NELES ND800 VALVE CONTROLLER

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Neles valve controller, as part of a total final control

element, provides a means of improving process

control accuracy. The ND800 can be used with

either cylinder or diaphragm-type pneumatic

actua-tors for rotary or linear valves. The ND800's unique

ability to obtain better process accuracy lies in its

use of a special control algorithm, derived from a

mathematical simulation model developed by

Metso Automation.

This control algorithm is the basis for achieving

dra-matic improvements in control valve performance

without concurrent changes in the control system.

The ND800 monitors valve performance while on

line, thus allowing for faster and more accurate

valve response.

The ND800 has no internal Iinks between modules.

As a result, it is highly resistant to wear and to the

effects of vibration. All moduls are easily

replacea-ble in the field. The rugged cover protects the unit

from environmental hazards and external abuse.

The ND800 valve controller uses a standard

two-wire 4-20 mA current loop and is HART-compatible

or Fieldbus powered digital signal 0-100 %,

provid-ing for low-cost installation. No external power

sup-ply is needed.

ADVANCED CONTROL PERFORMANCE

Microprocessor-controlled operation provides better accuracy and speed of response when compared with traditional positioners, resulting in reduced process vari-ability.

ECONOMICAL AND EASY TO USE

Low air consumption reduces operational costs.

Easy adjustment and parameter settings with local key-pad and display, or by using auto tunnig HART connec-tion or by Profibus PA.

DIAGNOSTICS

Built-in diagnostic capabilities accessed via the HART communication or Profibus PA connection allow more precise control and predictive maintenance. The ND800 allows predictive maintenance planning for the entire control valve by permitting valve performance on-line monitoring, trend analysis and deviation tracking. Graphic user interface, Windows-based Valve Man-ager software or PDM-configurator for Profibus PA can be linked into General Plant Management Systems.

CE-MARK

The ND800 carries the CE-mark concerning the coun-tries which belong to the European Economic Area.

FEATURES

Fast and accurate response

▫ Operating algorithm developed from a control valve mathematical simulation model guarantees faster and more accurate response to control valve signal change.

▫ Faster response reduces process variability.

▫ Spool-type air valve provides very high air capacity leading to fast response times.

▫ Stable operation, control algorithms and optimization of parameters result in optimal performance of the control valve.

Excellent vibration resistance

▫ Contact-free position feedback and spool valve drive do not depend on mechanical links which can be affected by vibration.

▫ The position sensor is immune to wear and unaffected by dirt.

▫ Feed back signal is free from electrical disturbances. ▫ Rugged construction, small moving masses and

mod-ular design with few parts.

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CONSTRUCTION MODULES

5 65 3 6 7 4 2 1 46 98 40 54 51 5

OPTIONS

▫ Intrinsically safe construction for hazardous areas accord-ing to CENELEC EEx ia IIC T6/T5, BS 6941, ZONE 2 ▫ CSA Class I, Division 1 and 2, Groups A, B, C and D. ▫ FM Class I, Division 2, Groups A, B, C and D. ▫ For Profibus PA approvals are pending

▫ Combination of limit switches; electro-mechanical or inductive proximities.

▫ Low Temperature option -40°C/-40°F. ▫ DIN 43650 A/ISO 4400 connection plugs. ▫ Valve Manager™ software for

point to point communication = HART 11. ▫ PDM/GSD-drivers in connection with Profibus PA

▫ Valve Manager™ software for Hart Multiplexer Networks = HART 12.

▫ Position transmitter, output 4-20 mA. EExi -approval also available.

▫ Pressure gauge kit. ▫ Air set.

▫ Conduit entries 1/2 NPT, M20 x 1.5 and R 1/2. ▫ Conduit male connector for Profibus PA

▫ Gold plated micro switches Profibus PA powered and con-figurated

* Note: All these modules are replaceable.

Part 4 and 98 are only recommended spare parts.

Item Part Name Material

1 Housing Aluminium

2 Cover Aluminium

*3 Prestage Stainless steel/aluminium *4 Spool valve Stainless steel/aluminium *5 Circuit board Std or Profibus PA (3 cards) *6 Position sensor –

*7 Differential pressure sensor –

40 Shaft Stainless steel

46 Protective cover Aluminium

51 Ear Stainless steel

54 Coupling’s jacket Plastic

*65 Pointer Plastic

98 Gasket Rubber

EXPLODED VIEW

PROFIBUS PA

▫ The ND84_ is a fieldbus powered. The configuration can be done either using local push buttons, PDM or some other suitable Profibus PA configurator.

Local keypad and LCD display

▫ Easy to use auto calibration without external devices. ▫ Time-saving self-calibration.

▫ No need for hand-held terminal during installation.

Valve Manager

™

▫ An embedded HART modem on the circuit board and a PDM or other suitable Profibus PA configurator allows remote parameter settings and access to predictive main-tenance system.

▫ Connection; Device description.

▫ Change of an address in connection with Profibus PA ▫ Configuration; Parameter settings.

▫ Characterization; Via Nelprof valve sizing program. ▫ On-Line Monitoring; input current, valve position, actuator

differential pressure and board temperature.

▫ Diagnostics; Control error trend, travel duration histogram and load factor trend.

▫ Testing; Hysteresis & dead band; step response – see separate instructions.

▫ HART Multiplexer Network makes predictive maintenance even easier.

Low air consumption

▫ Air consumption a fraction of that of today’s positioners.

Installation

▫ Suitable for rotary or linear, double-acting or spring-return pneumatic actuators in different sizes.

Enclosure

▫ Beacon position indicator on top.

▫ Metal case provides Faraday cage effect to protect elec-tronics from EMC interference. Protects against mechani-cal damage. Protection class according to IEC IP65 or Nema 4 and 4x.

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TECHNICAL SPECIFICATIONS

General

Suitable for rotary and sliding-stem valves.

Actuator connection in accordance with VDI/VDE 3845 standard.

Action: Double- or single-acting. Turning angle: min. 45° - max. 95°.

Characteristic: Linear, equal percentage or freely defined with 11-point characterization exactly to application requirements through Valve Manager™.

Environmental influence

Operational temp: -20° - +85°C / -4° - +185 °F. Standard -40° - +85°C / -40° - +185 °F. Optional Influence of temperature

on valve position: < 0.05%/°C. Influence of vibration

on valve position: < 1% under 2g 5-150 Hz and 1g 150-300 Hz

0.5g 300-2000 Hz.

Enclosure

Material: Anodized aluminium alloy. Protection class: IP65, Nema 4 and 4x. Mechanical position

indicator: on cover. Pneumatic ports: 1/4 NPT.

Electrical connection: Screw terminals internal for 2.5 mm2. Conduit entry: PG13.5 (1/2 NPT, M20 x 1.5 and R 1/2

as options). Weight: 2.1 kg / 4.6 lbs.

Pneumatics

Supply pressure: 2.5-8 bar / 36-115 psi. Effect of supply

pressure : < 0.2 %/10kPa / 0.14%/psi. Air quality: as defined by ISA S7.3 standard. Capacity

4 bar / 60 psi supply: max. 30 Nm3/h / 18 scfm with 6 mm spool valve

max. 12 Nm3/h / 7 scfm with 2 mm spool valve

Consumption

4 bar / 60 psi supply: 0.4 Nm3/h / 0.24 scfm in steady state position.

PRINCIPLE OF OPERATION

The ND82_ is a 4-20 mA loop-powered microprocessor-based valve controller. A 3.8 mA minimum required input sig-nal allows sufficient energy to begin communication via push buttons on the circuit board or via HART. A 275 HART hand-held terminal or a PC with HART modem (Valve Manager™) can be connected to the terminal strip located in the ND800 itself or in the DCS. Maximum load voltage is 13.5 Vdc with 20 mA input signal.

Using push buttons or HART the control parameters can be adjusted according to the actuator and valve in question. Then auto-calibration can be started via push buttons or HART. Display with three digits and text items shows the operation.

The ND84_ is a fieldbus powered 9 to 32 Vdc microcon-troller-based valve controller. The configuration can be done either using local push buttons, simatic PDM (Process Device Manager) or some other suitable Profibus PA configu-rator.

In control service the microcontroller µC reads input sig-nal (mA), position sensor (α) and differential pressure sensor (p). A change in input signal is detected by control algorithm inside µC. The microcontroller changes the pilot current to one of the prestage (PR) coils. The PR valve lowers the pilot pressure at the end of the spool valve (SV). The spool moves in the direction of low pressure to open the flow to the top of the actuator cylinder and to open the flow out from the other side of the piston. Differential pressure sensor (p) measures the cylinder pressure difference for µC. Increasing pressure difference over the piston moves the piston and rotates the feedback shaft. The position sensor measures the rotation for µC. The microcontroller calculates with the control algorithm a new pilot current until a new position of the actuator pro-portional to the input signal (mA) is reached. In the steady-state position the spool valve (SV) and prestage valve (PR) are closed. C SV C2 C1 PR 4-20mA 1 4 3 2 HART +HART P α µ S 5 8 7 6 1 4 3 2 + – Profibus PA

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Electronics

Supply power: Loop powered, 4-20 mA. No external power needed. Minimum signal: 3.8 mA.

Current max : 100 mA.

Load voltage: up to 13.5 Vdc/20 mA (corresponding 675 Ω.) (Maximum Voltage drop) Supply voltage: max. 30 Vdc

Intrisically safe: Terminals 1 & 3 EEx ia IIC T6 Ui = 28 Vdc Ii = 120 mA Pi = 1 W Ci = 16 nF Li = 0 H Polarity protection: -30 Vdc. Over current

protection: active over 25 mA. Supply power

Profibus PA: 9-32 Vdc Power consumption: 23 mA Electronic current

limitation: I max ≤ 24 mA in case of fault

Performance with moderate

constant-load actuators

Dynamic hysteresis and dead band < 0.8 %. Static hysteresis and dead band < 0.3 %.

Local keypad functions

* Calibration: Automatic / Manual * Control feedback: 0 - 3 (d and b) * Gain configuration: 0.1 - 3 (gain) * Mode selection: Auto/Man/Off.

* Signal: Dir: Direct/reverse acting

* Rotation: Rot: clockwise or counterclockwise to close

* AO: Dead Angle

* SAF: Cut-off safety range (default 2%) * Stroke limitation

Electrical connections

Input signal: 4-20 mA, 2-wire according to ANSI/ISA S50.1.

Approvals

Intrinsically safe; CENELEC EEx ia IIC T5/T6, code X CENELEC pr EN50021:1996

Ex nL IIC T6/T5, Zone 2 IEC79-15, First Edition 1987 Ex nC IIC T6/T5, Zone 2

British Standard: BS6941; 1988

Ex N IIC T6/T5, Zone 2

Intrinsically safe,

code XU CSA Class I, Division 1 and 2,

Groups A, B, C and D. Non-incendive

code NU FM Class I, Division 2, Groups A, B, C and

D certification.

Position transmitter (optional)

Output signal: 4-20 mA (galvanic isolation; 2500 Vdc). 0-100 % via Profibus PA -bus powered Supply voltage: 12 - 36 Vdc, 2-wire.

12 - 24 Vdc, for intrinsically safe. Power from external supply. Intrisically safe: Terminals 2 & 4

EEx ia IIC T6 U_i = 24 Vdc I_i = 120 mA P_i = 1 W C_i = 75 nF L_i = 0 H Accuracy: < 2%

Load resistance: max. 0-1200 Ω.

max. 0-600 Ω, for intrinsically safe. Approvals: Intrinsically safe as option.

CENELEC EEx ia IIC T5/T6.

Limit switches (optional)

Code K06: Micro switches OMRON D2VW-01, gold plated contacts

Ambient

temperature: -40...+85°C/+40...+185F

User interfaces

Local: 3 keys + LCD display.

HART: PC with Valve Manager software.

Device Connection Type: Current Input Terminal impedance (Rtt): min. 310 ohms Terminal capacitance (Ctt): max. 5000 pF Profibus PA: Simatic PDM Configurator

Electromagnetic protection

Protection standards:

EN50081-1 and EN50082-2. IEC 801-2 ESD, level 4.

IEC 801-3 electromagnetic field, level 3. IEC 801-4 Fast Transients, level 4.

CE marking

Electromagnetic

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DIMENSIONS, mm / inch

23 33 33 21 47.5 39.5 (26) 23 23.5 (35.4) (35.4) 13.9 26.8 ø6 M6 / 10 (VDI/VDE 3845) 137 137 29 5 ø 15 4 _{M5 / 18} F05-ø 50 172 44 PG13.5 PG13.5 38 55 70 46 2 ND800/S1 C1 C2 S 1/4 NPT C1 S C2 ND800A - L = 1/2 NPT - I = M20x1.5 - NJ = R1/2 2.76 1.81 0.08 1.73 0.90 2.16 6.77 5.39 1.87 5.39 1.49 0.93 1.55 (1.02) (1.39) 1.14 0.20 0.16 ø0.24 0.83 0.55 (1.39) ø0.59 1.05 1.30 1.30 0.90 (rotary) (linear) ND800/S1/K00 and ND800/S1/I00 C1 S C2 PG13.5 M6/10 1/4NPT M6x12 33 33 23 23 4 (3) 23.5 21 25 117 (35.4) (35.4) F05-Ø50(VDI/VDE3845) (1.39) 0.98 4.60 1.30 1.30 0.90 (0.12) 0.90 0.93 (1.39) 0.16 0.83 47.5 39.5 (26) 137 137 - L = 1/2 NPT - I = M20x1.5 - NJ = R1/2 5.39 1.87 5.39 1.55 (1.02) ND800/S1

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HOW TO ORDER

*) Slash shall always be marked in places shown above. *) Slash shall always be marked in places shown above.

1. 2. 3. 4. 5. *) *)

ND 8 2 2 - / S1 / K 05

-1. sign PRODUCT GROUP

ND Valve controller

2. sign SERIES CODE

3. sign INPUT SIGNAL RANGE

2 4-20 mA

3 Foundation Fieldbus, Bus Voltage 9 - 32 Vdc ( pending )

4

Profibus PA

Bus Voltage 9 - 32 Vdc

Transmission system to IEC 1158-2, Normative parts acc. to EN 50170 volume 2

Not applicable with 6. sign F, X, XU, ZU, NU, T, T1, T2, T3, P.

4. sign SPOOL VALVE CONNECTIONS

(S, C1, C2)

1 Ø 1 mm, double acting, available only _{with EC-actuators} 1/4 NPT, G 1/4 (S4) 2 Ø 2 mm, double action. 1/4 NPT, G 1/4 (S4) 6 Ø 6 mm, double action. 1/4 NPT, G 1/4 (S4) 11 Ø 1 mm, 3-way spool valve, single _{action, available only with EJ-actuators} 1/4 NPT, G 1/4 (S4) 21 Ø 2 mm, 3-way spool valve, single _action. 1/4 NPT, G 1/4 (S4) 61 Ø 6 mm, 3-way spool valve, single _action. 1/4 NPT, G 1/4 (S4)

5. sign ACTION

Double action, without sign. Specify 4. sign 1, 2 or 6. In connection with B_CU6,B_CU9, B_CU11, EC10 and EC12 actuators 4. sign must be 2. In connection with EC05 and EC07 4.sign must be 1.

Single action, without sign. Specify 4. sign 11, 21 or 61. In connection with B_JU8, QP1, QP2, EJ07 and EJ10 actuators 4. sign must be 21.In connection with EJ05 4.sign must be 11. Not applicable with double acting actuators.

A

Linear motion, applicable to Metso Automation D/R-series diaphragm actuator.

Not applicable to attachment face according to standard VDI/ VDE 3845 (6. sign S1).

21A is for RA and DA.

61A is for RB, RC, RD, RE and DB, DC, DE.

Also applicable to linear actuators according to IEC 60534-6-1 with own linkage set. Specify 4. sign 2, 6, 21 or 61 according to stroke volume, specify the stroke (20-60 mm or 60-100 mm).

*) 6. *)

ND 8 2 2 - / S1 / K 05

-6. sign OPTIONS

Standard, IP 65 enclosure, NEMA 4 and 4X. Built-in display and local keypad. PG 13.5 conduit entry.

Temperature range -20°C... +85°C / -4°F... +185°F.

Load voltage: up to 13.5 Vdc at 20 mA corresponding 675 Ω since Rev. 5.0 (maximum voltage drop). Supply voltage ≤ 30 Vdc. C Low temperature construction -40°C/-40°F._{High limit for temperature according to option in question.} F Valve controller without HART. Available with standard, X, XU, ZU _{and NU constructions.}

X

Intrinsically safe construction.

CENELEC EEx ia IIC T5/T6 certification (EN 50014, EN 50020). CENELEC draft prEN 50021, Ex nL IIC T5/T6, Zone 2; IEC79-15, Ex nC IIC T5/T6, Zone 2;

British Standard: BS 6941, Ex N IIC T5/T6, Zone 2. Temperature range -20°C... +75°C/-4°F... +167°F. T5, when temp. ≤ + 75°C/+167°F; T6, when temp. ≤ +50°C/+122°F. Load voltage up to 13.5 Vdc / 675 Ω / 20 mA.

(Maximum voltage drop/supply voltage ≤ 30 Vdc.)

XU

CSA Class I, Divisions 1 and 2, Groups A, B, C and D certification. 1/2 NPT conduit entry.

Temperature range –20°C... +70°C/-4°F... +158°F. Load voltage max. 13.5 Vdc / 675 Ω / 20 mA.

ZU

CSA Class I. Division 2, Groups A, B, C and D certification. 1/2 NPT conduit entry.

Temperature range –20°C... +70°C/-4°F...+158°F. Load voltage max. 13.5 Vdc / 675 Ω / 20 mA. No Zener Barriers needed.

NU

FM Class I. Division 2, Groups A, B, C and D certification. 1/2 NPT conduit entry.

Temperature range -20°C...+70°C/-4°F...+158°F. Load voltage max. 13.5 Vdc / 675 Ω / 20 mA. No Zener Barriers needed.

T

Position transmitter. Analog position feedback signal, output 4-20 mA.

Load voltage up to 13.5 Vdc / 675 Ω / 20 mA. (Maximum voltage drop/supply voltage ≤ 30 Vdc.)

T1 Position transmitter. Analog position feedback signal, output 4-20 mA. Intrinsically safe construction CENELEC EEx ia IIC T5/T6. (passive). Available only with option X.

T2

Position transmitter. Analog position feedback signal, output 4-20 mA. Intrinsically safe construction. CSA Class I, Groups A, B, C and D. (passive). Available only with options XU or ZU.

T3 Position transmitter. Analog position feedback signal, output 4-20 mA. Intrinsically safe construction. FM Class I, Division 2, Groups A, B, C and D. (passive). Available only with option NU. S1

Valve controller attachment face according to standard VDI/VDE 3845, equipped with an H-clip. When valve controllers are separate deliveries, VDI/VDE 3845 ear is supplied.

Not applicable to globe valve diaphragm actuators (5. sign A). S4 Valve Controller attachement face only for EC/EJ-actuators _{without air tubings.}

A

Pressure gauges, scale bar/psi/kPa, basic material brass, nickel plated housing stainless steel, glycerine filled.

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*) Slash shall always be marked in places shown above.

*) 6. *) 7. 8.

ND 8 2 2 - / S1 / K 05

-6. sign OPTIONS

P

Connection plug according to DIN 43650A / ISO 4400 (PG11). Not available with options X, XU, ZU, NU, XT1, XUT2, ZUT2, NUT3 and accessories L, I, NJ.

P1 Connnection plug male eurofast, Weidmuller 945565, PG13,5 / M12 Available only with sign 3. and 4.

P2 Connection plug male minifast,Turck RSFV48 / 13,5 Available only with sign 3. and 4.

Y Special construction, to be specified.

7. sign LIMIT SWITCH CODE

I Inductive proximity switches, defined with 8. sign. K Micro switches, defined with 8. sign.

8. sign LIMIT SWITCH TYPE

Inductive proximity switches (I), 2 pcs.

01

P+F; NJ2-12GK-N. DC > 3 mA; < 1 mA.

Intrinsically safe according to EEx ia IIC T6 (CENELEC EN 50014, EN 50020), 2-wire type.

Option of valve controller shall always be X (6. sign). 9. sign always X.

Temperature range -20°C... +65°C / -4°F... +149°F. 56

ifm IFC 2002-ARKG/UP. DC; 150 mA, quiescent current < 0.6 mA, 2-wire.

Not applicable to option X, XU, ZU, NU, P Temperature range -20°C... +80°C / -4°F... +176°F.

Micro switches (K), 2 pcs

05 OMRON D2VW-5, standard._{Not applicable to option X, XU, ZU, NU,}

06 OMRON D2VW-01, gold plated contacts, 30 V DC/125 V AC, 100 mA Not applicable to options X, XU, ZU, NU, P.

06B

OMRON D2VW-01, gold plated contacts 30 Vdc, I < 100 mA Bus Powered, no external power needed

Available only with sign 3. and 4.

*) *) 9.

ND 8 2 2 - / S1 / K 05

-9. sign OPTION OF LIMIT SWITCH

-Standard IP 65 enclosure. NEMA 4 and 4X. PG 13.5 conduit entry (4 pcs).

Temperature range according to switch type.

X Intrinsically safe construction. DEMKO EEx ia IIC T6 certification(EN 50014, EN 50020). Temperature range -20°C... +65°C / -4°F... +149°F.

P Connection plug according to DIN 43650A/ISO 4400 (PG11). Not available with options X, XU, ZU, NU and accessories L, I, NJ. Y Special construction, to be specified.

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Metso Automation, Field Systems Division

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

North America, 42 Bowditch Drive, P.O. Box 8004, 01545 Shrewsbury, USA. Tel. int +1-508-852-3567. Fax int. +1-508-852-3562 Latin America, Av. Central, 181- Chácaras Reunidas, 12238-430, São José dos Campos, SP BRAZIL.

Tel. int. +55 12 3935-3500. Fax int. +55 12 3935-3535

Asia Pacific, 501 Orchard Road, #05-09 Wheelock Place, 238880 Singapore. Tel. int. +65 735 5200. Fax int. +65 735 4566 www.metsoautomation.com