Metso ND9100H Installation Maintenance And Operating Instructions

Operating Instructions 7 ND91H 70 en • 1/2009

READ THESE INSTRUCTIONS FIRST! These instructions provide information about the safe handling and operation of the intelligent valve controller. If you require additional assistance, please contact the manufacturer or manufacturer's representative. Addresses and phone numbers are printed on the back cover. SAVE THESE INSTRUCTIONS! Subject to change without notice. All trademarks are property of their respective owners. Table of Contents 1 ND9000 PRODUCT FAMILY SUMMARY ....... 3 1.1 Key features........................................... 3 2 ND9100H INTELLIGENT VALVE CONTROLLER WITH HART COMMUNICATION..................... 4 2.1 General .................................................. 4 2.2 Technical description ............................ 4 2.3 Markings ................................................ 4 2.4 Technical specifications ........................ 5 2.5 Recycling and disposal ......................... 6 2.6 Safety precautions................................. 6 3 TRANSPORTATION, RECEPTION AND STORAGE ....................................................... 6 4 MOUNTING...................................................... 7 4.1 General .................................................. 7 4.2 Mounting on EC and EJ actuators......... 7 4.3 Mounting on Metso actuators with VDI/VDE mounting face ......................... 7 4.4 Mounting on linear actuator of nelesCV Globe....................................... 8 4.5 Mounting on linear actuator with IEC 60534 mounting face ...................... 8 4.6 Piping..................................................... 9 4.7 Electrical connections.......................... 12 5 LOCAL USER INTERFACE (LUI)................. 13 5.1 Measurement monitoring..................... 13 5.2 Guided start-up.................................... 13 5.3 Configuration menu ............................. 14 5.4 Mode menu.......................................... 14 5.5 Configuration parameters.................... 15 5.6 Valve travel calibration......................... 17 5.7 Special displays................................... 18 5.8 HART write protection.......................... 19 6 MAINTENANCE............................................. 19 6.1 Prestage............................................... 19 6.2 Spool valve assembly.......................... 19 6.3 Communication circuit board .............. 20 7 ERROR MESSAGES..................................... 20 7.1 Failsafe errors ...................................... 20 7.2 Alarms.................................................. 20 7.3 Errors ................................................... 21 7.4 Warnings.............................................. 21 7.5 Notifications ......................................... 22 8 TROUBLE SHOOTING.................................. 22 9 ND9100H/K00, ND9100H/I00 (WITH LIMIT SWITCHES) ............................. 23 9.1 Introduction.......................................... 23 9.2 Installing ND9100H/K00 or ND9100H/I00 on a valve controller............................. 24 9.3 Electrical connections.......................... 24 9.4 Adjustment........................................... 24 9.5 Removal of the limit switches ND9100H/K00 and ND9100H/I00 for accessing the valve controller........ 24 9.6 Circuit diagrams .................................. 24 9.7 Maintenance ........................................ 24 10 TOOLS........................................................... 24 11 ORDERING SPARE PARTS ......................... 24 12 DRAWINGS AND PARTS LISTS .................. 25 12.1 Exploded view and parts list, ND9100H. 25 12.2 Exploded view and parts list, ND9100H/K00 and ND9100H/I00........ 26 12.3 Mounting parts for E_05-14 actuators, rising signal opens valve ..................... 27 12.4 Mounting parts for B1C/B1J6-20 actuators.............................................. 27 12.5 Mounting parts for B1C/B1J25-50, B1C502 and B1J322 actuators............ 28 12.6 Mounting parts for Quadra-Powr® actuators.............................................. 28 12.7 Mounting parts for linear actuators of nelesCV Globe..................................... 29 12.8 Mounting parts for linear actuators with IEC 60534 mounting face .................... 30 12.9 Connection diagrams .......................... 31 13 DIMENSIONS ................................................ 35 14 EC DECLARATION OF CONFORMITY........ 36 15 TYPE CODING .............................................. 37

3 1 ND9000 PRODUCT FAMILY SUMMARY 1.1 Key features ❑ Benchmark control performance on rotary and linear valves ❑ Reliable and robust design ❑ Ease of use ❑ Language selection: English, German and French ❑ Local / remote operation ❑ Expandable architecture ❑ Advanced device diagnostics including ❑ Self-diagnostics ❑ Online diagnostics ❑ Performance diagnostics ❑ Communication diagnostics ❑ Extended off-line tests ❑ Intelligent Valve Diamond 1.1.1 Options ❑ Interchangeable communication options: ❑ HART ❑ FOUNDATION Fieldbus ❑ Profibus PA ❑ Limit switches ❑ Position transmitter (in HART only) ❑ Special corrosion resistant finish ❑ Exhaust adapter 1.1.2 Total cost of ownership ❑ Low energy and air consumption ❑ Future proof design allows further options at a reduced cost ❑ Optimised spares program. Reduced number of spares ❑ Retro-fit to existing installations (Neles or 3rd party) 1.1.3 Minimised process variability ❑ Linearisation of the valve flow characteristics ❑ Excellent dynamic and static control performance ❑ High-speed of response ❑ Accurate internal measurements 1.1.4 Easy installation and configuration ❑ Same unit for linear and rotary valves, double and single-acting actuators ❑ Simple calibration and configuration ❑ using Local User Interface ❑ using FieldCare software in a remote location ❑ Flush mounting capability to avoid tubing and mounting parts ❑ Low power design enables installation to all com- mon control systems 1.1.5 Open solution Metso is committed to delivering products that freely inter- face with software and hardware from a variety of manufac- turers; and the ND9000 is no exception. This open architecture allows the ND9000 to be integrated with other field devices to give an unprecedented level of controllability. ❑ FDT based multi-vendor support configuration. ND9000 DTM download page: www.metso.com/automation/nd9000 1.1.6 ND9000 in fieldbus networks ❑ Approved interoperability ❑ Host interoperability ensured ❑ FOUNDATION Fieldbus ITK version 5.01 certified ❑ Profibus PA profile version 3.0 PNO certified ❑ Easy to upgrade; can be done by replacing the HART communication board to fieldbus commu- nication board ❑ Excellent maintainability with firmware download feature ❑ Advanced communication diagnostics ❑ Digital communication via the fieldbus includes not only the set point, but also the position feed- back signal from the position sensor. No special supplementary modules for analog or digital position feedback are needed when using the fieldbus valve controller. ❑ Back up LAS functionality available in FOUNDA- TION Fieldbus enviroment ❑ Input selector and output splitter blocks available in FOUNDATION Fieldbus devices allowing advanced distributed control ❑ Multipurpose functionality ❑ Standard function blocks enables the freedom to use ND9000 intelligent valve controller either in continuous or on-off control applications ❑ Open and close information directly available via the fieldbus ❑ Open and close detection is based on either position measurement (soft limit switch) or mechanical limit switch information ❑ ND9000 download page: www.metso.com/automation/nd9000 1.1.7 ND9000 mounting on actuators and valves ❑ Mounted on single and double acting actuators ❑ Both rotary and linear valves ❑ Flush mounting capability ❑ Ability to attach options to electronics and mechanics later ❑ Possibility to mount also on valves that are in process with 1-point calibration feature 1.1.8 Product reliability ❑ Designed to operate in harsh environmental con- ditions ❑ Rugged modular design ❑ Excellent temperature characteristics ❑ Vibration and impact tolerant ❑ IP66 enclosure ❑ Protected against humidity ❑ Maintenance free operation ❑ Resistant to dirty air ❑ Wear resistant and sealed components ❑ Contactless position measurement 1.1.9 Predictive maintenance ❑ Easy access to collected data with FieldCare software ❑ Ingenious Valve Diamond to visualise control valve performance and diagnostics ❑ Logical trend and histogram collection ❑ Information collected on service conditions ❑ Extensive set of off-line tests with accurate key figure calculations ❑ Fast notifications using on-line alarms ❑ Condition monitoring tool available ❑ Real time monitoring of valve control parameters

2 ND9100H INTELLIGENT VALVE CONTROLLER WITH HART COMMUNICATION 2.1 General This manual incorporates Installation, Maintenance and Operation Instructions for the Metso ND9100H intelli- gent valve controller. The ND9100H may be used with either cylinder or diaphragm type pneumatic actuators for rotary or linear valves. 2.2 Technical description The ND9100H is a 4–20 mA loop-powered microcon- troller-based intelligent valve controller. The device operates even at 3.6 mA input signal and communi- cates via HART. The device contains a Local User Inter- face enabling local configuration. A PC with FieldCare software can be connected to the ND9100H itself or to the control loop. The powerful 32-bit microcontroller controls the valve position. The measurements include: ❑ Input signal ❑ Valve position with contactless sensor ❑ Actuator pressures, 2 independent measurements ❑ Supply pressure ❑ Spool valve position ❑ Device temperature Advanced self-diagnostics guarantees that all meas- urements operate correctly. Failure of one measure- ment does not cause the valve to fail if the input signal and position measurements are operating correctly. After connections of electric signal and pneumatic sup- ply the micro controller (µC) reads the input signal, position sensor (α), pressure sensors (Ps, P1, P2) and spool position sensor (SPS). A difference between input signal and position sensor (α) measurement is detected by the control algorithm inside the µC. The µC calculates a new value for prestage (PR) coil current based on the information from the input signal and from the sensors. Changed current to the PR changes the pilot pressure to the spool valve. Reduced pilot pres- sure moves the spool and the actuator pressures change accordingly. The spool opens the flow to the driving side of the double diaphragm actuator and opens the flow out from the other side of the actuator. The increasing pressure will move the diaphragm pis- ton. The actuator and feedback shaft rotate clockwise. The position sensor (α) measures the rotation for the µC. The µC using control algorithm modulates the PR- current from the steady state value until a new position of the actuator according to the input signal is reached. 2.3 Markings The valve controller is equipped with an identification plate sticker (Fig. 2). Identification plate markings from top to bottom include: ❑ Type designation of the valve controller ❑ Revision number ❑ Enclosure class ❑ Operational temperature ❑ Input signal (voltage range) ❑ Input resistance ❑ Maximum supply voltage ❑ Supply pressure range ❑ Contact details of the manufacturer ❑ CE mark ❑ Manufacturing serial number TTYYWWNNNN*) *) Manufacturing serial number explained: TT= device and factory sign YY= year of manufacturing WW = week of manufacturing NNNN = consecutive number Example: PH08011234 = controller, year 2008, week 1, consecutive number 1234. NOTE: The selection and use of the valve controller in a specific application requires close consideration of detailed aspects. Due to the nature of the product, this manual cannot cover all the likely situations that may occur when installing, using or servicing the valve controller. If you are uncertain about the use of the controller or its suitability for your intended use, please contact Metso’s Automation business for more information. Fig. 1 The principle of operation Fig. 2 Identification plate

5 2.4 Technical specifications ND9100H INTELLIGENT VALVE CONTROLLER General Loop powered, no external power supply required. Suitable for rotary and sliding-stem valves. Actuator connections in accordance with VDI/VDE 3845 and IEC 60534-6 standards. Flush mounting on nelesCV™ control valves. Action: Double or single acting Travel range: Linear; 10–120 mm with standard IEC parts. Larger strokes possible with suitable kits Rotary; 45–95°. Measurement range 110° with freely rotating feedback shaft. Environmental influence Standard temperature range: -40° to +85 °C / -40° to +185 °F Influence of temperature on valve position: < 0.5 % / 10 °K Influence of vibration on valve position: < 1 % under 2g 5–150 Hz, 1g 150–300 Hz, 0.5g 300–2000 Hz Enclosure Material: Anodised aluminium alloy and polymer composite Protection class: IP66, NEMA 4X Pneumatic ports: G 1/4 Electrical connection: max 2.5 mm2 Cable gland thread: M20 x 1.5 Weight: 1.8 kg / 4.0 lbs Mechanical and digital position indicator visible through the main cover Special corrosion resistant finish available Pneumatics Supply pressure: 1.4–8 bar / 20–115 psi Effect of supply pressure on valve position: < 0.1 % at 10 % difference in inlet pressure Air quality: According to ISO 8573-1:2001 Solid particles: Class 5 (3–5 µm filtration is recommended) Humidity: Class 1 (dew point 10 °C/50 °F below minimum temperature is recommended) Oil class: 3 (or <1 ppm) Capacity with 4 bar / 60 psi supply: 5.5 Nm3/h / 3.3 scfm (spool valve 2) 12 Nm3/h / 7.1 scfm (spool valve 3) 38 Nm3/h / 22.4 scfm (spool valve 6) Consumption with 4 bar / 60 psi supply in steady state position: < 0.6 Nm3/h / 0.35 scfm (spool valves 2 & 3) < 1.0 Nm3/h / 0.6 scfm (spool valve 6) Electronics Supply power: Loop powered, 4–20 mA Minimum signal: 3.6 mA Current max : 120 mA Load voltage: up to 9.5 V DC/20 mA (corresponding 475 Ω.) Voltage: max 30 V DC Polarity protection: -30 V DC Over current protection: active over 35 mA EEx ia IIC T6: Ui ≤ 28 V Ii ≤ 120 mA Pi ≤ 1 W Ci = 22 nF Li = 53 µH (ATEX approval is valid under these conditions) Performance with moderate constant-load, actuators EC05-EC10 Values at 20 °C / 68 °F and without any additional instru- ments, such as boosters or quick exhaust valves etc. Dead band acc. to IEC 61514: ≤ 0.1 % Hysteresis acc. to IEC 61514: < 0.5 % Local user interface functions ❑ Local control of the valve ❑ Monitoring of valve position, input signal, temper- ature, supply and actuator pressure difference ❑ Guided start-up function ❑ LUI may be locked remotely to prevent unauthor- ised access ❑ Calibration: Automatic/Manual ❑ 1-point calibration ❑ Control configuration: aggressive, fast, optimum, stable, maximum stability ❑ Mode selection: Automatic/Manual ❑ Rotation: valve rotation clockwise or counter- clockwise to close ❑ Dead angle ❑ Low cut-off, cut-off safety range (default 2 %) ❑ Positioner fail action, open/close ❑ Signal direction: Direct/reverse acting ❑ Actuator type, double/single acting ❑ Valve type, rotary/linear IEC/nelesCV Globe/FLI ❑ Language selection: English, German and French Approvals Intrinsically safe and non incendive ATEX EC-Directive 94/9/EC; EN 50014 EN 50020: 2 G EEx ia IIC T4...T6 EN 50284: 1 G EEx ia IIC T4...T6 EN50021: 3 G EEx nA II T4...T6 EN 50281-1-1: D T90 °C CSA CAN/CSA-C22.2-0,-142, -157; CAN/CSA-E60079-0,-11, -15 IS Class I, Div. 1, Groups A, B, C, D T4...T6 IS Class I, Zone 0, Ex ia IIC T4...T6 NI Class I, Div. 2, Groups A, B, C, D T4...T6 FM FM Class 3600, 3610, 3611, 3810: IS Class I, Div. 1, Groups A, B, C, D T4...T6 IS Class I, Zone 0, AEx ia IIC T4...T6 NI Class I, Div. 2, Groups A, B, C, D T4...T6 NI Class I, Zone 2, Ex nA II T4...T6

Electromagnetic Protection Electromagnetic compatibility Emission acc. to EN 61000-6-4 (2001) and FCC 47 CFR PART 15, SUBPART B, CLASS B (1994) Immunity acc. to EN 61000-6-2 (2001) CE Marking 89/336/EEC Electromagnetic compatibility 94/9/EC ATEX (when applicable) POSITION TRANSMITTER (optional) Output signal: 4–20 mA (galvanic isolation; 600 V DC) Supply voltage: 12 - 30 V Resolution: 16 bit / 0.244 µA Linearity: <0.05 % FS Temperature effect:<0.35 % FS External load: max 0–780 Ω max 0–690 Ω for intrinsically safe EEx ia IIC T6 Ui ≤ 28 V Ii ≤ 120 mA Rx = 0–690 Ω Pi ≤ 1 W Ci = 22 nF Li = 53 µH PROXIMITY SENSORS AND MICRO SWITCHES, 2 PIECES (OPTIONAL WITH EXTENSION MODULE) Code I02 P+F NJ2-12GK-SN Code I09 P+F; NCB2-12GM35-N0 Code I56 IFC 2002-ARKG/UP Code K05 Omron D2VW-5, micro switch Code K06 Omron D2VW-01 gold plated, micro switch 2.5 Recycling and disposal Most valve controller parts can be recycled if sorted according to material. Most parts have material marking. A material list is sup- plied with the valve controller. In addition, separate recycling and disposal instructions are available from the manufacturer. A valve controller may also be returned to the manufacturer for recycling and disposal. There will be a charge for this. 2.6 Safety precautions 3 TRANSPORTATION, RECEPTION AND STORAGE The valve controller is a sophisticated instrument, han- dle it with care. ❑ Check the controller for any damage that may have occurred during transportation. ❑ Store the uninstalled controller preferably indoors, keep it away from rain and dust. ❑ Do not unpack the device until installing it. ❑ Do not drop or knock the controller. ❑ Keep the flow ports and cable glands plugged until installing. ❑ Follow instructions elsewhere in this manual. CAUTION: Do not exceed the permitted values! Exceeding the permitted values marked on the valve controller may cause damage to the controller and to equipment attached to the controller and could lead to uncontrolled pressure release in the worst case. Dam- age to the equipment and personal injury may result. CAUTION: Do not remove or dismantle a pressurized controller! Removing or dismantling a pressurized prestage or spool valve of an ND9100 leads to uncontrolled pressure release. Always shut off the supply air and release the pressure from the pipelines and equipment before removing or dismantling the controller. Otherwise per- sonal injury and damage to equipment may result. WARNING: During automatic or manual calibration and tuning the valve operates between open and closed posi- tions. Make sure that the operation does not endanger people or processes! WARNING: Do not operate the device with electronics cover (39) removed! Electromagnetic immunity is reduced, valve may stroke. Explosion protection may be impaired. Intrinsic Safety (Ex i) WARNING: Ensure that the complete installation and wiring is intrinsically safe before operating the device! The equipment must be connected via a certified Zener barrier placed outside the hazardous area. ATEX WARNING: Electrostatic charge hazard! The pointer and display windows are non-conductive. Clean with a damp cloth only! Spark hazard! Protect the aluminium housing from impacts and fric- tion! ATEX WARNING: For use in the presence of combustible dust. Ignition protection relies on the enclosure. Protect the cover of the valve controller from impacts. When tem- perature is higher than 70 °C the temperature rating of the cable shall be higher than the temperature. NOTE: Avoid earthing a welding machine in close proximity to an ND9100H valve controller. Damage to the equipment may result.

7 4 MOUNTING 4.1 General If the ND9100H is supplied with valve and actuator, the tubes are mounted and the ND9100H adjusted in accordance with the customer’s specifications. If the controller is ordered separately, the mounting parts for the assembly must be ordered at the same time. Sample order: (B1CU13)-Z-ND9106HN The controller is equipped with the Metso flush mount- ing face, the old Neles mounting face and for connec- tion according to VDI/VDE 3845. Shaft coupling alternatives for the controller for Metso actuators are shown in Fig. 5. For mounting parts for Metso actuators, see 12.3 - 12.7. 4.2 Mounting on EC and EJ actuators See figure in Section 12.3. ❑ Mount the U-shaped coupling (47) to the shaft. Apply thread-locking compound to the screws (48) and tighten firmly. ❑ Remove all protective plastic plugs (5 pcs.) from all pneumatic connections. Mount the metal plugs (53) to the unused controller connections with sealant. For EJ (single acting, spring to close) and EJA (sin- gle acting, spring to open) actuators, mount a metal plug (54) with sealant to the C1 connection at the bottom of the controller. ❑ Mount the O-rings (38, 2 pcs.) into the air con- nections in the bottom of the controller. ❑ Mount the O-ring (49) into the square groove in the bottom of the controller. ❑ Place the valve controller on top of the actuator so that the pointer of the shaft washer (16) is located in the position shown in Fig.5. ❑ Fasten the screws (4). 4.3 Mounting on Metso actuators with VDI/VDE mounting face See figures in Section 12.4 -12.6. ❑ Mount the H-shaped coupling (47) to the shaft. Apply the thread-locking compound to the screw (48) and tighten firmly. ❑ Remove all protective plastic plugs from the pneu- matic connections (5 pcs.). Mount the metal plugs (54) with sealant to the unused controller connections at the bottom of the controller. ❑ BJ and other single acting actuators: mount a metal plug (53) with sealant to the C1 connection. ❑ Set the direction arrow of the actuator in the direction of the valve closure member and attach the ear (2) to the indicator cover in the position shown in Section 12.4. Secure the screw of the ear using e.g. Loctite and tighten firmly. ❑ Attach the bracket (1) to the ND9100H. ❑ Attach the bracket (1) to the actuator. The shaft coupling of the ND9100H must fit into the ear (2) so that the pointer of the shaft washer (16) is located in the position shown in Fig. 5. NOTE: The enclosure of ND9100H intelligent valve controller meets the IP66 protection class according to EN 60529 in any posi- tion when the cable entry is plugged according to IP66. Based on good mounting practice, the recommended mounting position is electrical connections placed down- wards. This recommendation is shown in our mounting position coding for control valves. If these requirements are not fulfilled, and the cable gland is leaking and the leakage is damaging valve controller or other electrical instrumentation, our warranty is not valid. Fig. 3 Mounting on EC and EJ actuators Fig. 4 Mounting on Metso actuator with VDI/VDE mounting face O-rings C2 S C1 The pointer on the coupling must stay in this sector 11

4.4 Mounting on linear actuator of nelesCV Globe See figure in Section 12.7. ❑ Attach the J-shaped feedback lever (47) to the valve controller shaft. Apply the thread-locking compound to the screws and tighten firmly. ❑ Remove all plastic plugs from all actuator connections (5 pcs.). Mount the metal plugs (53) to the unused controller connections with sealant. ❑ Mount the metal plug (54) with sealant to the connec- tion C1 at the bottom of the controller and mount the O-rings (38, 2 pcs.) to the connections. ❑ Attach the mounting plate (39) to the valve con- troller with screws (28). ❑ Mount the the conical plug (16) to the lever and select the position on the scale according to the valve stroke. ❑ Install the O-ring (31) to the actuator. Place the con- ical plug into the frame on the stem and tighten the screws (4). 4.5 Mounting on linear actuator with IEC 60534 mounting face See figure in Section 12.8 ❑ Attach the feedback arm with spacer to the valve controller shaft. Note the position of the mark on the shaft as in 12.8. Apply thread locking compound to the screws and tighten firmly. Attach the spring to the feedback arm as shown in Section 12.8. ❑ Mount the valve controller mounting bracket loosely to the yoke of the actuator. ❑ Remove all plastic plugs from all actuator connec- tions (5 pcs.). Mount the metal plugs (54) with seal- ant to the unused controller connections at the bottom of the controller. ❑ Mount the valve controller loosely to the mounting bracket guiding the pin on the actuator stem to the slot of the feedback arm. ❑ Align the bracket and the valve controller with the actuator stem and adjust their position so that the feedback arm is approximately at a 90° angle to the actuator stem (in the mid-stroke position). ❑ Tighten the valve controller mounting bracket screws. ❑ Adjust the distance of the valve controller to the pin on the actuator stem so that the pin stays in the lever slot at full stroke. Ensure also that the maximum angle of the lever does not exceed 45° in either direction. Maximum allowed travel of the lever is shown in Section 12.8. Best control per- formance is achieved when the feedback lever uti- lises the maximum allowed angle (±45° from horizontal position). The whole range should be at least 45°. ❑ Make sure that the valve controller is in right angle and tighten all the mounting bolts. ❑ Ensure that the valve controller complies with previous steps. Check that the actuator pin does not touch the valve controller case throughout the entire stroke of the actuator. If the actuator pin is too long it may be cut to size. ❑ Apply grease (Molykote or equivalent) to the con- tact surfaces of the actuator pin and the feed- back arm to reduce wear. Fig. 5 Shaft coupling alternatives VDI/VDE 3845 mounting 45° nelesCV Globe mounting pointer mark on housing 45° pointer mark on housing 45 EC/EJ flush mounting pointer mark on housing 45° 45° IEC 60534 mounting pointer mark on housing shaft end shaft end shaft end shaft end

9 4.6 Piping Table 2 provides the recommended tube sizes in accord- ance with actuator sizes. Tube sizes are the minimum val- ues allowed. Operating times may be tested by the FieldCare software. Connect the air supply to S (G1/4 ). Connect C1 and C2 (G1/4) to the actuator, see Fig. 6. ND9100H is connected direct to the EC or EJ actuator. Connections C1 and C2 (G1/4) must be plugged, see 12.3. Liquid sealants, such as Loctite 577 are recommended for the pipe threads. The air supply must be clean, dry and oil-free instru- ment air, see Section 2.4. CAUTION: Do not exceed the permitted supply pressure of the ND9100H! NOTE: A valve controller mounted on a spring actuator must be connected only as single-acting. See Fig. 6. NOTE: An excess of sealant may result in faulty operation of the controller. Sealing tape is not recommended. Ensure that the air piping is clean. Table 1 Spring rates Actuator type Spring rate (bar/psi) B1JK 3 / 43 B1J 4.2 / 61 B1JV 5.5 / 80 QPB 3 / 43 QPC 4.3 / 62 QPD 5.6 / 81 EJK 3 / 43 EJ 4 / 57 EJV 5 / 72 Adjust regulator pressure to a level that is max 1 bar (14.5 psi) + spring rate.

Table 2 Piping Actuator Actuator piping Spool valve EC Stroke vol. dm3 / in3 G 6 10 1/4 3/8 05 0.09 / 5 1/4 x x 2 07 0.2 / 12 1/4 x x 2 10 0.5 / 31 1/4 x x 3 12 1.2 / 73 1/4 x x 3 14 3.0 / 183 1/4 x x 6 16 7.7 / 470 3/8 x x 6 25 20.5 / 1250 3/8 x x 6 EJ Stroke vol. dm3 / in3 G 6 10 1/4 3/8 Spool valve 05 0.18 / 11 1/4 x x 2 07 0.4 / 24 1/4 x x 2, 3* 10 1 / 61 1/4 x x 3 12 2.4 / 145 1/4 x x 3 14 6 / 366 1/4 x x 6 16 15 / 915 3/8 x x 6 25 41 / 2500 3/8 x x 6 B1C Stroke vol. dm3 / in3 NPT 6 10 1/4 3/8 Spool valve 6 0.3 / 18 1/4 x x 2, 3* 9 0.6 / 37 1/4 x x 3 11 1.1 / 67 3/8 (x) x (x) x 3 13 2.3 / 140 3/8 x x 3 17 4.3 / 262 1/2 x x 6 20 5.4 / 330 1/2 x x 6 25 10.5 / 610 1/2 x x 6 32 21 / 1282 3/4 x x 6 40 43 / 2624 3/4 x x 6 50 84 / 5126 1 x x 6 502 195 / 11900 1 x x 6 B1J B1JA Stroke vol. dm3 / in3 NPT 6 10 1/4 3/8 Spool valve 8 0.9 / 55 3/8 (x) x (x) x 3 10 1.8 / 110 3/8 x x 3 12 3.6 / 220 1/2 x x 6 16 6.7 / 409 1/2 x x 6 20 13 / 793 3/4 x x 6 25 27 / 1648 3/4 x x 6 32 53 / 3234 1 x x 6 322 106 / 6468 1 x x 6 QP Stroke vol. dm3 / in3 NPT 6 10 1/4 3/8 Spool valve 1 0.62 / 37 3/8 (x) x (x) x 2, 3* 2 1.08 / 66 3/8 (x) x (x) x 3 3 2.18 / 133 3/8 x x 3 4 4.34 / 265 3/8 x x 6 5 8.7 / 531 3/8 x x 6 6 17.5 / 1068 3/4 x x 6 Air supply piping 10 mm or 3/8" for all actuators. Pipe sizes are nominal, i.e. approximately outer diameter. Inner diameter is typically 2 mm smaller. x = Standard pipe size used in Neles control valves. (x) = Minimum pipe size (if smaller than standard). *) Spool size 2 is preferred for accurate control and standard for Neles control valves. Spool size 3 can be used if fast full stroke times are required.

11 Fig. 6 Operation directions and air connections SINGLE-ACTING ACTUATOR, SPRING TO OPEN SINGLE-ACTING ACTUATOR, SPRING TO CLOSE DOUBLE-ACTING ACTUATOR, REVERSED PIPING Increasing input signal to open valve (not recommended) Default setting: DIR = OPE ROT = cC (close valve to clockwise) ATYP = 2-A PFA = OPE A0, CUTL and VTYP according to valve type 5.Increasing input signal to open valve (shown) Default setting: DIR = OPE ROT = cC (close valve to clockwise) ATYP = 1-A PFA = CLO (must be in the spring direction) A0, CUTL and VTYP according to valve type 7.Increasing input signal to close valve (shown) Default setting: DIR = CLO ROT = cC (close valve to clockwise) ATYP = 1-A PFA = OPE (must be in the spring direction) A0, CUTL and VTYP according to valve type 6.Increasing input signal to close valve (not recommended) Default setting: DIR = CLO ROT = cC (close valve to clockwise) ATYP = 1-A PFA = CLO (must be in the spring direction) A0, CUTL and VTYP according to valve type 4.Increasing input signal to close valve (shown) Default setting: DIR = CLO ROT = cC (close valve to clockwise) ATYP = 2-A PFA = OPE A0, CUTL and VTYP according to valve type . C1 C2 S C1 C2 S C1 C2 S 3. 8.Increasing input signal to open valve (not recommended) Default setting: DIR = OPE ROT = cC (close valve to clockwise) ATYP = 1-A PFA = OPE (must be in the spring direction) A0, CUTL and VTYP according to valve type DOUBLE-ACTING ACTUATOR Increasing input signal to open valve (shown) Default setting: DIR = OPE ROT = cC (close valve to clockwise) ATYP = 2-A PFA = CLO A0, CUTL and VTYP according to valve type 2.Increasing input signal to close valve (not recommended) Default setting: DIR = CLO ROT = cC (close valve to clockwise) ATYP = 2-A PFA = CLO A0, CUTL and VTYP according to valve type . C1 C2 S 1.

4.7 Electrical connections The ND9100H is powered by a standard 4–20 mA cur- rent loop that also functions as a carrier to the HART communication. The input signal cable is led through a M20 x 1.5 cable gland. Connect the conductors to the terminal strip as shown in Fig. 7. It is recommended that the earthing of the input cable shield be carried out from the DCS end only. The position transmitter is connected to 2-pole terminal PT as shown in Fig. 7. The position transmitter needs an external power supply. The ND9100H and the position transmitter circuits are galvanically isolated and with- stand a 600 V AC voltage. Please note following before mounting the cover of the valve controller: ❑ Attach the LUI (223) cabling to the sticker on the reverse side of the LUI. Check that the cabling does not get squeezed by the electronics cover (39) or the device cover (100). ❑ Check using a feeler gauge that the clearance between the position indicator (109) and the electronics cover is 1 mm. NOTE: The ND9100H equals a load of 475 Ω in the current loop. Fig. 7 Terminals HART connection Fig. 8 Electrical connections HAZARDOUS LOCATION Exi barrier Uout max 28 V Iout max 120 mA Pmax 1 W Exi barrier Uout max 28 V Iout max 120 mA Pmax 1 W ND9100H_T Position Transmitter NONHAZARDOUS LOCATION Li 53 µH Ci 22 nF Imax 120 mA Umax 28 V Pmax 1 W Li 53 µH Ci 22 nF Imax 120 mA Umax 28 V Pmax 1 W not connected

13 5 LOCAL USER INTERFACE (LUI) The local user interface may be used to monitor the device behaviour as well as configuring and commis- sioning the controller during installation and normal operation. The local user interface consists of 2 row LCD and 4 button keypad interface. There are also cus- tom graphical characters for special conditions. 5.1 Measurement monitoring When the device is powered, it enters the measurement monitoring view. The following measurements may be viewed from the display. The Table 3 identifies the default unit and also optional unit of the measurement. If the unit selection is altered from the FieldCare soft- ware to US units, the pressure default unit will automati- cally be changed to psi and temperature unit to Fahrenheit. The active unit may be changed by pressing the ? key constantly. The display shows the current unit selection on the top row of the display. You may change the selection by pressing + or - while keeping the ? key pressed down. When the buttons are released the current selection will be activated. If the device has been idle for 1 hour, and there is no user activity on the local user interface, the measure- ments will start scrolling on the display. This enables the user to view all the measurements through the win- dow of the main cover. 5.2 Guided start-up Guided startup offers a fast view of the most critical parameters of the ND9100H controller, actuator and valve configuration. After verifying the parameters the valve travel calibration is recommended. The guided start-up is entered by pressing the = and ? keys simultaneously. The configuration parameters are listed in following order, see explanation from 5.5: Valve type VTYP Actuator type ATYP Positioner fail action PFA Valve rotation direction ROT Valve dead angle A0 If you modify any of the parameters you will also need to calibrate and tune the device. See 5.6 for detailed description. Fig. 9 Local user interface (LUI) Table 3 Default / optional units of measurements Measurement Default unit Optional unit valve position Percentage of full scale Angle, where 0 % refers to 0 (angle) target position Percentage of full scale none current loop setpoint mA Percentage of full scale actuator pressure difference bar psi supply pressure bar psi device temperature °Celcius °Fahrenheit Fig. 10 Measurement unit change — continuous push — brief push

5.3 Configuration menu The local user interface is organised in a menu struc- ture. To enter the menus press + and - simultane- ously in the measurement monitoring view panel. To move to the next or previous selection by pressing + or - accordingly. 5.4 Mode menu If the user wants to change the valve operating mode, press the ? key at the MODE selection. The mode will start to flash and by pressing + or - you may alter the operation mode selection. User accepts the current selection by pressing the ? key. There are two options for the operating mode. 5.4.1 AUTO During the auto mode, the controller controls the valve position according to the incoming setpoint signal from the 4–20 mA signal source. This mode is used during the normal process control service. 5.4.2 MAN During this mode the valve position may be controlled manually by using the keyboard and pressing the + or - buttons. The position of the manually driven valve is not saved in the memory of the controller, i.e. the valve will not return to the same position after signal failure. However, the valve may be driven back into position after signal fail- ure by using + and - keys.The manual control starts from the current position of the valve after the MAN-mode is activated. In order to change the manual setpoint return to the measurement monitoring view and go to target position measurement. Press the ? key shortly to acti- vate the target position editing, text TPOS starts to blink and now you are able to edit the setpoint by pressing + or - button. The setpoint changes in 0.1 % increments/ decrements in spite of the selected unit and the valve starts to move immediately. A continuous push changes the setpoint faster. In order to view other measurements, press the ? or = keys and select a measurement. Repeat the previous steps if you would like to alter the set- point value again. Fig. 11 Guided start-up NOTE: You may cancel any action by pressing the = button. Cancelling of operation returns user interface view one level up in menu hierarchy. — brief push Fig. 12 Configuration — brief push

15 5.5 Configuration parameters When PAR is on the display you may enter the configura- tion menu by pressing the ? key. In this menu the most important configuration and signal modification parame- ters are viewable. You may view the current value and edit them by pressing the ? key at the relevant parameter. The name of the parameter will appear on the upper row of the display and the current value is on the lower row. 5.5.1 Performance level, PERF If you want to change the tuning of the valve position control, the PERF selection is available. The default fac- tory value is C. ❑ Once PERF is displayed press the ? key to enter the edit state and PERF starts to blink. ❑ Select between five values by pressing the + or - key. ❑ After the desired value is displayed, press the key ? to conclude the operation 5.5.2 Low cut-off, CUTL Low cut-off safety range CUTL ensures the valve clos- ing against mechanical travel stops. The factory default value is 2 %. ❑ Once CUTL is displayed press the ? key to enter the edit state and the CUTL will start to blink. The currently selected value appears as a percentage (%) on the display. ❑ Modify the parameter value by pressing + or - keys alternately until the desired value appears on the display. ❑ After the desired value is displayed, press the key ? to conclude the operation. 5.5.3 Signal direction, DIR The opening and closing direction of the valve with rais- ing current loop signal is defined by signal direction parameter DIR. ❑ When DIR is displayed press the ? key to enter the edit state and DIR starts to blink. ❑ Select either the OPE or CLO values by pressing the + and - keys. The value OPE signifies the raising signal 4–20 mA to open the valve and CLO means the raising signal to close the valve. ❑ To conclude, press the ? key when the desired value is shown on the display. See default values in Fig. 6. 5.5.4 Valve type, VTYP To compensate for nonlinearity of the position feedback caused by the actuator linkage mechanism of a linear control valve, the appropriate selection must be made on the VTYP display. ❑ After selecting VTYP on the display, press the ? key to enter the edit state and the VTYP starts to blink. ❑ Select between four values rot, LIn, nCG or FLI using the + and - keys. The value rot indi- cates a rotary valve and LIn a linear valve. Use nCG only for nelesCV Globe valves to accommo- date special linkage geometry. Use FLI only for linear valves when linkage geometry is not needed to be corrected by valve controller firmware. ❑ To conclude press the ? key when the desired value is shown on the display. 5.5.5 Actuator type, ATYP In order to optimise the control performance the device needs to be informed about the actuator type. ❑ After selecting ATYP on the display, press the ? key to enter the edit state and ATYP starts to blink. ❑ Select between two values 2-A or 1-A using the + and - keys. The value 2-A indicates a double acting actuator and 1-A a single acting actuator. ❑ To conclude press the ? key when the desired value is shown on the display. Fig. 13 Setpoint change in MAN mode Table 4 Performance level Selection Meaning Description A Aggressive Immediate response to signal changes, overshoots b Fast Fast response to signal changes, small overshooting C Optimum Very small overshoot with minimum step response time d Stable No overshooting, slow response to input signal changes E Maximum stability No overshooting, deadband may increase, slow but stable behaviour For use with volume boosters and/or very fast actuators, additional performance levels A1 to D1 can be used. Characteristics of these extended levels are the same as those in the table above. However, with performance level settings A1 to D1, adaptive properties of the ND9000 control algorithm are disabled. NOTE: Perform valve calibration and tuning always when VTYP has been changed. NOTE: Perform valve calibration and tuning always when ATYP has been changed.

5.5.6 Positioner fail action, PFA Positioner fail action will take place in case of signal failure or when the controller software discovers a fatal device failure. For single acting actuators set value in the spring direction. For double acting actuators see Fig. 6 for correct settings. ❑ Once PFA is displayed, press the ? key to enter the edit state and the PFA will start blinking. ❑ You may select between two values by pressing the + or - key. The CLO value indicates that the valve ought to be closed in fail action situations. The OPE value indicates the valve to be opened in fail action situations. ❑ After the desired value is displayed, press the key ? to conclude the operation. 5.5.7 Valve rotation direction, ROT The application-specific parameter ROT defines the relationship between position sensor rotation and valve action. ❑ Once ROT is displayed press the ? key to enter the edit state and ROT starts to blink. ❑ Now you may select between two values by pressing the + or - key. The value cC indicates clockwise rotation for closing the valve and ccC means counterclockwise to close. ❑ After the desired value is displayed, press the key ? to conclude the operation. 5.5.8 Valve dead angle, A0 The α0 setting is made for Metso segment and ball valves. This setting takes into account the "dead angle" α0 of the ball valves. The entire signal range is then used for effec- tive valve opening 90° - α0 . Use 0 % as the "dead angle" for the valves not mentioned in Table 5. ❑ After selecting A0 on the display, press the ? key to enter the edit state and A0 starts to blink. The value currently selected appears as a per- centage (%) on the display. ❑ Modify the parameter value by pressing + or - keys alternately until the desired value appears on the display. ❑ Press the ? key to make your selection and return to the setting state. 5.5.9 Low cut-off, low limit, high cut-off, high limit ND9100H supports signal cut-off and limiting in both ends of the operating range. The configuration parame- ters are: low cut-off, low limit, high cut-off and high limit. NOTE: Perform valve calibration and tuning always when con- troller fail action parameter has been changed. NOTE: Perform valve calibration and tuning always when ROT has been changed. Fig. 14 Principle of setting 100 80 60 40 20 0 0 20 40 60 80 100 α0 α0 POSITION INPUT SIGNAL = Basic setting = α0 setting Increasing input signal closes valve Increasing input signal opens valve cut-off safety range 2 ± 0.5 % Table 5 Dead angle in percentage Valve size Valve series MBV QMBV 1) MBV QMBV 2) D, P, C T5, QT5 QX- T5 T25, QT25 QX- T25 R, QR E R- SOFT 3) FL 4) ZX mm in Dead angle, % 15 1/2 15 20 3/4 15 25 1 14 - - 25.5 19.5 - - 15 25.5 27 12.5 25/1 1/1 14.5 11 25/2 1/2 8 11 25/3 1/3 8 10 25/4 8 40 1 1/2 12 - - 24.5 12.5 - - 12 16 21 12.5 50 2 10 9 13.5 24.5 12.5 18 8 17 20.5 23 12.5 65 2 1/2 9 - - - - - - 13 - 18 80 3 10 8 12 18 8 16.5 8.5 9 8.5 15.5 100 4 10 8 12 16.5 8.5 16 9 8 7 14.5 125 5 12 - - - - 12 6.5 8 - 150 6 10 8 11.5 16 9 13.5 8 13.5 13 200 8 9 7 8.5 12 6.5 9.5 7 11.5 250 10 9 7 7.5 13.5 9.5 7 10.5 300 12 8 6 6.5 9.5 7.5 6 9.5 350 14 6 6 - 5 9.5 400 16 5 5.5 9.5 (14") 5 9.5 450 18 6 7.5 (16") 500 20 6 4.5 600 24 5.5 6 650 26 7 700 28 7 6 750 30 6 800 32 - 900 36 5.5 1) Seat supported 2) Trunnion 3) Soft seated R-valve 4) Low Cv Finetrol Fig. 15 Dead angle

17 ❑ If the input signal is smaller than low cut-off, the valve will be fully closed. ❑ If the input signal is smaller than low limit, the valve stays in the low limit. ❑ If the input signal is greater than high cut-off, the valve will be fully opened. ❑ If the input signal is greater than high limit, the valve stays in the high limit. The cut-off overrides the limit as follows: ❑ If the low cut-off > low limit, the low limit is not active. ❑ If the low cut-off < low limit, both low cut-off and limit are active. ❑ If the low cut-off is set to zero, the low cut-off is not active. ❑ If the high cut-off < high limit, the high limit is not active. ❑ If the high cut-off > high limit, both high cut-off and limit are active. ❑ If the high cut-off is set to 100 %, the high cut-off is not active. Only the low cut-off is adjustable using the LUI. Low limit, high cut-off and high limit are configurable via FieldCare software. 5.5.10 Language selection, LANG ❑ Select between three languages EnG, GEr or FrE using the + and - keys. ❑ To conclude press the ? key when the desired value is shown on the display. 5.6 Valve travel calibration Select CAL from the menu by using + or - keys and press the ? key. Define the calibration type AUTO, MAN or TUNE. You may also select TUNE after AUTO and MAN calibration separately as seen in Fig.16. 5.6.1 AUTO calibration function During the calibration process the display will show the fol- lowing text: CALrun. After calibration the ND9100H scrolls CALIBRATION SUCCESSFUL text. You may interrupt the cal- ibration sequences at any time by pressing the = key. After the calibration sequence is finished, press the = key twice to get back to the measurement view. Please refer to Chapter 7 if this sequence has failed and an error message is displayed. If you cannot drive the valve into a fully open position or if there is no mechanical limit stop, a manual calibration is required. 5.6.2 MAN calibration function After selecting the MAN calibration function from the menu press the ? key to activate the procedure. With the + or - keys drive the valve manually to the closed (0 %) position and then press the ? key. If you cancel the operation, the old values of the previous calibration will be restored. Drive the valve into the desired maxi- mum opening position (100 %) with the + and - keys and press the ? key. If this sequence has failed and an error message is shown, see Chapter 6. 5.6.3 TUNE function During the tuning the ND9100H controller searches for optimum internal control parameters for the valve posi- tion control. At any time you may interrupt the tuning sequence by pressing the = key. The tuning will not alter the PERF parameter. If calibration and tuning are performed in sequence, the cancelling of tuning does not restore the old cali- bration values. 5.6.4 1-Point calibration 1-point calibration is useful in cases in which the valve controller needs to be changed but it is not possible to run the normal calibration and the valve is not allowed to change position (the valve is active, for example). This procedure does not ensure the best possible control performance, and it is always recommended to run either AUTO or MAN calibration and tuning, as soon as possible. The primary way to calibrate valve position is to use either AUTO or MAN calibration. Before starting 1-point calibration, read the warnings and notes below and check that the valve is mechan- ically locked. Before starting 1-point calibration, adjust the TPOS value in the MAN mode (see sec- tion 5.4.2) to correspond with the physical position of the valve. Once the 1-point calibration is started, the first view shows RNG above and NN.N below (see Fig. 16). NN.N presents the maximum turning angle (in degrees) that the valve can perform. To change the value: ❑ Press ?, NN.N begins blink ❑ Press + and - buttons to change the value After the correct valve operation angle is set, press ? button. NOTE: If AUTO CAL or MAN CAL is selected, the valve controller must be in AUTO mode. 1-point calibration may run in both AUTO and MAN mode. Fig. 16 Calibration selection WARNING: Automatic calibration drives the valve against the mechanical open and closed travel limits of the valve-actuator assembly and a tuning procedure is performed. Make sure that these procedures can be safely executed.

During the calibration process the display will show the following text: CALrun. After calibration the ND9100H scrolls CALIBRATION SUCCESSFUL text. You may inter- rupt the calibration sequences at any time by pressing the = key. After the calibration sequence is finished, press the = key twice to get back to the measurement view. Please refer to Chapter 7 if this sequence has failed and an error message is displayed. The valve can be unlocked when the calibration is suc- cesfully finished. 5.7 Special displays 5.7.1 User interface locked In order to prevent unauthorised access, the Local User Interface may be locked. In this mode measurements may be viewed but configurations and calibrations are prohibited. You may lock and unlock the device only via HART. When the Local User Interface is locked the lock symbol will be activated on the display. 5.7.2 Online-alarm active If an online alarm has been detected the solid & sym- bol is activated. This symbol will disappear after the recovery from online alarm. You may view the reason for the alarm by viewing the latest event while pushing the = and - keys simultaneously or by using FieldCare software where all events may be viewed. 5.7.3 Viewing of latest event You may view the latest event by pressing the = and - keys simultaneously in the measurement monitoring view. The message is scrolled on the top row of the dis- play twice. You may stop the scrolling by pressing the ? key. By pressing the = key, the message will disap- pear. For the list of events see Chapter 7. 5.7.4 Fail-safe active When the ND9100H detects serious device failure (set- point, valve position and control signals) it enters fail- safe mode, which drives the control valve into the posi- tion defined in the parameter controller fail action (PFA). Fail-safe mode is indicated by the display as seen in Fig 19. The error message is displayed until the cause of error is eliminated and the ND9100H unit is restarted, i.e. the power loop is momentarily discon- nected. 5.7.5 Reduced performance When the ND9100H detects spool valve measurement failure, it enters reduced performance mode.This is indicated by the blinking & in the display, see Fig. 20. In reduced performance mode valve control can not be optimized. To correct the problem replace the spool valve assembly and perform auto calibration. WARNING: Supply pressure can be connected to the valve controller only after 1-point calibration is success- fully completed. If supply pressure is connected to the valve controller before successful 1-point cali- bration, the valve may move and cause danger. NOTE: If an incorrect valve operation angle is given to the valve controller during 1-point calibration, valve oper- ation will be incorrect. In this case, you must perform 1-point calibration again with correct valve operation angle value. NOTE: If the valve position is not stable (due to heavy vibra- tion etc) during 1-point calibration, the calibration will not end successfully. Check that the valve position is fully stable during this operation. Fig. 17 LUI locked Fig. 18 Online alarm message Fig. 19 Failsafe display Fig. 20 Reduced performance display scrolling text scrolling text

19 5.8 HART write protection The ND9100H is delivered from the factory with the default set as HART write protection OFF. Reading and changing parameters is allowed. HART protection may be enabled with a switch (DIP1) located on the commu- nication circuit board under the Local User Interface module, Fig. 21. Changes that may influence the valve position cannot be made using the FieldCare software or HART hand held when switch no. 1 (on the left-hand side of the switch block) is ON. 6 MAINTENANCE The maintenance requirements of the ND9100H valve controller depend on the service conditions, for instance, the quality of instrument air. Under normal service conditions there is no requirement for regular maintenance. When maintaining the ND9100H ensure that the supply air is shut off and pressure is released. In the following text the numbers in brackets ( ) correspond to the part numbers in the exploded view as shown in Chapter 12, unless otherwise stated. The ND9100H valve controller includes the following interchangeable modules: prestage unit (120), spool valve unit with sensor (193) and communication circuit board with optional position transmitter (215). The modules are located below the covers (39) and (43). In the event of failure the whole module must be changed. The module retrofit must be assembled in a clean, dry environment. In reassembly apply thread- locking compound (for instance, Loctite 243) and tighten the screws firmly. 6.1 Prestage 6.1.1 Removal ❑ Open the prestage cover (43) attached with M4 screw (44). Unplug the prestage wire connector on the spool sensor board. Unscrew the M4 screws (139, 2 pcs.) and lift up the prestage module. Remove the O-ring (140). 6.1.2 Installation ❑ Place a new O-ring (140) into the groove on the spool valve and press the prestage into place. Make sure the nozzle is guided into the O-ring properly. The screws guide the prestage body into the correct position. Tighten the screws (139) evenly. ❑ Push the prestage 2-pole wire connector into the socket on the spool sensor board. The wire con- nector may only be fitted in the correct position. Replace the prestage cover (43) and tighten the M4 screw (44). 6.2 Spool valve assembly Before removing the spool valve assembly (193) the prestage (120) must be removed. See 6.1. 6.2.1 Removal ❑ Unscrew the M4 screws (47, 3 pcs.), M3 screws (48, 2 pcs.) and M3 screw (49). Remove the spool valve assembly. ❑ The spool valve may be cleaned if special atten- tion is paid to a clean environment and proper procedure. After unscrewing the M4 screws (47, 3 pcs.) the spool valve may be lifted from the fix- ture. Hold the ends of the body with your fingers to avoid dropping the spool from the body. Clean the spool and the bore of the body with care. Do not leave any fibres from cleaning materials in the bore or on the spool. Do not scratch the mat- ing surfaces of the spool and body. The restrictor is located under the spool valve in the fixture. It may be cleaned when the spool valve is removed. Fig. 21 HART write protection NOTE: Whenever any maintenance operations have been done for the ND9100H, the device should be cali- brated and tuned. 1 2 ON NOTE: The prestage must be handled carefully. In particular the moving parts of the prestage should not be touched when the protective cover is not in place. NOTE: Each spool valve body has an individual correspond- ing spool which cannot be replaced by any other spool. Never alter the orientation of the spool. The orientation of the spool is marked on the spool valve body, see Fig. 22.

6.2.2 Installation ❑ Ensure that the gasket (174) is properly located in the groove on the bottom of the spool valve assembly. Mount the spool valve assembly on to the housing and tighten the M3 and M4 screws evenly. Ensure the O-ring (140) slots inside the groove fully. Mount the prestage unit directly on the spool valve unit as in 6.1. 6.3 Communication circuit board 6.3.1 Removal ❑ Loosen the M8 grub screw (110) off the position indicator (109) and turn the position indicator from the shaft. Remove the cover off the prestage (43). Remove the cover of the circuit boards attached with M3 screws (42, 4 pcs). ❑ Remove the M3 screws (217, 4 pcs.). Hold the sides of the circuit board and lift it directly upwards and outwards. Handle the board care- fully, touching only the sides. 6.3.2 Installation ❑ Mount the new communication circuit board carefully. ❑ Locate the pins with the matching connector on the board. Tighten the M3 screws (217) evenly. ❑ Install the cover of the circuit boards and the cover of the prestage (43). ❑ Mount the position indicator (109) on the shaft and tighten the M8 screw (110) temporarily. The final orientation and locking of the position indi- cator should be done after installation of the valve controller to the actuator. 7 ERROR MESSAGES 7.1 Failsafe errors 7.2 Alarms Fig. 22 Spool valve assembly NOTE: If the maintenance operations have been done for the spool valve assembly, the device must always be cal- ibrated and tuned. NOTE: Ground yourself on the body of the device before touching the circuit board. NOTE: Do not remove the Valve Controller Board (210)! Removing the board will void the warranty. 195 194 140 160 174 175 0327000170 Assembly direction of spool Sticker on fastener (160) Fig. 23 Communication board Display message Description POSITION SENSOR FAILURE Position sensor measurement failed. Change the ND9000 device to a new one. SETPOINT SENSOR FAILURE mA measurement failed. Change the ND9000 device to a new one. PRESTAGE SHORTCUT ERROR Shortcut in the prestage unit. FAE nnn Fatal malfunction in the device. nnn is a number between 001 - 004. Change the ND9000 device to a new one. Display message Description DEVIATION ALARM Valve deviation out of limits. STICTION LOW ALARM Stiction has exceeded the low limit. STICTION HIGH ALARM Stiction has exceeded the high limit. LOAD FOR OPENING LOW ALARM Load for opening has exceeded the low limit. LOAD FOR OPENING HIGH ALARM Load for opening has exceeded the high limit. SPOOL VALVE PROBLEM Spool valve problem in the controller. Check the spool valve unit and replace if necessary. PNEUMATICS PROBLEM Inconsistent actuator pressures. Check pneumatic connections and actuator leakage. FRICTION PROBLEM Valve is not moving correctly. Check load factor. 215

21 7.3 Errors 7.4 Warnings Display message Description PRESTAGE CUT ERROR Prestage wire is cut or connector is loose. PRESSURE SENSOR 1 FAILURE Actuator pressure sensor has failed. The device performance level is reduced. Change the ND9000 device to a new one during next maintenance activity. PRESSURE SENSOR 2 FAILURE Actuator pressure sensor has failed. The device performance level is reduced. Change the ND9000 device to a new one during next maintenance activity. PRESSURE SENSOR 3 FAILURE Supply pressure sensor has failed. This does not affect the performance level. SPOOL VALVE SENSOR FAILURE Spool valve sensor failed. Check the sensor connections. The device performance level is reduced. Change the ND9000 device to a new one during next maintenance activity. TEMPERATURE SENSOR FAILURE Temperature measurement failed. The accuracy of the measurements is reduced. Change the ND9000 device to a new one during next maintenance activity. STATISTICS DATABASE ERROR Failed to store statistics. New measurements will be lost. EVENT DATABASE ERROR Failed to store events. The new events will be lost. POSITION CALIBRATION FAILED Travel calibration failed. Check the configuration parameters and controller mounting. Check that the controller shaft is correctly aligned. TUNING FAILED Tuning procedure failed. Check that the valve is moving properly. Check the prestage and spool valve unit. POSITION SENSOR RANGE ERROR Position sensor range failed during calibration. Valve controller shaft failed to rotate minimum 45 degrees. Check the configuration parameters and controller mounting. Check that the controller shaft is correctly aligned. CALIBRATION TIMEOUT Calibration timeout occurred. Check configuration and installation. CALIBRATION START FAILED The calibration starting conditions are not met. Check the supply pressure. TUNING RANGE ERROR Tuning procedure failed. Check the prestage and spool valve unit. SPOOL SENSOR RANGE ERROR Spool sensor range failed during position calibration. Check the configuration parameters. Check the prestage and spool valve unit. Display message Description TOTAL OPERATION TIME WARNING Operating time exceeded limit. VALVE FULL STROKES WARNING Valve stroke counter limit reached. VALVE REVERSALS WARNING Valve reversals counter limit reached. ACTUATOR FULL STROKES WARNING Actuator stroke counter limit reached. ACTUATOR REVERSALS WARNING Actuator stroke counter limit reached. SPOOL FULL STROKES WARNING Spool stroke counter limit reached. SPOOL REVERSALS WARNING Spool reversals counter limit reached. STEADY STATE DEVIATION WARNING Warning that steady state deviation has increased. DYNAMIC STATE DEVIATION WARNING Warning that dynamic state deviation has increased. STICTION LOW WARNING Warning that stiction has exceeded the low limit. STICTION HIGH WARNING Warning that stiction has exceeded the high limit. LOAD FOR OPENING TOO LOW Warning that load for opening has exceeded the low limit. LOAD FOR OPENING TOO HIGH Warning that load for opening is has exceeded the high limit. SUPPLY PRESSURE OUT OF LIMITS Supply pressure has exceeded the specified operating conditions. TEMPERATURE OUT OF LIMITS Temperature has exceeded the specified operating conditions. HUNTING DETECTION WARNING Valve hunting detected. Change performance level to less aggressive to stabilize valve. Check that the spool valve capacity is suitable for the actuator. REDUCED PERFORMANCE ACTIVATED Valve controller performance is reduced due to defective spool valve sensor. Change the spool valve assembly. TOO LOW SUPPLY PRESS FOR 1-ACT ACTUATOR Too low supply pressure level for 1-acting actuator. VALVE REVERSALS TREND WARNING Warning that valve reversals per day has exceeded the limit. SETPOINT REVERSALS TREND WARNING Warning that setpoint reversals per day has exceeded the limit. VALVE TRAVEL TREND WARNING Warning that valve travel per day has exceeded the limit. VALVE REVERSALS WH STABLE SETP WARNING Warning that valve reversals while setpoint is stable, per day, has exceeded the limit

7.5 Notifications 8 TROUBLE SHOOTING Mechanical/electrical defects 1. A change in the valve position setpoint will not affect the position of the actuator ❑ Supply pressure too low ❑ Spool valve sticks ❑ Incorrect configuration parameters ❑ Actuator and/or valve jammed ❑ Signal wires incorrectly connected, no value on display ❑ Circuit boards are defective ❑ Calibration and tuning has not been carried out ❑ Device is in manual mode ❑ Prestage is defective ❑ Device is in fail-safe mode 2. The actuator goes to the end position with a small change of input signal ❑ Tubes between controller and actuator are incor- rect, see Fig. 6 ❑ The parameter settings PFA and ROT are incor- rectly selected. 3. Inaccurate positioning ❑ Spool valve dirty ❑ Too high actuator load ❑ Supply pressure too low ❑ Spool or pressure sensors are defective ❑ Actuator leakage 4. Overshooting or positioning too slow ❑ Change PERF value ❑ Spool valve dirty ❑ Supply air tube too small or supply air filter dirty ❑ Valve sticks ❑ Check leakages in tubes between controller and actuator ❑ Check leakages in mechanical stop screws 5. Error during valve travel calibration ❑ Valve controller is in MAN mode ❑ Check the coupling alignment with the pointer, see Fig. 5. ❑ The parameter settings PFA and ROT are incor- rectly selected ❑ The actuator or valve did not move or was stuck during calibration ❑ Supply pressure too low ❑ Spool valve dirty Display message Description CALIBRATION SUCCESSFULL Position calibration successfully performed. TEST CANCELLED Off-line test has been cancelled. TEST DONE Off-line test has been successfully performed. TEST FAILED Off-line test failed. Repeat the test sequence. CALIBRATION CANCELLED Calibration has been cancelled. PARAMETERS BACKUP RESTORED Parameter backup database has been activated. PT NOT ACTIVATED (Only with position transmitter option). The position transmitter is not energized. 1PT CAL FAILED 1-point calibration failed. Check the mounting of the valve controller. Verify input parameter (range) value. Check rotation parameter (ROT). TUNE OK Tuning has been successfully performed. REDUCED PERFORMANCE DEACTIVATED Spool valve measurement and normal valve control is recovered.

23 9 ND9100H/K00, ND9100H/I00 (WITH LIMIT SWITCHES) 9.1 Introduction 9.1.1 General description ND9100H can be equipped with limit switches. ND9100H/K00 has 2 microswitches and ND9100H/I00 2 inductive proximity switches. Limit switches are used for electrical position indication of the valves and other devices. The switching points may be chosen freely. 9.1.2 Markings The limit switch is provided with an identification plate sticker, see Fig. 26. Identification plate markings from top to bottom are: ❑ Type designation ❑ Electrical values ❑ Enclosure class ❑ Temperature range ❑ Conduit entry ❑ Serial number The type designation is described in Chapter 15. 9.1.3 Technical specifications 9.1.3.1 ND9100H/K00 Microswitch type: OMRON D2VW-5 (05) OMRON D2VW-01 (06) (gold-plated contacts) Protection class IP67 Resistive load: 3A: 250 V AC (05) 5A: 30 V DC 0.4A: 125 V DC 100 mA: 30 V DC/125 V AC (06) Switch accuracy: < 2° Number of switches: 2 Protection class of cover: IP66 (DIN 40050, IEC 60529) Conduit entry: M20 x 1.5 Ambient temperature: -40° to +80 °C (-40° to +176 °F) Weight: Approx. 0.8 kg (1.8 lbs) (limit switches only) Materials: Body: Aluminium alloy, epoxy-coated Internal parts: Stainless steel and polymer Sealing: Nitrile and neoprene rubber 9.1.3.2 ND9100H/I00 Proximity switch: Inductive, diameter 8–14 mm (0.31–0.55 in) Sensing range 2 mm (0.08 in) Protection class IP67 P+F NJ2-12GK-SN (02) P+F NJ2-12GM-N (07) ifm IFC2002-ARKG/UP (56) Other switch types on special order Electrical values: According to switch type Switch accuracy: < 1° Number of switches: 2 Protection class of housing:IP66 (DIN 40050, IEC 60529) Conduit entry: M20 x 1.5 NPT 1/2 = -CE1 R 1/2 = -CE3 Ambient temperature: -40° to +51 °C (-40° to +124 °F)(02) -20° to +62 °C (-4° to +144 °F)(07) -20° to +80 °C (-4° to +176 °F)(56) Fig. 24 ND9100H/K00 layout Fig. 25 ND9100H/I00 layout 2 micro switches terminals M20 x 1.5 2 cams ground 2 proximity terminals M20 x 1.5 ground 2 cams switches potential equalization Fig. 26 Identification plate

Weight: Approx. 0.8 kg (1.8 lbs) (limit switches only) Materials: Body: Aluminium alloy, epoxy coated Cover: Polycarbonate Internal parts: Stainless steel and polymer Sealing: Nitrile and neoprene rubber 9.2 Installing ND9100H/K00 or ND9100H/I00 on a valve controller The limit switch may be installed on an existing valve controller. ❑ If the valve controller is already mounted on an actuator/valve assembly, operate the actuator into the closed or open position. ❑ Remove the cover (100), the pointer (109), the LUI (223), the prestage cover (43) and electron- ics cover (39). ❑ Turn the shaft (311) onto the shaft (11). Fasten the screw (312) using a locking agent such as Loctite. Unfasten the screws (314) in the cam discs (313). ❑ Mount the electronics cover (39) and the housing (300) on the valve controller. ❑ ND9100/K00: Turn the cam discs (313) to avoid contact with the micro switches, if required. ❑ Mount the LUI (223) on the bed (306). ❑ Mount the pointer (109) on the shaft (311). Adjust the limit switch according to 9.4. 9.3 Electrical connections Before connecting the power, make sure that the elec- trical specifications and the wiring meet the installation conditions. See the diagrams in 12.9. Refer to the infor- mation on the identification plate. ND9100/I00: Observe the functioning of the proximity switch; activated when the active face is either covered or free. 9.4 Adjustment The pointer (109) need not be removed for adjustment. When the limit switch is ordered together with the valve and the actuator, the valve controller switches are fac- tory-adjusted. The limits may be adjusted by altering the position of the cam discs (313) on the shaft. The lower switch is activated at the closed limit and the upper switch at the open limit. ❑ With the actuator in the open or closed position, locate the switching point by turning the cam disc so that the switch state changes approx. 5°–6° before the limit. ❑ ND9100/I00: Use the LED indicator or a separate measuring instrument as an aid. ❑ After re-installation of the actuator, first adjust its mechanical limits according to the valve, then the valve controller, and finally the limit switch. ❑ When adjustment is completed, turn the pointer (109) so that the yellow line is parallel with the valve closure member. 9.5 Removal of the limit switches ND9100H/K00 and ND9100H/I00 for accessing the valve controller ❑ Remove the cover (100) and the pointer (109). ❑ Detach the cam discs (313). ❑ Remove the LUI cabling from the circuit board. ❑ Loosen the screws (303) and remove the hous- ing (300). ❑ Remove the electronics cover (39). ❑ Proceed with the valve controller as applicable. ❑ Re-install the limit switch according to 9.2 and check the adjustment according to 9.4. 9.6 Circuit diagrams The internal circuitry of the limit switch is shown in the connection diagrams in 12.9 and on the sticker inside the cover (ND9100H/K00 only). 9.7 Maintenance Regular maintenance of the limit switch is not neces- sary. 10 TOOLS No special tools required. 11 ORDERING SPARE PARTS Spare parts are delivered as modules. The modules available are indicated in 12.1 and 12.2. When ordering spare parts, always include the follow- ing information: ❑ Valve controller type designation and serial number from the ID plate ❑ The code of this manual, the part number, the part name and quantity required Fig. 27 Limit switch adjustment 16 15 14 13 12 11 Open Close

25 12 DRAWINGS AND PARTS LISTS 12.1 Exploded view and parts list, ND9100H Item Qty Description Spare modules 1 1 Housing 8 1 Exhaust cover 9 2 Screw 11 1 Shaft 15 1 O-ring 16 1 Washer 18 1 Wave spring 19 1 Bushing 36 1 Grounding screw 39 1 Electronics cover 42 4 Screw 43 1 Prestage cover 44 1 Screw 47 3 Screw 48 2 Screw 49 1 Screw 100 1 Cover x 107 4 Screw 109 1 Pointer 110 1 Grub screw 120 1 Prestage unit x 139 2 Screw 193 1 Spool valve assembly x 210 1 Valve Controller board 215 1 Communication circuit board x 217 4 Screw 218 1 Support 219 2 Screw 220 2 Threaded spacer 221 3 O-ring 222 1 Isolation part 223 1 Local user interface (LUI) x 228 2 Screw *) Mounting parts: coupling (12), screws (14) 100 39 1 8 110 109 228 215 220 218 210 11 221 15 16 12* 14* 44 43 120 219 139 9 107 48 47 223 42 217 49 193 19 18 222 36

12.2 Exploded view and parts list, ND9100H/K00 and ND9100H/I00 358 357 355 100 110 109 107 313 302 301 300 311 315 303 306 307 308 346 349 348 347 314 350 351 305 304 312 223 36 Item Qty Description 36 1 Grounding screw 100 1 Cover 107 4 Screw 109 1 Pointer 110 1 Screw 223 1 Local user interface (LUI) 300 1 Housing 301 1 Gasket 302 1 Screw 303 4 Screw 304 1 Bracket 305 2 Screw 306 1 Bed of Local User Interface (LUI) 307 3 Screw 308 2 Screw 311 1 Shaft 312 2 Screw 313 2 Cam disc 314 2 Screw 315 6 Terminal block 346 1 Bushing (I00) 347 2 Inductive proximity sensor (I00) 348 1 Fastening plate 349 2 Screw 350 1 Washer 351 1 Screw 355 2 Microswitch (K00) 357 2 Spring washer (K00) 358 2 Screw (K00)

27 12.3 Mounting parts for EC05-14/EJ05-14 actuators, rising signal opens valve 12.4 Mounting parts for B1C/B1J6-20 actuators 38 47 48 49 4 27 15 53 54 ND9100 E_05 - 14 Item Qty Description 4 3 Screw 15 1 Coupling 27 2 Screw 38 2 O-ring 47 1 Coupler socket 48 2 Screw 49 1 O-ring 53 2 Plug 54 1 Plug (EJ only) Item Qty Description 1 1 Mounting bracket 2 1 Ear 3 4 Washer 4 4 Screw 28 4 Screw 29 1 Screw 36 1 Couplings jacket 47 1 Coupler socket 48 2 Screw 53 1 Plug (BJ actuators only) 54 2 Plug Item Qty Description 1 1 Mounting bracket 2 1 Draught piece 3 4 Washer 4 4 Screw 13 2 Screw 14 2 Hexagon nut 28 4 Screw 29 1 Screw 47 1 Coupler socket 48 2 Screw 53 1 Plug (BJ actuators only) 54 2 Plug ND9100 VDI/VDE 3845 ND9100 Neles attachment face attachment face

12.5 Mounting parts for B1C/B1J25-50, B1C502 and B1J322 actuators 12.6 Mounting parts for Quadra-Powr® actuators Item Qty Description 1 1 Mounting bracket 2 1 Draught piece 3 4 Washer 4 4 Screw 27 4 Washer 28 4 Screw 47 1 Coupler socket 48 2 Screw 53 1 Plug (BJ actuators only) 54 2 Plug ND9100 Item Qty Description 1 1 Mounting bracket 2 1 Ear 4 4 Screw 28 4 Screw 29 1 Screw 30 4 Screw 35 1 Adapter plug (QP II 1/S- 6/S only) 35 1 Adapter plate (QP II 2B/K thr. 6_/K) 36 1 Couplings jacket 47 1 Coupler socket 48 2 Screw 53 1 Plug 54 2 Plug Item Qty Description 1 1 Mounting bracket 2 2 Coupling half 3 1 Adapter 4 4 Screw 5 4 Hex nut 6 1 Screw 7 4 Screw 8 4 Washer 9 4 Screw 10 4 Washer 47 1 Coupler socket 48 2 Screw 53 1 Plug 54 2 Plug ND9100 ND9100

29 12.7 Mounting parts for linear actuators of nelesCV Globe 3 4 31 28 48 47 16 54 38 53 39 Item Qty Description 3 2 Washer 4 2 Screw 16 1 Conical plug 28 4 Screw 31 1 O-ring 38 2 O-ring 39 1 Mounting plate 47 1 Feedback lever 48 4 Screw 53 2 Plug 54 1 Plug Set conical plug to the scale according to the stroke

12.8 Mounting parts for linear actuators with IEC 60534 mounting face 1 11 9 14 12 11 3 6 5 19 18 15 8 7 2 4 Scale on this side Stroke 10 - 120 mm 16 17 Feedback lever in horizontal position at mid travel of stroke. Plane in the shaft in this position with feedback lever 54 Allowed travel range 45–90° 45-90° (10 - 120 mm) Stroke Item Qty Description 1 1 Bracket 2 1 Feedback lever 3 1 Filling piece 4 1 Clearance remove spring 5 4 Cross rec head screw 6 4 Washer 7 4 Hexagon screw 8 4 Washer 9 4 Hexagon screw 11 4 Spring washer 12 2 Hexagon nut 14 2 Clamp 15 1 Fixing plate 16 1 Special screw 17 1 Hexagon nut 18 2 Washer 19 2 Hexagon screw 54 2 Plug

31 12.9 Connection diagrams 12.9.1 ND9100H/K05 and ND9100H/K06 11 red 12 13 15 16 14 A K black blue black red OPEN CLOSED Connection diagram shows limitswitch when actuator is in intermediate position. Switch A (upper) is activated at the open limit of the travel and switch K (lower) at the closed limit. Electrical characteristics: OMRON D2VW-5 (K05): 5 A - 30 V DC, 0.4 A - 125 V DC, 3 A - 250 V AC blue OMRON D2VW-01, gold-plated contacts (K06): 100 mA - 30 V DC / 125 V AC Ambient temperature -40 ° ... +80 °C / -40° ... +176 °F

12.9.2 ND9100H/I0 11 blue brown K A Factory adjustment: Active faces of proximity switches are covered when the actuator is in intermediate position. Active face A (upper switch) becomes free at open limit of travel and face K (lower switch) at closed limit. The function can be inverted on site by re-adjusting the cam discs. Sensing distance 2...4 mm, depending on type of switch Supply voltage 8 V DC (Ri 1 kΩ) Current consumption active face free, > 3 mA active face covered, < 1 mA Intrinsically safe II 2 G EEx ia IIC T6. According to CENELEC EN50014 and EN50020. Voltage (Umax), current (Imax), inductance (Li) and capacitance (Ci) according to certificate of switch, see table. PROXIMITY SWITCH - + - blue brown + OPEN CLOSED Type of proximity switch Electrical values Umax Imax Li Ci (V) (mA) (µH) (nF) Ex classification Certificate 13 14 16 150 P+F NJ2-12GK-SN 02 16 52 50 P+F NJ2-12GM-N 07 16 52 50 30 II 2 G EEx ia IIC T6 II 2 G EEx ia IIC T6 PTB 00 ATEX 2049 X PTB 00 ATEX 2048 X

33 12.9.3 ND9100H/I56 11 - + 13 14 16 + - DC DC K A black black black black OPEN CLOSED Factory adjustment: Active faces of proximity switches are free when the actuator is in the intermediate position. Active face A (upper switch) becomes covered at the open limit of the travel and face K (lower switch) at the closed limit. The function may be inverted on site by re-adjusting the cam discs. Connections: Either wire can be connected to + or -. PROXIMITY SWITCH ifm electronic IFC2002-ARKG/UP 2-wire type Sensing distance 2 mm Rated voltage U = 10 - 36 V DC Output current < 150 mA active face covered, LED on Quiescent current < 0.6 mA active face free Ambient temperature -20˚ ... +80 ˚C / -13˚ ...+176 ˚F

12.9.4 Control drawing HAZARDOUS LOCATION Exi barrier Uout max 28 V Iout max 120 mA Pmax 1 W Exi barrier Uout max 28 V Iout max 120 mA Pmax 1 W ND9100H_T SHD Position Transmitter NONHAZARDOUS LOCATION Li 53 µH Ci 22 nF Imax 120 mA Umax 28 V Pmax 1 W Li 53 µH Ci 22 nF Imax 120 mA Umax 28 V Pmax 1 W Class I, Division 1 and 2, Groups A, B, C, D Class I, Zone 0, AEX ia, Group IIB/IIC T4/ T5/T6 T4: Ta = -40…80 °C T5: Ta = -40...65 °C T6: Ta = -40...50 °C FM Notes: 1. The Intrinsic Safety Entity concept allows the interconnection of two Intrinsically safe devices Approved by FM Approvals with entity parameters not specifically examined in combination as a system when: Uo or Voc or Vt ≤ Vmax, Io or Isc or It ≤ Imax, Ca or Co ≥ Ci + Ccable, La or Lo ≥ Li + Lcable, Po ≤ Pi. 2. Dust-tight conduit seal must be used when installed in Class II and Class III environments. 3. Control equipment connected to the Associated Apparatus must not use or generate more than 250 Vrms or Vdc. 4. Installation should be in accordance with ANSI/ISA RP12.06.01“Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations” and the National Electrical Code® (ANSI/NFPA 70) Sections 504 and 505. 5. The configuration of associated Apparatus must be FM Approved under Entity Concept. 6. Associated Apparatus manufacturers installation drawing must be followed when installing this equipment. 7. No revision to drawing without prior Approval by FM Approvals. 8. The enclosure must be bonded. 9. Nonincendive wiring concept: The Nonincendive wiring concept allows the interconnection of devices with Nonincendive wiring parameters: Vmax = 30V, Ci =22 nF, Li =53 µH 10. Nonincendive wiring parameters: Voc or Vt ≤ Vmax, Ca or Co ≥ Ci + Ccable, La or Lo ≥ Li + Lcable. 11. The configuration of Associated Nonincendive Field Wiring Apparatus must be FM Approved under Nonincendive wiring concept. 12. Associated Nonincendive Field Wiring Apparatus manufacturers installation drawing must be followed when installing this equipment. Shield terminal is without any electrical connection. If wanted, shields can be connected to this terminal Shrink tubes are recommended to avoid short-circuits

35 13 DIMENSIONS M6 x 12 4 0.16 29.5 1.16 114 4.49 25 0.98 23.5 0.93 3 0.12 M20 x 1.5 33 1.30 33 1.30 28 1.10 19 0.75 G1/4 35.4 1.39 35.4 1.39 F05-ø50(VDI/VDE3845) ø6/10 G1/8 15.5 0.61 18 0,71 ND9100 19 0.74 14 0.55 26.8 1.05 ø6 ø0.23 33 1.29 27 1.06 35.4 1.39 35.4 1.39 F05-ø50(VDI/VDE3845) 6 0.23 10.5 0.41 13 0.51 20 0.78 26 1.02 M6/10 G1/4 G1/4 G1/4 G1/8 G1/8 G1/8 33 1.29 170 6.69 56 2.20 38 1.49 4 41 1.61 23.5 0.92 29.5 1.16 32 1.25 140 5.51 54.5 2.14 51 2.0 134 5.27 81 3.18 24 0.94 49 1.92 35 1.37 M20 x 1.5 0.15 49.5 1.95 20 0.78 ND9100/I, ND9100/K

37 15 TYPE CODING . INTELLIGENT VALVE CONTROLLER ND9100H 1. 2. 3. 4. 5. 6. 7. 8. 9. ND 9 10 3 H X1 T ND9100H WITH LIMIT SWITCH ND9100H/K00 OR ND9100H/I00 ND 9 10 6 H N K05 1. PRODUCT GROUP ND Intelligent Valve Controller 2. SERIES CODE 9 Series 9000 valve controller with universal shaft and attachment face according to standard VDI/VDE 3845, EC/EJ actuators and old Neles standard. Relevant shaft adapter included in mounting kits. When valve controllers are separate deliveries, shaft adapter kit is supplied. 3. ENCLOSURE 10 Standard IP66 / NEMA 4X enclosure 4. SPOOL VALVE PNEUMATIC CONNECTIONS (S, C1, C2) 2 Low capacity. Stroke volume of actuator < 1 dm3 G 1/4 3 Medium capacity. Stroke volume of actuator 1...3 dm3 G 1/4 6 High capacity. Stroke volume of actuator > 3 dm3 G 1/4 5. COMMUNICATION / INPUT SIGNAL RANGE H 4–20 mA, HART communication. Supply voltage 30 V DC. Load voltage: up to 9.5 V DC at 20 mA corresponding to 475 Ω (maximum voltage drop). 6. APPROVALS OF STANDARD ENCLOSURE VALVE CONTROLLER N No approvals for hazardous areas. M20 x 1.5 conduit entry. Temperature range -40°to +85 °C / -40° to +185 °F. X1 ATEX certification: - II 1 GD, EEx ia IIC T4...T6 T90 °C (EN 50014,EN 50020, EN 50284, EN 50281-1-1) ND91_HX1: Ui ≤ 28 V, Ii ≤ 120 mA, Pi ≤ 1 W, Li = 53 µH, Ci = 22 nF. M20 x 1.5 conduit entry. Temperature range: T4; -40° to +80 °C / -40° to +176 °F T5; < +65 °C / < +149 °F, T6; < +50 °C / +122 °F Not available with any limit switches (8. sign I or K). X2 ATEX certifications: - II 2 GD, EEx ia IIC T4...T6 T90 °C (EN 50014, EN 50020, EN 50281-1-1) ND91_HX2: Ui ≤ 28 V, Ii ≤ 120 mA, Pi ≤ 1 W, Li = 53 µH, Ci = 22 nF. M20 x 1.5 conduit entry. Temperature range: T4; -40° to +80 °C / -40° to +176 °F T5; < +65 °C / +149 °F, T6; < +50 °C / +122 °F. Only with ATEX certified inductive limit switches (e.g. I02, I09). X3 ATEX certifications: - II 3 GD, EEx nA IIC T4...T6 T90 °C (EN 50014, EN 50021, EN 50281-1-1) No Zener Barrier needed. ND91_HX3: Ui ≤ 30 V, Pmax = device limits itself, Li = 53 µH, Ci = 22 nF. M20 x 1.5 conduit entry. Temperature range: T4; -40° to +85 °C / -40° to +185 °F T5; < +75 °C / +167 °F, T6; < +60 °C / +140 °F. U1 FM / CSA certifications: - IS Class I, Division 1, Groups A, B, C, D, T4...T6 - IS Class I, Zone 0, AEx ia, IIC, T4...T6 ND91_HU1: Ui ≤ 28 V, Ii ≤ 120 mA, Pi ≤ 1 W, Li = 53 µH, Ci = 22 nF. M20 x 1.5 conduit entry. Temperature range: T4; -40° to +80 °C / -40° to +176 °F T5; < +65 °C / +149 °F, T6; < +50 °C / +122 °F. Not available with any limit switches (8. sign I or K). 6. APPROVALS OF STANDARD ENCLOSURE VALVE CONTROLLER U2 FM / CSA certifications: - NI Class I, Division 2, Groups A, B, C, D, T4...T6. - NI Class I, Zone 2, Ex nA II T4...T6 No Zener Barrier needed. ND9_HU2: Ui ≤ 30 V, Pmax = device limits itself, Li = 53 µH, Ci = 22 nF. External load resistance 0 – 780 Ω. M20 x 1.5 conduit entry. Temperature range: T4; -40° to +85 °C / -40° to +185 °F T5; < +70 °C / +158 °F, T6; <+55 °C / +131 °F. Not available with any limit switches (8. sign I or K). 7. OPTIONS OF VALVE CONTROLLER T ND9_H_T only: Internal 2-wire (passive) position transmitter. Analogue position feedback signal, output 4–20 mA, supply voltage 12–30 V DC, external load resistance 0–780 Ω. ND91_HX1T and ND91_HX2T: Ui ≤ 28 V, Ii ≤ 120 mA,Pi ≤ 1 W, Li = 53 µH, Ci = 22 nF, external load resistance 0–690 Ω ND91_HX3T: Ui ≤ 30 V, Pmax = device limits itself, Li = 53 µH, Ci = 22 nF, external load resistance 0–780 Ω ND91_HU1T: Ui ≤ 28 V, Ii ≤ 120 mA, Pi ≤ 1 W, Li = 53 µH, Ci = 22 nF, external load resistance 0–690 Ω ND91_HU2T: Ui ≤ 30 V, Pmax = device limits itself, Li = 53 µH, Ci = 22 nF, external load resistance 0–780 Ω M Special corrosion resistant finish. External aluminium surfaces protected by hard anodizing with PTFE. Coating thickness 20 µm. Not painted. Not available with 7. sign G. G Exhaust adapter. 1 x 1/2 NPT thread, Not available with 7. sign M. Y Special construction, to be specified. 8. LIMIT SWITCH TYPE Inductive proximity switches, 2 pcs. IP66 / NEMA 4X enclosure. M20 x 1.5 conduit entry (2 pcs). I02 P+F; NJ2-12GK-SN, 2-wire type, DC; > 3 mA; < 1 mA. Intrinsically safe according to ATEX II 2 G EEx ia IIC T6. Temperature range -40° to +51 °C / -40° to +124 °F. Option of valve controller shall always be X2 or X3 (6. sign). Not applicable to 6. sign "X1", "U1" and "U2". I09 P+F; NCB2-12GM35-N0, 2-wire type, DC; > 3 mA; < 1 mA. Intrinsically safe according to ATEX II 2 G EEx ia IIC T6. Temperature range -25° to +100 °C / -13° to +212 °F. Option of valve controller shall always be X2 or X3 (6. sign). Not applicable to 6. sign "X1" , "U1" and ”U2”. I56 ifm IFC2002-ARKG/UP, 2-wire type, DC; 150 mA, 10 – 36 V DC, leakage current < 0.6 mA. Temperature range -20° to +80 °C / -4° to +176 °F. Not applicable to 6. sign "X1", "X2", "X3", "U1" and "U2". Mechanical micro switches, 2 pcs. IP66 / NEMA 4X enclosure. M20 x 1.5 conduit entry (2 pcs). K05 OMRON D2VW-5; 3 A - 250 V AC, 0.4 A - 125 V DC, 5 A - 30 V DC. Temperature range -40° to +80 °C / -40° to +176 °F. Not applicable to 6. sign "X1", "X2", "X3", "U1" and "U2". K06 OMRON D2VW-01; gold plated contacts, 100 mA - 30 V DC / 125 V AC. Temperature range -40° to +80 °C / -40° to +176 °F. Not applicable to 6. sign "X1", "X2", "X3", "U1" and "U2". 9. OPTIONS OF LIMIT SWITCH Y Special construction, to be specified.

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