7 Program setupWith the Program Setup command the user can change the general setting of the program (Figure29). The Communications section contains the communication port (COM port in the PC), baudrate and master type (primary/secondary) settings. In the Units section the user can select whichunits to use, e.g. for the actuator supply pressure. All the changeable units can be changed in theProgram Setup window.Program setup is saved in the registry file. The next time Valve Manager is started the setup is readautomatically.

Figure 29. Program Setup window.

11.8 PrintThis command prints information read from the ND800 valve controller. The user is asked whichinformation to print in the Print Data window (Figure 30).

Figure 30. Print Data window.

11.9 Print SetupOpens the standard printer setup window. Changes in printer setup are saved to Windows settings.

11.10 ExitExits Valve Manager. The user is warned if some information has been changed but not sent to theND800 valve controller or if information has been read from the ND800 but not saved into thedatabase.


12. Edit menu

12.1 Create a new plant areaThis function allows the user to create a new plant area in the database. The user must give theplant area a name; description and comments can also be given (Figure 31).

Figure 31. Creating a new plant area window.


12.2 Create a new tagThis function allows the user to create a new tag in the database. The user can fill in the informationrequested by Valve Manager (Figure 32). After pressing OK, Valve Manager asks in which plantarea the new tag should be installed. Also process data for the new tag are requested.

Figure 32. Creating a new tag window.


13. View menuThe View database window (Figure 33) shows all the information in the database and is openedwith the command View|View Database. Presentation of the database can be selected by threemethods: Hierarchical, All Tags and Selected Tag. The Hierarchical presentation shows the‘Plant Area - Tag’ structure of the database. All Tags lists all the tags found in the database.Selected Tag shows the tag selected in the Connection frame (see Chapter 5.).Selecting a plant area shows information on that plant area and double-clicking a plant area showsall the tags in that plant area. Selecting a tag displays the information of the tag and tag-relatedfunctions.Pressing the Delete button deletes selected plant area or tag. Plant area cannot be deleted if itcontains tags. Pressing the Print button prints selected plant area or tag. Printing tag prints thelatest information of the tag (e.g. latest configuration and diagnostics).

Figure 33. View Database window.


13.1 UsersPressing the Users button displays a list of all the operations made to the tag. List includes the dateand time of the operation, user name and an description of the operation made (Figure 34).

Figure 34. Users window.

13.2 ConfigurationPressing the Configuration button shows the same configuration data (Figure 35) as the Settingsand Characterization windows. In addition it also shows a list of dates and times of previouslymade configurations. Selecting a date and time from the list displays the correspondingconfiguration data. Selected configuration can be sent to the device by Send To Device button.


Figure 35. Configuration window.

13.3 Process dataPressing the Process data button displays the process data information (Figure 36). The Processdata window contains information on flow medium, temperature of the flow medium, valve inletpressure, pressure difference over the valve and actuator supply pressure.The Process data section also includes a list of older process data.Older process data can be viewed by clicking a date and time from thelist.

Figure 36. Process data window.

13.4 DiagnosticsPressing the Diagnostics button displays the diagnostic information saved for the current tag(Figure 37). When the Diagnostics window is opened the latest diagnostics is shown. Olderdiagnostics can be viewed by clicking a date and time from the list.


Figure 37. Diagnostics window.

13.5 TestsPressing the Tests button displays the tests saved for the current tag (Figure 38). The type of testcan be selected with the two radio buttons. Older tests can be viewed by clicking a date and timefrom the list.


Figure 38. Tests window.

13.6 Changing general informationBy pressing the Change General Info button the user can change the general information for thecurrent tag. The window shown is the same as in Edit|Create new tag (Figure 32), only the tagfield is hidden.

13.7 Changing process dataBy pressing the Change Process Data button the user can change the process data for the currenttag (Figure 39).

Figure 39. Change Process Data window.

13.8 Changing plant areaBy pressing the Change Plant Area button the user can move the tag to another plant area (Figure40).


Figure 40. Change Plant Area window.

13.9 Changing alert limitsBy pressing the Change Alarm Limits button the user can change the limits for the current tag.The window opened is the same as the Alert Settings window opened from Diagnostics window(Figure 17). This button is enabled for the ND800 with SW revision 1 to 5.01 and Nelflow revision 5.

13.10 General diagnostics limitsBy pressing the General Limits button the user can set general diagnostic limits that are used if notag specific limits are available. The General Alert Limits window looks the same as the AlertSettings window (see Figure 17).General limits are used only for ND800 revisions 1 to 5.01 and Nelflow revision 5.


14. Calibration menu

Note! Remote testing and calibration should be done at the minimum input signal of 8 mAbecause of the energy saving mode of ND800.

Warning! When calibrating modules, the ND800 valve controlled should be removed fromautomatic control.

Warning! If the user stops a calibration sequence, the ND800 may not function properlyuntil the calibration sequence is successfully completed again.

14.1 Automatic travel calibrationSelecting the command Calibration|Automatic Travel Calibration opens a Calibration window(Figure 41). The automatic valve travel calibration runs a calibration routine in the ND800 valvecontroller which calibrates valve travel according to the mechanical limits of the actuator. Thecalibration is started with the Start button. While the calibration is running, it can be stopped withthe Stop button. The state of calibration is shown at the bottom of the window and the user isinformed of the success of the calibration. Calibration will require some time.

Warning! Calibration will move the valve from the closed position to the fully open position!Make sure you are allowed to perform calibration.

Figure 41. Automatic Travel Calibration window.

14.2 Prestage TrimPrestage Trim can be used to optimize the control performance of the ND800 to the present supplypressure level and pneumatic prestage. All ND800s are trimmed in the factory according to thecertain supply pressure level. The user can choose between automatic and manual prestage trim.Automatic prestage trim should be always performed when the prestage module is changed. Manualprestage trim should be performed when the actual supply pressure level differs from the configuredvalue shown in the Manual Prestage Trim window (Figure 43). If the actual supply pressure level ishigher than that shown in the Manual Prestage Trim window, the ND800 may become unstable. Ifthe actual supply pressure level is lower, the ND800 control performance decreases.


Note! Prestage trim is applicable to ND800 revisions 4 and 4.01.

Automatic prestage trim

Select Automatic when the prestage module has been changed. The pressure outlets C1 and C2must be plugged during the trimming. The supply pressure level should be the same as in the field,since it is recorded by the ND800 during automatic trimming. However do not exceed 6 barg (87psig) in trimming. If actual pressure differs from pressure used for trimming it can be manuallycorrected after field installation by using the Manual Prestage Trim option. The automatic prestagetrim lasts about 5 - 10 minutes. During trimming the text “tri” is displayed on the LCD of the ND800.If trimming fails, check the prestage assembly and C1/C2 plugging.

Figure 42. Automatic Prestage Trim window.

Manual prestage trimSelect Manual when the configured supply pressure level requires modification. This should not bedone during process control.

Figure 43. Manual Prestage Trim window.

14.3 Position sensor calibrationIf the position sensor module is changed, it must be calibrated before use. The calibration is donewith the command Calibration|Position Sensor Calibration. The calibration routine can beperformed by following the instructions in the calibration window (Figure 44).The first step is to give the serial number of the sensor and temperature compensation data (Figure44). The compensation data can be read from the file delivered with the position sensor. The datacan also be entered manually but it is most reliable when read from the file. Make sure that theserial number of the position sensor module matches the serial number in the Valve manager. Notethat only numbers in the serial code need to be given. The Next button proceeds to the nextstep. If no compensation data is available for the specific position sensor the average data can beused. Average data file (AVERAGE.POS) is found from the Valve Manager directory. In the ND800revision 5.02 the average compensation data is stored in the memory of the device. This average


data can be used by selecting the Use average compensation data in the device check box. Thischeck box is displayed only if the revision of the device is 5.02.

Figure 44. Position Sensor Calibration window (step 1).

The second step is to rotate feedback shaft to the position which corresponds 45° opening of thevalve. For more information see ND800 Installation, Maintenance and Operating Instructions(Figure 45). The linear range of the sensor is also asked during this step7. Pressing the Next buttonfinishes the calibration.NOTE! Check the position sensor calibration by rotating the position sensor within theactual valve travel range. If the position sensor was adjusted to the wrong angle duringcalibration, the ND800 may enter the fail-safe mode showing error code E51 or E528. In thiscase the sensor should be adjusted to the correct angle and the position sensor calibrationshould be restarted. If the error code E51 or E52 is also shown at the correct angle, thesensor should be manually turned 10 degrees clockwise (E52) or counterclockwise (E51)and the ND800 should be cold-started by switching the current off and on. This 10 degreesturn and reset sequence should be repeated until the ND800 cold-starts without error codeE51 or E52. Then the position sensor calibration should be carried out at that angle. Theturn and reset sequence and calibration should be repeated until the position sensorcalibration can be carried out at the correct angle shown in ND800 Installation,Maintenance and Operating Instructions.

7 110 degs in HW revisions 1,2,3 and 4. For others see ND800 Installation, Maintenance andOperating Instructions8 Does not apply to ND800 SW revisions 1 and 2


Figure 45.Position Sensor Calibration window (step 2).

14.4 Pressure sensor calibrationIf the pressure sensor module is changed, it must be calibrated before use. The calibration is donewith the command Calibration|Pressure Sensor Calibration. The calibration routine can beperformed by following the instructions in the calibration windows (Figure 46).The first step is to disconnect the actuator tubing from the ND800 which releases the pressure inthe pressure outlets of the ND800. Make sure that there is no pressure in the pressure outlets C1and C2. Pressing the Next button executes the pressure sensor zero calibration.The second step is to connect the supply pressure to the corresponding pressure inlet of the ND800(Figure 47). Pressing the Next button proceeds to the next window.The third step is to give the value of the supply pressure and the range of the pressure sensor (seeND800 Installation, Maintenance and Operating Instructions) (Figure 48). Pressing the Next buttonexecutes the pressure sensor span calibration and finishes the calibration.

Figure 46. Pressure Sensor Calibration window (step 1).




14.5 Input signal measurement calibrationThe measurement of the input signal is calibrated with this function. After calibration the ND800measures 4 and 20 mA correctly. The calibration is started with the command Calibration|InputSignal Measurement Calibration. The calibration routine can be performed by following theinstruction in the calibration window (Figure 49).

Figure 49. Input Signal Measurement Calibration window (step 1).

14.6 Temperature measurement calibrationTemperature measurement can be calibrated with the command Calibration| TemperatureMeasurement Calibration. After calibration the temperature compensation of the position


measurement is executed correctly. The calibration routine can be performed by following theinstructions in the calibration window (Figure 50).

Figure 50. Temperature Measurement Calibration window.

14.7 Position transmitter output calibrationPosition transmitter output can be calibrated with the command Calibration|Position TransmitterOutput Calibration. After calibration the output of the position transmitter is 4 mA when thecalibrated valve travel is 0% and 20 mA when the calibrated valve travel is 100%. This command isvalid only for the ND800 with position transmitter function. The calibration routine can be performedby following the instructions in the calibration window (Figure 51). During calibration the output ofthe position transmitter must be measured with a current meter.

Figure 51.Position Transmitter Output Calibration window (step 1).

14.8 Changing circuit board moduleIf a circuit board module is changed, all the module parameters in the configuration memory of thecircuit board must be updated. The updating must be done by executing calibrations and trimming inthe following order:

• Position transmitter output calibration (if available)• Input signal measurement calibration (see NOTE 1)• Temperature measurement calibration (see NOTE 1)• Pressure sensor calibration• Automatic prestage trim• Position sensor calibration (see NOTE 2)


NOTE 1: Circuit board module is supplied factory-calibrated for input signal measurement andtemperature measurement. So these calibrations are not necessarily needed to perform during thereplacement of the circuit board.NOTE 2: Circuit board module is supplied with default parameters of position sensor’s temperaturecompensation data. In circuit board replacement you can use this data or specify serial number ofthe position sensor to get original data.

Finally, configure device appropriately by using the Settings window and execute AutomaticTravel Calibration.


15. Flowmeter menuFlowmeter menu contains a graphical user interface for Nelflow. Nelflow is a ND800 basedcontroller to transmit flow rate signal from control valve equipped with connection to transmitters.Nelflow calculates the flow rate based on pressure differential over the valve and capacity coefficientat measured opening angle. Communication is made via HART. The operation principle is illustratedin Figure 52.

Q

0

20

40

60

80

100

120

0 20 40 60 80 100

Capasity - curve

NDflow

pot. FLOWFLOW

P1 , T P2

Figure 52. Nelflow operating principle

Flowmeter-menu includes the following functions:• Configuration• Cv-curve calibration• Channel calibration• Unit selectionFlowmeter related monitoring can be seen on same window as other basic monitoring of ValveManager (Figure 53). Flowmeter monitoring is possible when flow transmitter circuit is connected tothe voltage supply unit (DCS or corresponding).


Figure 53. Flowmeter-menu

Different units related only to Nelflow configuration can be selected at the Flowmeter menu byselecting Unit selection|Flow (Figure 53). SI reset and US reset commands return the defaultvalues for the units as follows:

SI USFlow l/s gpm

Pressure barG psiTemperature °C °F

Length m ftDiameter mm inDensity kg/m3 lb/ft3


15.1 Monitoring

Figure 54. Nelflow’s dynamic variables

Additional dynamic variables with Nelflow

In addition to dynamic variables that can be monitored with ND800, four additional dynamicvariables can be monitored with Nelflow:• Flow graph shows actual flow rate calculated by the Nelflow.• Up- and downstream pressures graph shows up-stream and downstream pressures used in

flow calculation.• Medium temperature graph shows medium temperature if it is used in flow calculation.• Flow to travel graph shows actual installed valve characteristics

Y-axis can be scaled manually by the user or leave it to be scaled automatically.


15.2 ConfigurationAll the Nelflow configuration related settings are defined in Configuration window (Figure 55)which has four different pages. When the user opens the configuration window first time theconfiguration data is read from the Nelflow if it is connected. The current configuration is set as thedefault values for the new configuration. The menus and their contents depend on the user rights.Read only users cannot send anything to the device nor into the database.

15.2.1 Valve selection

Valve is selected on Valve selection page. There are two possibilities on how the valve specificinformation, which practically means size, cv-, xt-, Fl- and z- curve, is handled. The user can select anew valve from the Metso Automation database or he can use the curves on the device (Figure 55).The old valve selection is used in cases where the valve’s cv curve is calibrated by the MetsoAutomation and the user adds rest of the site specific configuration. If the valve is not alreadyselected the most common place for the user to do it is here. There exist two combo boxes forselecting the type and size of the valve and with the Max travel edit box the user can change thetravel range for the valve. When the new configuration is sent to Nelflow the old cv-curve is first readfrom the valve and saved into the database from where it can be brought back later if needed.

Figure 55. Valve selection

15.2.2 Medium

Medium and its parameters are defined on Medium page. There are available five differentmediums: Water, Liquid, Gas, Steam and Pulpstock. Water and steam do not need any specialmedium information, their values are included as factors on the program.Liquid needs four parameters: Density, Vapour pressure, Critical pressure and Reynold´snumber factor (Figure 56). Reynold´s number factor is associated only with very viscotic liquid,


small valves or with small flow rates, the value is in most cases 1. The parameter values will betaken into account in flow calculations only if the configuration is performed before fittingof Cv-curve. Critical pressure and steam pressure influence on the accuracy when measuring theflow rate in cavitating circumstances.

Figure 56. Medium configuration for liquid

Figure 57. Settings for gas related to medium configuration

Gas requires four parameters: Molecular weight, Gas specific gravity, Compressibilityfactor and Ratio of specific heats (Figure 57). If the molecular weight is given, the programcalculates the sole weight of the gas and vice versa. If the contraction value is unknown, the defaultvalue is 1.0.


Figure 58. Settings for pulp related to medium configuration

There are three pulp types: Kraft, Mechanical and Recycled (Figure 58). The default value isKraft.

15.2.3 Channel settingsNelflow has four input channels, to which the 4 - 20 mA transmitters can be connected (Figure 59).Input 1 is Valve inlet pressure and Input 2 is Outlet pressure or Differential pressure. Input 3is Valve inlet temperature which is possible only with steam or gas. Input 4 is Consistency whichis possible only with pulp.

Figure 59. Channel settings

Input parameters:Each input channel has three parameters:• Measured value: Setting the range of the transmitter i.e. transmitter values are defined with 4

and 20 mA.• Constant value: If the variable is known to be constant the value is given here.


Measuring mode is chosen by selection button Measured or Constant. Channel 2 can be used alsoto measure Differential pressure, when using channel 2, you will choose Outlet pressure orDifferential pressure.

Outlet parameters:Nelflow has one outlet, which is flow rate. Output settings require three parameters:• Full scale flow: Flow rate with max. flow (20mA), this is used for outlet scaling.• Low-flow cutoff: This parameter can be used to restrict the small flow measurements off the

flow rate calculation.• Output time constant: This parameter can be used to filter out and to level down the flow

measurement fluctuation caused by flow dynamics.

15.2.4 Transmitter locationThe transmitters can be installed in separately delivered orifice plates when the valve could becalibrated by Metso Automation.The transmitters could also be installed somewhere in the pipeline and use the Cv calibration curvesdelivered by Metso Automation which are based on IEC standard. The deviation from the IECstandard could be taken care of by describing the inlet- and outlet pipes from the transmitters to thevalve (Figure 60). Default setting is that the transmitters are in the flanges when the Inlettransmitter in flange and Outlet transmitter in flange checkboxes are checked. If the checkmark is removed there appears a frame including all information needed for the transmitterinstallation description.

Figure 60. Pipeline settings

Pipeline from transmitter to valve is described by defining the following parameters:• Pipe length: Pipe length from the valve flange to transmitters.• Pipe diameter: Pipe diameter on the pipeline from valve to transmitter.


• Number of pipe bends: When calculating the influence of the single resistance on pressureloss all the bends are handled as 90° bends.

• Elevation: Elevation between valve and transmitter.

15.2.5 Status bar in configuration window

Status bar consists of five fields: Date, User, data transfer marks R or S, view andconfiguration date (Figure 59).• Date is current date• User is the user who has entered the Valve Manager -program• Data transfer marks indicate the status of the data transfer (S = sending, R = reading), also

the name of the window is highlighted.• Views are of three different kinds and the chosen one is seen on status bar. Different

alternatives are handled later on view drop-down menu.• Configuration date -field is in fact a list of choices, which includes all those configuration dates

saved on database, which are connected to the equipment and this can only be seen on database view. From the choice list the user can pick old configurations parameters from the database to be seen or to be sent to the equipment as new values.

15.2.6 Dropdown menu in configuration window

Configuration window has five drop-down menus (Figure 60): Data transfer, Database functions,Configuration, View and Window. Window menu is used only for closing the window, thisconcerns all flow meter related windows in Valve Manager.

Figure 61. Data transfer dropdown menu

Data transfer (Figure 61): This menu is used to HART communication between Valve Managerand Nelflow field device. Communication contains sending and reading of the configuration relatedparameters. If the data transfer is ongoing, the data transfer menu is disabled. The data transfermenu is inactive also if there is no connection to the equipment.

Figure 62. Database functions dropdown menu

Database functions (Figure 62): If the user has sent new configuration data to Nelflow, Saveconfiguration data Nelflow to database command is available. Settings made by this function canbe saved into Valve Manager database. Date of the saving moment will be the key to new recordand can be seen also on the status bar choice list.

Figure 63. Configuration dropdown-menu

Configuration (Figure 63): On this menu a new basis is defined for configuration. If the user wantsto use the current settings as basis Copy data from Nelflow to new configuration command is tobe chosen, this will be possible after the settings have been read from Nelflow. If the older settingsare wished to be used, Copy data from database to new configuration command should bechosen. To enable this the earlier saved record from database must be chosen on the databaseview.


Figure 64. View dropdown menu

View (Figure 64): The program function here deviates because of the different views. Newconfiguration view is for new settings. The other two are meant to show the earlier made settingsor to choose earlier made settings as a basis for new implementation. The check mark on the statusbar indicates the chosen view . If the New configuration is chosen the fields related toconfiguration are available, otherwise they are off use. Values on Nelflow menu selection isavailable after the data has been read from Nelflow. The interleaves are enabled or disabled andtheir contents may vary according to the view selected.

15.3 CalibrationCalibrating Nelflow in this window means that the user creates the most accurate Cv-curve, whichdescribes the valve in use. The first factory calibration of the Nelflow is divided into three main tasks:

1. The user chooses the most suitable Cv-curve from Metso Automation database and sends it tothe valve (Figure 65).

2. The accurate calibrated reference flow meter is installed to the same pipeline in the valve inletpipe. Valve is calibrated by using reference flowmeter with own calculations program. ValveManager is used to read the database containing the measurement results.

3. Valve Manager will perform corrections to Cv curve based on the measurements. The new Cvcurve can then be sent to the valve.

After factory calibration only the two last mentioned functions will be performed when recalibratingNelflow. There are also other alternatives to calibration (manual calibration or Valve Managerdatabase), which will be handled later on.


Figure 65. Calibration by using the Metso Automation database

There are four possibilities in Calibration data source (Figure 65)1. Measured flow data: Data gained from the reference measurements is saved to ASCII text file

with the help of for example Notepad. The file must contain three columns separated with spaceor tabulator: aperture, reference flow and flow reported by the valve.

2. Manual: Only the current Nelflow curve can be manually changed (Figure 68). With the currentpolynome fitting is calculated first 21 points. The user can change both aperture and Cv- value.After changes the curve is refitted with Refit command in Cv-data drop-down menu (Figure70).

3. Cv-curve from database): These are curves that have earlier been saved on databases (Figure67). They are completed polynomes and no separate fitting is necessary.

4. Cv-curve from Metso Automation Tables: The user chooses Cv-curve for the valve by usingthe combo boxes Valve type and Size (Figure 65). The user can also change the maximumopening angle always to smaller by using Max travel text edit field and Move curve button.The function will be activated when the curve fitting has been done. If the valve is not found intables, the user picks up the most suitable Cv-curve.


Figure 66. Polynome fitting points

Cv-curve is created by fitting two fifth grade polynomes to the points (Figure 66). Fitting is started byclicking Fitted calibration curve point inside Show frame. Overlapping dialog will appear, thisincludes two text edit fields and three buttons (Figure 14). Edit fields are the limits for the fittingareas seen as yellow stripes. First curve is fitted to the points, which are on the area of the aperture0 % -> Max and other curve points Min -> 100 %. The connection point of the polynomes is insidethis area marked with gray line. The user can change the fitting area limits and perform the refittingby pushing Recalculate button. Finally the last polynome is confirmed by clicking OK or dismissedby Cancel.


Figure 67.Calibration from Valve Manager database

Calibration date in database -choice box is only seen if the calibration source is Valve Managerdatabase. Dates are the keys to the database records. Keys are created directly when thepolynomes are saved into the database. The user can choose what ever calibration made and savedearlier to the database by using this choice box. Database contains the required rates and limitvalues for polynomes, but not data points.Calibrated Cv-curves must be as smooth as possible to enable a reliable flow calculation.


Figure 68. Manual calibration

Manual calibration handles only the current Nelflow Cv-curve. Values of the Cv-curve can be seenon edit fields on the right side of the window (Figure 68). They appear when the source for thecalibration curve is selected Manual. In manual calibration it is possible to move the curvehorizontally by given the corresponding factor on the Factor for horizontal move text field and bypushing Multiply button. Manual calibration is possible only when the Cv-curve is read first fromNelflow.All Cv-curves and data points are seen simultaneously in Show frame according to the user’schoice. Cv-curves can be distinguished from each other by different colours on legends inside Showframe. Cv-curve created from reference measurements is seen in blue in the middle of the curveindicating the acceptable area. The red endings of the curve indicate that no measurement pointswere found on these areas, which may cause inaccuracy to flow calculation on the apertures inquestion.

15.3.1 Dropdown menus in the calibration window

There are four dropdown menus in calibration window (Figure 68): Data transfer, Cv data,Database and Window.

Figure 69. Data transfer dropdown menu


Data transfer (Figure 69): This menu is used for HART communication in between Valve Managerand Nelflow positioner and to read reference measurement file. Communication concerns readingand sending Cv-curve and other required parameters. If the data transfer is ongoing, the datatransfer menu cannot be entered. Without connection to the equipment the data transfer menu isalso disabled.

Figure 70. Cv-data dropdown menu

Cv-data (Figure 70): If the user wants to recalculate earlier fitted Cv-curves, it is possible in thismenu with two functions. The lower choice is for the purpose if the user doesn’t want to take theconfigurations into account in curve fitting. The new configuration must be sent to the Nelflowbefore it is considered in cv or xt calculations.

Figure 71. Database dropdown menu

Database (Figure 71): When Cv-curve has been sent to Nelflow it pays to save it also into thedatabase, this can be done with the functions in this menu. Then the curve that was used at thecurrent time can be easily found in Valve Manager database, and there is no need for recalibrationsof the equipment, in case the curve in the memory has been corrupted.


16. Security menu

16.1 Change PasswordThis function allows the user to change the password, the maximum length of which is 10characters (Figure 72). The user must give the old password and the new password twice.

Figure 72. Change Password window.

16.2 Edit UsersThe Edit Users window (Figure 73) allows the administrator(s) to edit user access rights. Theadministrator can add and remove users with the Add and Delete commands. When adding anuser to the users list the administrator also chooses access authorization for the user from threealternatives:• The Administrator updates user privileges and has the right to read and write all the

information in Valve Manager. Valve Manager must always have at least one administrator.• Read / Write authorization allows the user to read and write all the information in Valve

Manager.• Read Only authorization allows the user to read all the information from the device and to save

it in the database, but not to change any information in the device. Read only user also cannotrun tests or calibrations.

The Update function can be used if the password or access rights of a user is being changed.

Figure 73. Edit Users window.


17. TroubleshootingProblem / Error Explanation / Correction

Wrong password. Check that you do not have Caps Lock on.Password is case-sensitive (‘a’ is different from‘A’).

Could not initialize HART communication. Check that the COM port used is correct andthat no-one (e.g. mouse) is using the port.

In Win2000 check the serial port settings asdescribed in readme.txt file.

Could not find any devices. Check that the COM port used is correct. Checkthe 4-20-mA loop wire connections. Check theHART modem connection. Check that supplyvoltage is more than 12.5 V.

Communication error. Check that the connections between the PC anddevice are OK. If the reason is a nonconformant4-20-mA analogue output, contact your nearestMetso Automation representative (for moreinformation see Chapter 3.4).

Device is in write protect mode. Write-protect switch on PCB (Printed CircuitBoard) in the ND800 valve controller is switchedON (see ND800 Installation, Maintenance andOperating Instructions 7 ND 70).


18. Remotely Accessible Information (HART)The following lists explain all the remotely accessible information available from the ND800 valvecontroller to Valve Manager and vice versa via HART communication.

18.1 Identification and CommunicationTag User-defined field device identifier.Date User-defined date.Description User-defined description of the tag.Message User-defined text.Device ID code Unique ID code for the device used in HART

communication.Device type Type of ND800 valve controller (with or

without position transmitter).Manufacturer Manufacturer of the device used in HART

communication.Final assembly number User defined number.Universal CMD revision Revision of HART universal commands.Device CMD revision Revision of device-specific HART

commands.Device function flags Flags indicating device functionality in

HART communication (EEPROM control,multisensor,...).

SW revision Revision of ND800 valve controller SW.HW revision Revision of ND800 valve controller HW.Polling address Short address of the slave device used in

HART communication.Response preambles Number of preambles in slave device

response in HART communication.Primary variable (PV) code Code of dynamic variable mapped to PV in

HART communication.Possible codes (same for the other dynamicvariables):0 = actual travel1 = travel setpoint2 = actuator pressure3 = PCM temperature

Second variable (SV) code Code of dynamic variable mapped to SV inHART communication.

Third variable (TV) code Code of dynamic variable mapped to TV inHART communication.

Fourth variable (FV) code Code of dynamic variable mapped to FV inHART communication.

Primary variable (PV) unit code Unit code of dynamic variable mapped to PVin HART communication.Possible unit codes:For variables displaying actual travel andtravel setpoint 57 = %For variable displaying actuator pressure 6 = psi 7 = barFor variable displaying PCB temperature 32 = °C


33 = °FSecond variable (SV) unit code Unit code of dynamic variable mapped to SV

in HART communication.Third variable (TV) unit code Unit code of dynamic variable mapped to TV

in HART communication.Fourth variable (FV) unit code Unit code of dynamic variable mapped to FV

in HART communication.Burst mode control Control burst mode of the slave device

(ON/OFF) used in HART communication.Burst mode command Command number sent in burst mode in

HART communication. Allowed commandsare 1, 2, 3, 33, 110.

1st burst variable code Code of 1st dynamic variable in BURST CMD#33 in HART communication.Possible codes (same for the other burstvariables):0 = actual travel1 = travel setpoint2 = actuator pressure3 = PCM temperature

2nd burst variable code Code of 2nd dynamic variable in BURST CMD#33 in HART communication.

3rd burst variable code Code of 3rd dynamic variable in BURST CMD#33 in HART communication.

4th burst variable code Code of 4th dynamic variable in BURST CMD#33 in HART communication.

Pressure unit code Unit code of pressure measurement(bar/psi).

Temperature unit code Unit code of temperature measurement(degC/degF).

Master preambles Number of preambles required in masterrequest in HART communication.

18.2 Settings and characterizationGain Position gain.Parameter D Positioner feedback parameter D.Parameter B Positioner feedback parameter B.Split range low and high Split range configuration parameters.a0 adjustment Valve position at lower limit value of input

signal. Percentage of calibrated valve travel.Cut-off safety range Lower limit value of input signal that closes

valve. Percentage of input signal range.Position sensor rotation Rotation direction of position sensor axis as

viewed from ND800 valve controller.Signal direction 20-mA action of input signal (valve

open/closed).Valve acting type Type of the valve (linear/rotary).Position transmitter direction Direction of the position transmitter output

(direct/reverse).Modification curve control Status of position setpoint to valve travel

modification, i.e. control valve flowcharacterization (on/off).

Modification curve Position setpoint to valve travel modificationcurve, i.e. control valve flow characterizationcurve.


18.3 MonitorInput Signal 4-20-mA loop current from analogue output

of control system measured by ND800.Position Setpoint Valve position setpoint according to which

ND800 controls valve position (percentage ofcalibrated travel range).

Actual Position Actual position of valve measured by ND800(percentage of calibrated travel range).

Actuator Pressure Actuator pressure measured by ND800(bar/psi).

PCB Temperature Temperature of PCB (Printed Circuit Board)measured by ND800 (deg C/deg F).

18.4 Diagnostics and TestingEvent log table List of events occurred in ND800.Travel deviation trend Trend of deviation between setpoint position

and actual position of control valve.Travel vs. time histogram Valve travel duration histogram.Actuator load factor trend Trend of actuator load calculated according

to supply pressure given by user.Valve full strokes and number of reversals Amount of valve movement and reversals.Actuator full strokes and number ofreversals

Amount of actuator movement and reversals.

Step response test Step response test data.Hysteresis loop test Hysteresis loop test data.

18.5 OthersActuator type Type of the actuator (double-acting or

single-acting).ND800 serial number Serial number of the ND800.Electronics serial number Serial number of the PCB.Position sensor serial number Serial number of the position sensor.

valve manager for hart modems user’s...

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