neles valvguard™ system series vg800b -...

Neles ValvGuard™ SystemSeries VG800BRev. 2.0Installation, Maintenance andOperating Instructions

9 VGB

70 en • 12/2009

2 9 VGB 70 en

READ THESE INSTRUCTIONS FIRST!These instructions provide information about safe handling and operation of the device.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 Contents1 INTRODUCTION.............................................. 3

1.1 General .................................................. 31.2 Compatibility .......................................... 31.3 Basic functionality .................................. 31.4 Communication ...................................... 31.5 Principle of operation ............................. 31.6 Markings ................................................ 51.7 Technical specifications ........................ 51.8 Recycling and disposal ......................... 61.9 Safety precautions ................................. 7

2 MOUNTING AND INSTALLATION.................. 72.1 General .................................................. 72.2 Mounting on Metso actuators

with VDI/VDE mounting bracket............. 72.3 Mounting on linear actuators with Metso

or IEC60534 mounting face..................... 82.4 Mounting of the Remote Communication

Interface (RCI) module........................... 82.5 Piping and air supply ............................. 82.6 Electrical connections............................ 82.7 Additional instrumentation ................... 11

3 COMMISSIONING AND OPERATION .......... 113.1 Using Local User Interface (LUI) ......... 11

4 USING METSO DTM ANDHART COMMUNICATION ............................. 144.1 User Interface ...................................... 144.2 Decommissioning ................................ 24

5 MAINTENANCE............................................. 245.1 RCI unit ................................................ 24

6 SAFETY MANUAL......................................... 257 TROUBLE SHOOTING.................................. 268 ERROR CODES............................................. 269 TOOLS........................................................... 2610 ORDERING SPARE PARTS ......................... 26

11 DRAWINGS AND PARTS LISTS .................. 2811.1 Exploded view and parts list, VG800B. 2811.2 Mounting parts for B1JU8-322 actuators 2911.3 Mounting parts for Quadra-Powr®, ST, SP

and Valv-Powr® actuators ................... 2911.4 Mounting parts for linear actuators with

IEC 60534 mounting face..................... 3011.5 Mounting parts for limit switches for

EX d enclosure..................................... 3112 DIMENSIONS................................................. 32

12.1 VG800B................................................ 3212.2 RCI ....................................................... 32

13 CONFIGURATION PARAMETERS............... 3314 TYPE CODING............................................... 34

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1 INTRODUCTION

1.1 GeneralThese instructions describe the Metso’s Neles ValvGuardsystem for use in safety related on/off duty.

ValvGuard comprises two components, the Remote Com-munication Interface (RCI), which is installed close to thecontrol room and the VG800B a 'smart field device,' whichis mounted on the field located ESD valve actuator. Thegeneral arrangement is shown in Fig. 1.

ValvGuard is a safety system, great care must be takento properly understand the final installation require-ments before commencing installation of any compo-nent. Failure to do this may result in a faulty installationand improper operation.

1.2 CompatibilityValvGuard may be used with any cylinder or diaphragmspring return actuator, but it is recommended for usewith the Metso range of actuators since full designapplicability is known and mounting parts are available.See Chapter 2.

1.3 Basic functionalityValvGuard operates at two independent levels, thesafety level and the diagnostic level.

1.3.1 The safety circuitThe 0/24 VDC output signal from plant safety-PLC orequal safety system is connected to the RCI within thecross connection control cabinet. The RCI output iswired to the VG800B in the field using standardcabling. Within the VG800B a spool valve controls theair supply to the valve actuator. The spool valve is ener-gized by the 24 V DC supply (ESD valve open) and isde-energized (ESD valve closed) at 0 V. The layout isshown in Fig. 3.

1.3.2 The diagnostic functionProgramming and data collection functions are control-led by the micro controller (µC). The µC takes its powerfrom the normal state 24 V DC supply. In the 0 V condi-tion the µC is inactive. µC functionality is configuredremotely by a software package called Metso DTM.Certain functions can also be controlled locally by useof push buttons mounted within the VG800B casing. Itis necessary to remove the cover of the VG800B fieldunit to do this. Please refer to Fig. 13.

1.4 CommunicationRemote communication from the control room with theVG800B is possible via HART protocol and a PC fittedwith a suitable modem wired to the RCI.

There is a second 'real-time' communication systemwhich enables the µC to send messages to the RCI andfurther on to the plant DCS system. This is described later.

1.5 Principle of operation

1.5.1 The remote communication interface (RCI)

The Remote Control Interface (RCI) is mounted in thecontrol cabinet of the plant safety PLC and connectedto it's output.

The nominal safety PLC output is 24 V but a 15 % vari-ance on this is acceptable.

The RCI has two functions:

❑ To transmit HART signals to and from theVG800B field device. A suitable HART modem/interface is connected between the PC and theRCI to facilitate this.

❑ To receive real-time signals from the VG800Bfield unit. These signals are displayed on threeLight Emitting Diodes (LEDs) mounted on theRCI housing. The RCI also has relay potentialfree contact outputs which correspond with the

Fig. 1 ValvGuard system

SAFE AREACONTROL ROOM

ELECTRICAL ROOM

ALARM / OK

TESTINGDCS

SAFETY PLC

HART

COMMUNICATION

RCI

HAZARDOUS AREA

VG800B

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LED display. Three signals are given, refer to Fig. 3.Green = OK Yellow = Test Red = Alarm

1.5.2 The VG800B field deviceIn service the 24 V DC supply powers the prestage(PR) redundant coils (A and B) which controls the airpressure on the spool valve (SV) in such a position thatkeeps the SV return spring compressed, Fig. 4. The SVis arranged so that the actuator air supply is maintainedon the actuator piston in opposition to the actuatorreturn spring thereby keeping the ESD valve open orclose. When an emergency occurs, the power at thecontrol room is switched to zero, this de-energizes theboth PR coils and vents the pressure on the SV causingthe SV return spring to change the SV position to shutoff the air supply and to vent the air above the actuatorpiston. The actuator spring then closes the ESD valve.When power is restored the PR coils are energized and

air pressure once more causes the SV to compress theSV return spring. Air supply pressure is again appliedto the actuator piston which opens the ESD valve.

It is also possible for the µC to operate the ESD valve. Thisis done during commissioning and diagnostic testing. TheµC takes power from the 24 V DC supply which is appliedto PR coil (B). During a test the µC is able to isolate PR coil(B) from the power supply causing the voltage to drop tozero. This causes the same valve closing action asalready described in respect of 0 V on PR coils (A and B)since these are in parallel. As the ESD valve begins toclose the position sensor monitors the valve position.When the valve reaches the pre programmed travel pointthe µC once again energizes the PR coil (B), whichcauses the ESD valve to open or close again. During par-tial closure testing the µC monitors the output from theposition sensor and compares this with the actuator airpressure. If the relationship between these parametersshows an error the test is aborted.

Fig. 2 VG800B hardware

ND800

HART

HART

10 Hz PWM

Leakage sensor

CPU

Display

Pushbuttons

DigitalI/O

PSBTF

control

SFcontrol

ADC

Pneumaticblock

Positionsensor

Pre

ssure

senso

r

PWMamplifier

RCI out

0/24 V DC

Amplifier board

NOTE:When a test is running, and the yellow LED indicates atest, simultaneously the green LED is lit and the corre-sponding relay indicates an OK status. After the test (ifthe test has failed or there is some other error) the redLED will light and the corresponding relay indicate analarm. See detailed function from Fig. 8.

Fig. 3 Remote Communication Interface (RCI)

RCI

24 / 0 V

HART

10 Hz PWM

HART

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

Coil A Coil B PR

SV

Controlcircuit

toactuator

0 / 24 V DC

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1.5.3 Leakage detection (option)The leakage detection system for ValvGuard system isan option. It is applicable for both valve configurations:fail safe action open or close. The ValvGuard fielddevice constantly monitors leakage sensor signal andstores measurement data into its non-volatile memorywhen the valve is in closed position. The collected datacan be viewed as a trend using the Metso DTM soft-ware. Leakage signal trend is shown in millivolts asfunction of measured trend time.

The hardware consists of a sensor head and a signalconditioner board. The conditioner is an add-on circuitboard that is installed inside the field device case. It isattached to a connector provided. The transducer isequipped with a 1...3 meter shielded cable asrequested. The leakage detection hardware is shown inFig. 2.

The sensor is preferably placed on valve body, proxim-ity to a valve seat. This gives the best leakage detectionsensitivity. Other option is to attach the transducer onthe actuator bracket, on a separate bar or on a waveguide. Although this technique somewhat attenuatesthe leakage noise, it doesn't substantially reducedetection performance.

The transducer is mounted on a flat, machined surface.To ensure minimal signal attenuation and good signalcoupling, any paint or rust should be removed from thecontact area. Also, silicon grease or glue between sen-sor head and metal surface will significantly enhancesignal coupling. It should be noted that surface temper-ature of the mounting position must not exceed+125 °C (+257 °F).

Leakage detection performance depends on severalfactors. Those factors include sensor placement, valveconfiguration, process environment (flow media, pres-sure level), background noise etc. Detection thresholdis mainly determined by pressure level, valve size andflow media. Higher the pressure difference across thevalve lower the detectable leakage. The minimumdetectable leakage order of magnitude is some litresper minute, at its best around 1 litre/minute. This sens-ing level is adequate to locate damaged valves thatrequire maintenance actions.

The flow (or leakage) inside a valve must be turbulent inorder to emit high frequency noise and thus be detect-able by the transducer. Turbulent flow occurs morereadily with gas than liquid flow. This behaviour alsocauses apparently inconsistent result: The valve isclosed and some leakage is detected. Then whenslowly opening the valve, at some point leakage signaldrops abruptly even though the flow is increasing. Thisis happening because the flow becomes laminar andhigh frequency acoustic emission ceases.

1.6 MarkingsThe VG800B field device is provided with an identificationplate, see Fig. 5. Identification plate markings are:

❑ Type designation of the field device❑ Input values❑ Enclosure class❑ Operational temperature❑ Approvals❑ Supply pressure range❑ Manufacturing series number❑ CE mark

Alternative markings on the optional plate, Fig 6

❑ Filter regulator❑ Conduit entry

Manufacturing series number

1.7 Technical specifications

1.7.1 GeneralValvGuard may be used with any cylinder or diaphragmspring return actuator, but it is recommended for use withthe Metso range of actuators since full design applicabil-ity is known and mounting parts are available. See theSection on 'Mounting for Further information or contactyour local Metso’s Automation business office.

Fig. 5 Identification plate

Fig. 6 Optional plate

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1.7.2 SpecificationsGeneral

The VG800B valve controller is suitable for rotary andsliding stem valves.

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

Action: Single acting

Turning angle: Min 45°, max 95°

Environmental influence

Operational temp.: -40°...+85 °C (-40°...+185 °F)

Enclosure

Material: Anodized aluminium alloy

Protection class: IP65, NEMA 4 and 4X

Pneumatics ports: 1/4 NPT

Electrical connection:Screw terminals internals for 2.5 mm2

Conduit entry: PG 13.5 M20 x 1.5 (with adapter) 1/2 NPT (with adapter)

Weight: 3.6 kg (7.9 lb)

Pneumatics

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

Air quality: Acc. to ISO 8573-1:2001Solid particles: Class 5(or 3-5 µm filtration)Humidity: Class 1(dew point 10 °C/50 °F belowminimum temperature)Oil class: 3 (or <1 ppm)

Capacity: At 4 bar (58 psi) supply pressure:feed 36 Nm3/h (22 scfm),exhaust 41 Nm3/h (24 scfm)

Maximum airconsumption: At 4 bar (58 psi) supply pressure:

actuator pressurized 0.44 Nm3/h(0.26 scfm),actuator vented 0.64 Nm3/h(0.38 scfm)

Electronics

Supply voltage: Max 28 V DC

RCI-Input: Min 21 V DC, I = 100 mA, max 30 V DC

Polarity protection: -30 V DC

Voltage range: 16.5...28 V DC (I-load ~20 mA)

Maximum current: 100 mA (RCI-VG800)

Two (SPDT) relay outputs of RCI-unit: 24 V DC, 0.5 A

RCI module is located at electric cross connectionroom (safety area).

Local keypad functions

Calibration: Automatic / Manual

Mode Selection: Auto / Off

Testing: Partial valve test / pneumatic test

Power-up selection:Off / On / Cal

Normal position: Close / open

Rotation: Rot: clockwise / counterclockwise

Protect (HART write protection):Off / On

Actuator type: Rotary / linear

Approvals

Flame proof, (B1) ATEX II 2 G Ex d IIC T5...T6 certificationaccording to EN60079-0, EN60079-1

Explosionproof, (B2) FM certification,Class I, Division 1 and 2, Groups B, C and D,Class II and Class III, Groups E, F and G,FM 3600, 3615, 3810.

(B3) CSA certification,Class I, Divisions 1 and 2, Groups B, C, D,Class II, Division 2, Groups E, F and Gand Class III.CSA C22.2 no142-M1987/CSA C22.2no30-M1986/CSA C22.2 no 25-1966.

TÜV: Approved up to SIL 3968/EL 115.01/05

User interfaces

Local: 3 keys + LCD display

HART: PC with HART modems togetherwith Metso DTM orHART Handheld with DD for VG800

Electromagnetic protection

Protection standards:Immunity acc. to EN 61000-6-2 (2001)Emission acc. toEN 61000-6-3 (2001)IEC 801-3 electromagnetic field, level 3IEC 801-4 Fast Transients, level 4

CE marking

89/336/EECElectromagnetic compatibility

94/9/ECATEX

1.8 Recycling and disposal Most ValvGuard parts can be recycled if sortedaccording to material. Most parts have material mark-ing. A material list is supplied with the device. In addi-tion, separate recycling and disposal instructions areavailable from the manufacturer. A field device can alsobe returned to the manufacturer for recycling and dis-posal against a fee.

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1.9 Safety precautions

2 MOUNTING AND INSTALLATION

2.1 GeneralEach emergency valve will be equipped with an individ-ual ValvGuard system including the VG800B field deviceand the Remote Communication Interface module (RCI).

The ValvGuard system comprises a full safety loop fromthe plant safety system output module (cross connec-tion control cabinet) down to the VG800B field device.

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

2.1.1 Mounting of VG800B field deviceWhen the VG800B field device is supplied with a valveand actuator the whole unit will be supplied as speci-fied by the customer for his installation. WhenValvGuard is ordered separately the mounting partsmust be ordered at the same time.

Example Order: (BJ 13)-Z-VG800B. (See type coding inlater section).

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

When mounting VG800B field device to an other manufac-turer's actuator, special mounting brackets are needed.Metso may be able to help in this process

2.2 Mounting on Metso actuators with VDI/VDE mounting bracket

See drawings in Section 11.2 and 11.3.

❑ Allow the actuator spring to be in the 'extended'position.

❑ Set the actuator's position indication arrow on theindicator cover to indicate a 'closed' valve for anESD valve (or 'open' for a vent or blow-off valve).Attach the draught piece (2) to the indicator coverin the position shown in position Fig 7. Secure thedraught piece by tightening the retaining screw.The screw should be locked by the use of Loctiteor similar thread locking compound.

❑ Attach bracket (1) to the VG800B field device.❑ Attach Bracket (1) to the actuator. The coupling on

the Shaft of the VG800B (40) must be engaged withthe draught piece (2) shown in Fig 7.

CAUTION:Opening the cover of VG800B field device enclosureis allowed for authorized and trained persons only!Misuse of powered VG800B field device may cause adangerous situation.

CAUTION:Do not exceed the permitted values!Exceeding the permitted values marked on the valve con-troller may cause damage to the controller and to equip-ment attached to the controller and could lead touncontrolled pressure release in the worst case.Damage to the equipment and personal injury may result.

CAUTION:Do not remove or dismantle a pressurized controller!Removing or dismantling a pressurized prestage, spoolvalve or pressure sensor of an VG800B leads to uncon-trolled pressure release. Always shut off the supply airand release the pressure from the pipelines and equip-ment before removing or dismantling the controller.Otherwise personal injury and damage to equipmentmay result.

WARNING:During automatic or manual calibration the valveoperates between open and closed positions.Make sure that the operation does not endangerpeople or processes!

ATEX NOTE:Follow EN60079-14 and EN60079-17 for installationand EN60079-19 for repair of the device.

ATEX WARNING:Electrostatic charge hazard!The identification plate is non-conductive.Clean with a damp cloth only!

Ex d WARNING:Do not open the device when energized!Explosion protection is lost.Electromagnetic immunity is reduced, valve maystroke.

Ex d WARNING:Use a cable gland with suitable Ex d certification.For ambient temperature over 70 °C / 158 °F use aheat resistant cable and cable gland suitable for atleast 90 °C / 194 °F.

NOTE:Avoid earthing a welding machine in close proximityto an VG800B valve controller.Damage to the equipment may result

Fig. 7 Mounting on Metso actuator with VDI/VDEmounting face

C2

S

C1

40

The mark on the shaftshould stay in this sector

Shaftmark =yellow dot

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2.3 Mounting on linear actuators with Metso or IEC60534 mounting face

See drawings in Sections 11.4 and 11.5.

❑ Temporally fit an Filter/regulator air set to theactuator port so that the valve can be stroked toany position. Set actuator to its mid stroke posi-tion. (See serial plate for the actuator/valveassembly stroke length.

❑ Assemble the feedback lever arm to the control-ler input shaft. Make sure that the lettering onarm faces towards the VG800B.

❑ Assemble the controller mounting bracketloosely to the slotted leg of the actuator. Ensurethat the mark on the shaft and the feedback leverarm operate in the quadrant shown.

❑ Ascertain dimension "A" for the stroke of theactuator as mentioned above. Now place a markon the lever arm at this distance from the centreof the VG800B input shaft. When assembled theactuator pin shown in Section 11.4 and 11.5 mustcorrespond with this mark.

❑ Mount VG800B loosely on to its mountingbracket.

❑ Adjust the VG800B mounting bracket and theand the VG800B itself so that it is "square" to theactuator in all planes. At the same time the feed-back lever must be horizontal (at 90° to the actu-ator centre line).

❑ Tighten bracket fixing screws.❑ Adjust the VG800B on its bracket so that the distance

"A" (as marked in earlier) is maintained between theVG800B shaft centre and the actuator pin.

❑ Tighten all fixing screws/bolts, then re-check thatthe VG800B mounting complies with previoussteps. Carefully stroke the valve and ensure thatthe actuator pin does not foul the VG800B case.(It may be necessary to shorten this pin in thecase of small actuator with a stroke of 1.25").

❑ Assemble the spring to the feedback arm asshown.

❑ Apply grease to the contact point of the pin andthe lever arm.

❑ Finally stroke the actuator and check for properfunction of the assembly.

2.4 Mounting of the Remote Communication Interface (RCI) module

The Remote Communication Interface (RCI) module isa DIN rail mountable device having approximately thefollowing dimensions:

104 mm (H) x 110 mm (D) x 16 mm (W) or (4.1" x 4.3" x 0.6").

The RCI module can be mounted in the same electricalcross connection control cabinet, where the plantsafety-PLC or other safety system is mounted.

If there is not enough space in the control cabinet forthe RCI modules a separate cabinet is required to pre-vent any damages.

Note that the RCI modules must always be located on

the safe side of the plant (e.g. in non hazardous area).

A principle mounting arrangement of RCI module andVG800B field device can be seen in Fig. 8.

2.5 Piping and air supply

Table 1 provides the recommended tube sizes inaccordance with actuator sizes. Tube sizes are theminimum values allowed. For supply air choose a tubeone size bigger. Operating times can be monitored bythe Metso FieldCare.

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

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

For the pipe threads liquid sealants, such asLoctite 577, are recommended.

The air supply must be clean, dry and oil-free instrumentair, see Section 1.7.3. Air supply shall be connected allthe time after the shipping plugs have been removed.

2.6 Electrical connectionsThe VG800B is powered by a standard 24 V DC. HARTis carried over the supply voltage between the RCI andthe VG800B. It is recommended that the HART modemis connected to the RCI, where the connection is pro-tected against short-circuiting.

The input signal cable is led through a M20x1.5 conduitentry (1/2" NPT for VG_B2_ and VG_B3_). Connect theconductors to the terminal strip according to Fig. 9.Check the voltage drop from Fig. 10.

Check the wire polarity before connection. The control-ler has 30 V polarity protection. EMC requirementsrequire earthing of the input cable shield either at theDCS end or at the VG800B end, but never at both ends.

Cable shall be one or more single-twisted pair shieldedor multiple-twisted pair with overall shield. Unshieldedcable may be used if it is demonstrated that ambientnoise or crosstalk does not affect communication

Contacts of relays in the RCI unit:

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

NOTE:The RCI unit is not an isolator!

CAUTION:Do not exceed the permitted supply pressure ofthe VG800B!

NOTE:Too much sealant may cause faulty operation of thecontroller. Sealing tape is not allowed.Ensure the cleanliness of the air piping.Always use a filter regulator with 5 µm filtration or better.

NOTE:Without earthing the valve position measurement mayhave interference in a strong magnetic field.

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Fig. 8 Connection diagram

HARTMODEM

VG800BHART

FILTERINPUTREGULATOR

R

1MGND

PGND

RCI

TESTING

OK/ALARM

6

5

4

3

2

1

8

9

12

11+

–

Vin

1

3

10

–

+1

PWMDEMODULATOR

yellow

red

green

Fig. 9 Terminals in VG800B

86

57

42

13

HART-connection (ø 2,3 mm) Earth connection

24 V DC from RCI

Fig. 10 Voltage drop for cabling

Maximum cable lenght

020406080

100120140160180

0 500 1000 1500 2000 2500 3000

Cable lenght [m]

Cab

le lo

op r

esis

tanc

e [Ω

/km

]

Table 1 Piping

ActuatorPiping

Cu/Stainless steel Cu/Stainless steel

B1J B1JAStroke vol. dm3/

in3 NPT 3/8 1/2 10 12

8 0.9/55 3/810 1.8/110 x x12 3.6/220 1/2 x x16 6.7/409 x x20 13/793 3/4 x (x) x (x)25 27/1648 x (x) x (x)32 53/3234 1 (x) x x322 106/6468 x x 61

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Fig. 11 Operation directions and air connections

SINGLE-ACTING ACTUATOR

SINGLE-ACTING ACTUATOR

1. Spring to close valve, e.g. B1J

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

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

Default setting:ASt = OFFrot = ccC (pressure relief rotation to counterclockwise)Pro = OFFnoP = CLOAct = rotdisplay = 100 %

2. Spring to open valve, e.g. B1J

Setting:ASt = OFFrot = cC (pressure relief rotation to clockwise)Pro = OFFnoP = CLOAct = rotdisplay = 100 %

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

C1

C2

S

C1

C2

S

C1

C2

S

ASt: defines position of unit to which it remains after voltage failure, re-booting or when voltage is connectedfor the first time to the unit (see 3.1.1.4 Automatic start-up function ).

rot: rotation direction when pressure is relieved from cylinder.

The commisioning modes are:

OFF On = AUTO CAL

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2.7 Additional instrumentationIf additional instrumentation is needed for speedrequirement please contact Metso’s Automation busi-ness for detailed information.

3 COMMISSIONING AND OPERATIONVG800B is commissioned and configured with the helpof local user interface (LUI), graphical user interface orMetso FieldCare.

3.1 Using Local User Interface (LUI)The LUI consist of three push buttons and a LCD dis-play. The status of VG800B can be seen from the dis-play. The keyboard and display of the VG800B areshown in Fig.12. Operations and display are controlledby +, - and r keys.

Two setting functions are available: m or c.Both of these names refer to the function to be adjusted orchanged. In the AUTO or OFF mode the display indicatesthe valve travel in percentage. Default value from factory isOFF. In case of some error, the error code is displayed inthe LCD display. By pushing r button the error code iscleared, and the mode and valve opening is displayedagain. By pushing + and - for 5 seconds, the user entersthe menu described in the Fig.13. All the different optionsare blinking in the menu and + and - buttons scrollthrough the different options. From the menu the user canchange the operation mode of the device (AUTO/OFF),start a valve test or an actuator pressure test, start anautomatic or a manual calibration procedure, set autostart after re-booting or at power-up, select the rotationdirection of the valve and set the HART write protection On

or OFF. By pushing the + and - shortly the user can safelyreturn to the previous level or abort a test or a calibrationprocedure.

The local user interface (LUI) keyboard can also be totallydisabled with a parameter setting (Section 3.1.1.9).

If a function is not allowed a text 'Err' is displayed in theLCD. This could happen for instance if trying to start thecalibration in the automatic mode.

3.1.1 VG800B functionsSee keyboard operations Fig. 13

VG800B includes following keyboard functions:

Mode setting = m

Testing = tSt

Calibration = c

Auto Start = ASt

Normal Position = noP

Rotation = rot

Protection = Pro

Actuator type = Act

3.1.1.1 Mode settingIn the OFF mode calibration is allowed but not testing.RCI's error signal is lit. In the AUTO mode testing isallowed but not calibration. RCI's OK signal is lit.

3.1.1.2 TestingThe VG800B has two kind of diagnostic tests: Thepneumatic test Pt checks the proper operation of thepneumatics of the field device while a valve stroke testSt checks the operability of the whole valve assemblyby partial stroking the valve as configured from the nor-mal position.

3.1.1.3 CalibrationBy pressing the r an automatic valve travel measure-ment calibration is started. More detailed description ofthis is given in section 3.1.3.

3.1.1.4 Automatic start-up functionThe automatic start-up function ASt defines the fielddevice action after the 24 V is switched on. OFF meansthat the field device will remain in OFF mode after start-up. On means that the field device will go to AUTOmode and start the automatic diagnostics as config-ured. CAL means that after start-up the field device willperform an automatic travel measurement calibrationbefore going to AUTO mode.

3.1.1.5 Normal positionThe valve normal position selection noP defines the valveposition in normal energized condition. The two possibil-ities are OPE for fully open and CLO for fully closed.

3.1.1.6 RotationThe rot defines actuator rotation direction when pres-sure is relieved from a cylinder- or diaphragm actuator.The value cC means clockwise rotation for closing andccC means counter clockwise to close.

3.1.1.7 ProtectionThe Pro defines HART write protection On or OFF. TheVG800B is delivered from factory with HART write protec-tion OFF as default setting. Reading and changing param-eters with Metso FieldCare is thus allowed.

Fig. 12 LCD-display and keyboard

MODE::

CALIB

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Fig. 13 Keyboard operations

& > 5 s

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

&

> 5 s

> 5 s

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3.1.1.8 Rotary vs. linear valve selectionThe act defines a style of valve. rot is for rotary valvesand Lin is for linear valves to compensate for non linear-ity of the position feedback caused by the actuator link-age mechanism of linear valves. The appropriateselection must be made at Act display.

You can return to operation state from any setting bypressing + and - keys shortly simultaneously for lessthan 1 second, repeating if necessary

3.1.1.9 HART write protectionThe VG800B is delivered from the factory with HARTwrite protection OFF as the default setting. Readingand changing parameters is thus allowed. HART pro-tection can be enabled with a switch (DIP1) located onthe circuit board, Fig. 14. Changes which may influ-ence the valve position cannot be made using the DTMprogram when switch no. 1 (on the left-hand side of theswitch block) is ON. For detailed information see theDTM User's Guide.

3.1.2 ConfigurationThe basic factory setting of the VG800B assume springto close the valve and a clockwise closing direction forthe position sensor when pressure is relieved from thecylinder or diaphragm actuator.

❑ Connect the air supply and voltage from RCI unit.Make sure that the voltage is between21...30 V DC, measured from the + and - termi-nals of VG800B

❑ Set the operation mode to OFF. Press the + and- for 5 seconds and the m starts to blink.

❑ Press + key shortly as many times as ASt

appears on the display. Press r to change"power-up" position to correspond On by scrolling+ or - keys. After selection press r key, whichreturns you back to A5t mode.

❑ After selecting noP on the display, press r keyand the current parameter value will be shownon the display. Now you may select between twovalues by pressing + or - key. The value CLO sig-nifies the pressure on the actuator to close thevalve and OPE means the pressure to open thevalve. Press the r key to finalize your selection

and return to noP mode. See default values in Fig.11 and function in Fig. 13.

❑ The next setting is rot where you will select bypressing r key either clockwise- or counterclock-wise rotation of the valve when pressure isrelieved from cylinder- or diaphragm actuator.After your choice with + or - keys press r keywhich returns you back to rot mode.

❑ Press + key as many times as the letter Act

appear on the display and by pressing r key youcan select by scrolling with + or - key desiredstyle of valve. The rot is for rotary valves and Lin isfor linear valves. To conclude press r key whendesired value is shown on the display.

3.1.2.1 CalibrationAfter the above-mentioned settings you can start cali-bration by scrolling with + or - key so far that displayshows c, which is blinking on the display. Press rto select AUTO or MAN calibration, which are alsoblinking depending on which one you have selected byscrolling with the + or - keys.

As a result of calibration the position sensor is fixed tocorrespond fully open and close position of a valve.

AUTO calibration function:

❑ For safety reasons the r key needs to bepressed for 5 seconds to activate the AUTO cali-bration function. During calibration the displayshows the text CAL. After calibration the VG800Breturns automatically to the c function.

❑ At any time you may interrupt the calibrationsequences by pressing the + and - keys simulta-neously.

❑ After the a calibration sequence is finished pressthe + and - keys simultaneously to get back tothe operation state. If this sequence has endedand an error message Err appears on the dis-play, see Chapter 8.

Now the VG800B will work with basic settings.

MAN calibration function:

❑ After selecting the MAN calibration function fromthe display press the r key to activate the proce-dure.

❑ With the - key drive the valve to the closed (0 %)position and then press the r key.

❑ Drive the valve into the open position (100 %)with the + key and press the r key.

❑ If an error message Err appears on the display,see Chapter 8.

❑ Press the + and - keys simultaneously to returnto the operation state.

Now the VG800B will work with basic settings.

Fig. 14 DIP switches

1

DIP1

DIP1OFF

1 1 2

ON

1 2

ON

DIP1ON

1 1 2

ON

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

14 9 VGB 70 en

3.1.3 TestingAdditionally to the above mentioned functions, there aretwo local tests: Pneumatic test and a valve stroke test.

To be able to run the tests, the operation mode has tobe AUTO. Tests are not allowed in OFF mode. Scrollwith + or - keys as far as display shows tSt. Press thenr key and select with + or - desired test performance.By selecting Pt the unit will carry out internal pressuretest and ensures that pneumatic portion is available.During this operation the display shows 100 %. Byselecting St you can make partial valve stroke whichwill move the valve the configured (default value 20 %)amount from the normal energized position.

3.1.4 Safety protectionBefore going back to the operation mode of a valve theuser can write protect the unit by using Pro setting.Once Pro is displayed press r key and the currentparameter value will be shown on the display. Now youcan select with two values by pressing + or - key. Thevalue OFF means that user is able to make changes ofsettings, tests and read diagnostics by using DTM. Thevalue On means that unit is write protected and user isonly able to read diagnostics but changes of settingsand tests are not allowed

When all the parameters are correctly set, return tooperation state by pressing the + and - key simultane-ously for short time. The display should show 100 %and AUTO mode.

4 USING METSO DTM ANDHART COMMUNICATION

Metso DTM (Device Type Manager) is part of an opensolution for field device management that provides thebest possible support during the commissioning, oper-ation and maintenance of your site. The DTM, withwhich Metso adheres to FDT (Field Device Tool) specifi-cations, provides a user interface for configuration,monitoring, calibration, diagnostics, and testing of thedevice. Operational principle is illustrated in Fig. 15.Communication with the device is done with HARTcommunication protocol by connecting into terminals 8and 9 of the RCI unit located in safe area. See Fig. 15.

4.1 User Interface

4.1.1 User Interface ElementsFig. 16 shows the DTM user interface. The user inter-face elements indicated by numbers are explained inmore detail below.

Fig. 15 Connections

Fig. 16 DTM user interface

Control room (Safe area)

(Hazardous area)

Factory floor

VG800B

HART-communication

ALARM

TESTING

OK

SCS / DCS

RCI

9 VGB 70 en 15

1. Toolbar

The toolbar contains icons with which you can performvarious actions and access various information in DTM.

2. Status Bar

DTM status bar shows the following elements:

❑ Online/offline status of the DTM: or

❑ Device type and revision:

❑ Communication status: when the DTM is in con-nection with the device, the letters on the statusbar flash blue to indicate which action is under-way:

❑ UL indicates Upload❑ DL indicates Download❑ M indicates Monitoring❑ C indicates Calibration❑ T indicates Testing

❑ Device Status: ❑ When the DTM is online, the overall status

(OK, Warning, Alarm) is shown:

❑ When the DTM is offline, the device status is not monitored:

3. Navigation Tree

The navigation tree shows the hierarchy of the configu-ration views in DTM.

❑ Click on by a navigation tree item to open thatarea of the tree and view the sub-items below it.

❑ Click on a sub-item to open the correspondingconfiguration view in the view area (marked 4 inFig. 16) to the right.

❑ Click on by a navigation tree item to close thatarea of the tree.

4. View Area

View area shows the individual configuration views ofDTM.

4.1.1.1 Toolbar Icons and MenusThe toolbar contains the following icons:

❑ Click Upload to upload information from thedevice to the DTM. The DTM reads deviceparameters, such as device identification, con-figuration, and diagnostics. Click the arrow bythe icon to open the Upload menu.

❑ Click Download to download informationfrom the DTM to the device.

❑ Click Stop Communication to stop theupload or download communication that is cur-rently underway. The icon is enabled when theDTM is uploading or downloading information.

❑ Click Accept Configuration to accept theoffline configuration you have done in the DTM.Click the arrow by the icon to open the AcceptConfiguration menu.

❑ Click Settings to open DTM Settings view. ❑ Click Hide Navigation Tree to hide the navi-

gation tree from view. ❑ Click Help to open DTM online help.Upload Menu

The Upload menu is available when DTM is in onlinemode. To open Upload menu, click the arrow by theUpload icon. Fig. 18 shows the Upload menu.

In the menu,

❑ Click Current View to upload the device param-eters for the view that is currently visible in theview area of the DTM interface.

❑ Click Device Identification to upload deviceidentification parameters.

❑ Click Configuration to upload configurationparameters.

❑ Click Diagnostics to upload diagnostics param-eters.

❑ Click Advanced to upload advanced parame-ters.

❑ Click All to upload all parameters. It may takeseveral minutes to upload all parameters.

Accept Configuration Menu

The Accept Configuration menu is available when DTMis in Offline mode. To open Accept Configurationmenu, click the arrow by the Accept Configurationicon. Fig. 19 shows the Accept Configuration menu.

Fig. 17 DTM toolbar

Fig. 18 Upload menu

Fig. 19 Accept Configuration menu

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In the menu,

❑ Click Accept Configuration to accept the offlineconfiguration you have done in the DTM.

❑ Click Undo (Current View) to undo the changesyou have made on the view that is currently visi-ble in the view area of DTM.

❑ Click Undo (All) to undo all the changes youhave made in the DTM since the last download.

❑ Click Export to save a copy of the DTM configu-ration on your PC or local PC network.

❑ Click Import to load a previously saved DTMconfiguration.

4.1.2 Device IdentificationIn the DTM, the Device Identification views containinformation on Operation Unit and Positioner Informa-tion and parameters.

4.1.2.1 Operation UnitTo open Operation Unit view,

1. In DTM Navigation Tree, click Device Identificationto view its sub-items.

2. Click Operation Unit.On the Operation Unit view, enter the following informa-tion:

❑ HART Tag: Device Tag (max 8 characters).Default = VG800

❑ Description: Enter a description of the device(max 16 characters)

❑ Date: Enter a date, e.g. the date when youinstalled the device. Default = 1.1.2003

❑ Message: Enter any other relevant information(max 32 characters). Default = VG800.

4.1.2.2 Positioner InformationPositioner Information view contains the following infor-mation:

❑ Device Type: Default = VG800❑ Manufacturer: Manufacturer name.

Default = Metso❑ Device ID: A unique device ID code that is used

in HART Communication❑ SW Revision: Software revision number❑ HW Revision: Hardware revision number❑ Final Assembly Number: A number defined by

the user❑ Device Serial Number: A manufacturer-specific

number for the device❑ Electronics Serial Number: A manufacturer-

specific number for electronics❑ Position Sensor Serial Number: a manufac-

turer-specific number for position sensor

4.1.3 ConfigurationThis section explains General configuration, Assembly-related, and Leakage measurement device parame-ters. Read through the topics to gain a thorough under-standing of DTM configuration procedures.

4.1.3.1 GeneralActual Mode

Actual Mode shows the current actual mode. Possibleactual modes are as follows:

❑ Error❑ Operate❑ Off mode, calibrating❑ Off mode, calibration allowed❑ Pneumatics test on❑ Valve test on❑ OK, testing allowed❑ Alarm, testing allowedTarget Mode

Target Mode allows you to choose a new operatingmode:

❑ If you change the operating mode of the deviceby downloading a new Target Mode value to thedevice, then Actual Mode does not match thenew mode.

❑ A blue asterisk appears in front of Actual Modeto indicate that the information in Actual Modeand Target Mode does not match.

❑ Upload General view again to update the infor-mation it contains and get the current ActualMode value.

Target Mode options are as follows:

❑ Off: Calibration allowed❑ AUTO: Testing allowedPower-up Mode

Power-up Mode defines the field device action atdevice power-up.

Power-up mode options are as follows:

❑ Off: This is the default option for Power-up Mode.The device remains in Off mode. Calibration isallowed, but testing is not allowed.

❑ Auto: The device enters Auto mode. Testing isallowed, but calibration is not allowed.

❑ Calibration & Auto: The device performs travelcalibration and enters Auto mode.

Device Keyboard

❑ Disabled❑ Enabled

4.1.3.2 Assembly Related

Valve Acting Type

Valve Acting Type determines the type of the valve clos-ing element. Valve Acting Type is one of the following:

❑ Rotary ❑ Linear

NOTE:These parameters are valve assembly related. There-fore, you should check that the safety valve assemblyconforms to the setting of this parameter.

9 VGB 70 en 17

Rotation Direction to Fail Safe

Rotation Direction to Fail Safe defines actuator rotationdirection when pressure is released from a cylinder.

❑ Set Clockwise to close if the actuator rotatesclockwise when pressure is released

❑ Set Counterclockwise to close if the actuatorrotates counterclockwise when pressure isreleased.

Fail Safe Action

❑ Open❑ Close

4.1.3.3 Leakage Measurement

Optional leakage measurement can be enabled withthis parameter. Then the field device measures leakageof the valve always when the valve is in closed position(or in the range of Valve Dead Angle parameter). Ifleakage measurement is not available, the parametershould be set disabled.

Select "Enable" from the Leakage Measurement drop-down menu.

❑ If Leakage Measurement is not enabled, thenMeasurement Time is set to 0.

❑ If Leakage Measurement is enabled, then the fol-lowing parameters are enabled. Default = disa-bled.

Parameters

❑ Measurement Time: Leakage MeasurementTime. If Leakage Measurement is enabled,default = 30 seconds. When leakage measurement is used with thevalve where fail safe action is close, then leakagecan be measured only during 100 % valve test.Then the measurement time defines time whichvalve is in closed position and measures leakage.

❑ Stabilizing Time: If Leakage Measurement isenabled, default = 0 seconds. When leakage measurement is used with thevalve where fail safe action is close, then Stabiliz-ing time is time what is waited in closed position(during 100 % valve test) before leakage meas-urement is started.

❑ Valve Dead Angle: Dead angle in a ball or seg-ment valve. Default = 1 %.When leakage measurement is used with thevalve where fail safe action is close. If valve posi-tion is closed (0 %) or in dead angle parameterleakage is measured.

4.1.4 Monitoring

You can use monitoring to observe four different varia-bles (listed below) indicating VG800 operation. All of

these variables show on-line information, and you canreceive real-time information on the condition of theVG800. The monitored information ensures that VG800is working correctly. Read through the following topicsto gain a thorough understanding of DTM monitoringfunctions and procedures.

4.1.4.1 Start Monitoring

To open Monitoring Settings view,

1. In DTM Navigation Tree, click Monitoring to view itssub-items.

2. Click Start Monitoring.Start Monitoring Parameters

US/SI units settings affect how some variables areshown.

❑ Monitoring State: shows the current monitoringstate.

❑ Actual Travel: the actual position of the valve.❑ Leakage Signal: the output signal of an optional

seat leakage sensor.❑ Actuator Pressure: the pressure opposed to the

spring.❑ PCB Temperature: the temperature of the circuit

board.How to Start Monitoring

Click Start to start monitoring. When monitoring hasstarted,

❑ The M on the status bar flashes.❑ Start button changes to Stop button. Click Stop

to stop monitoring.How to Start Logging

Click Logging... to begin logging.

❑ After you click Logging..., the Log File windowopens.

❑ In the Log File window, choose a name and a filepath for the file in which variable values will besaved.

NOTE:Leakage Measurement view is available only forVG800 device revision 2.0.

NOTE:Monitoring is available when the DTM is online (connected).

Fig. 20 Monitoring


18 9 VGB 70 en

How to Zoom In and Out in a Graph

To zoom in on a graph,

1. Click and hold the left mouse button down on apoint in the graph that is at a corner of the area youwish to zoom in on and view closer.

2. With the mouse button held down, drag the mouse todraw a box around the area you wish to zoom in on.

3. Release the mouse button. The graph zooms in onthe area you outlined with the box.

To zoom out of a graph,

1. Click on the graph to make sure that it is in focus.2. Press Z on your computer keyboard.Actual Travel

The Actual Travel graph displays the actual travel ofthe safety valve measured by the VG800 device. Actualtravel is shown as a percentage of calibrated valvetravel. You can monitor on-line how the valve travelchanges during a valve test.

Leakage Signal

The Leakage Signal graph shows the output signal ofan optional seat leakage sensor. The sensor is con-stantly monitoring valve tightness. It reacts to ultra-sounds that are associated with small seat leakages.Small changes in the reading during monitoring arenormal. Due to the construction of the leakage monitor-ing system there is also a small signal level presenteven if there is no actual seat leakage or the sensor isnot installed.

Actuator Pressure

Actuator Pressure:

❑ Actuator Pressure is the pressure opposed to thespring.

PCB Temperature

The PCB Temperature graph shows the temperatureinside the VG800 valve controller on the Printed CircuitBoard (PCB). Use the temperature information to checkthat the environmental termperature is within specifiedambient temperature limits. This ensures reliability ofthe VG800 device.

4.1.5 DiagnosticsVG800 continuously monitors safety valve behavior. Itrecords trends and possible alerts that are shown inthe various Diagnostics views in DTM. Trends showhow the valve has operated over certain periods oftime. Alerts inform you of potential problems in valveoperation, device performance and device faults.

Diagnostics information is important for performancemonitoring and maintenance needs. Since Diagnosticsinformation is on on-line data, you can check safety valveconditions at any time in real time without disturbing theprocess. Trends, test counters and alert reports help youdetermine maintenance needs. Such predictive mainte-nance ensures that the safety valves and thus the wholeprocess work more smoothly, safely, and reliably.

This section explains Diagnostics information and func-tions. Read through the topics to gain a thoroughunderstanding of VG800 Diagnostics procedures.

4.1.5.1 Alert handlingIf the Error signal of the RCI unit is lit, an error code isshown on the LCD display. The same error code can beretrieved by using the DTM software. To retrieve theerror code connect a HART modem to the RCI unit,make a connection to the field device and read thediagnostics, see Fig. 8. The error code is shown in theEvent log window. The error codes are explained inTable 4.

4.1.5.2 Counters❑ Number of Valve Tests: Number of successful

valve tests that have been performed.❑ Number of Pneumatics Tests: Number of suc-

cessful pneumatics tests that have been performed.

4.1.5.3 Breakaway Pressure TrendThis trend shows the pressure level at which the valvestarts to move in a valve test over total valve operationtime, Fig. 21. The trend data is calculated and updatedevery time a valve test is performed. The breakawaypressure trend can be used to analyse valve loadchanges and predict future behaviour of the safetyvalve.



NOTE:Leakage Signal view is shown only for device revision2.0.



Fig. 21 Breakaway pressure trend

9 VGB 70 en 19

Time Counters

Breakaway Pressure Trend shows two time countersabove the trend graph:

❑ Operation Time (h): Operation time comprisesthe total time in hours during which the devicehas been operating. Resetting the statistics doesnot affect the total time.

❑ Measured Trend Time (h): The time in hours thatis used to collect the data for the trend.

Trend Graph

❑ The Y-axis shows the breakaway pressure in bar.The y-axis' default range is 0...7 bar, but is scalesautomatically according to current unit settings.

❑ The X-axis shows the time in hours that repre-sent the time when the trend data was collected.The right-most column represents the most cur-rent data. Columns to the left of it represent olderdata and therefore the hours are shown as nega-tive numbers.

❑ Breakaway pressure high and low limits are dis-played as dashed red lines.

❑ If trend item upload fails, the trend is notupdated, i.e. no data appears on the trend. Tryuploading the view again.

❑ You can zoom horizontally.

4.1.5.4 Leakage Signal TrendThe leakage trend illustrates the valve's seating tight-ness development over valve operation time, Fig. 22.An ascending trend may be an indication of valve seatwear. Monitoring of the seat tightness requires anoptional sensor accessory to be installed.

Time Counters

Leakage Signal Trend shows two time counters abovethe trend graph:



Trend Graph

❑ The Y-axis shows the leakage signal in mV. They-axis' default range is 0...3200 mV.

❑ The X-axis shows the time in hours that repre-sent the time when the trend data was collected.The right-most column represents the most cur-rent data. Columns to the left of it represent olderdata and therefore the hours are shown as nega-tive numbers.

❑ The Leakage Alarm limit is displayed as adashed red line

❑ If trend item upload fails, trend is not updated,i.e. no data appears on the trend. Try uploadingthe view again.


4.1.5.5 Load Factor TrendThe Load Factor Trend shows the load factor of theactuator as a percentage, Fig. 23. The load factor iscalculated and recorded every time a succesfull valvetest is performed. Use the Load Factor Trend to analyzethe condition for the safety valve:

❑ A high load factor indicates the presence of highfriction or that the actuator is undersized.

❑ The load factor shows the actuator load withrespect to the present actuator spring force. Inother words, a load factor of 100 % indicates thatthe actual load may exceed the spring force.

Time Counters



Trend Graph

❑ The Y-axis shows the Load Factor as a percent-age. The y-axis' default range is 0...100 %.

❑ The X-axis shows the time in hours that repre-sent the time when the trend data was collected.The right-most column represents the most cur-rent data. Columns to the left of it represent older

Fig. 22 Leakage signal trend

Fig. 23 Load Factor Trend

20 9 VGB 70 en

data and therefore the hours are shown as nega-tive numbers.

❑ Load Factor high and low limits are displayed asdashed lines.

❑ If trend item upload fails, trend is not updated,i.e. no data appears on the trend. Try uploadingthe view again.


4.1.5.6 Event LogEvent Log contains two columns:

❑ Event: List of 20 latest events and alerts storedin VG800 memory.

❑ Time: number of operating hours since loggingbegan.

The events are shown in Table 2.

4.1.5.7 Device Alert SettingsYou can use Alert Settings to set limits for differentdevice information and statistics. That way you will bealerted when these alert values are exceeded. Set theAlert Settings initially to high values so that no or onlyfew unnecessary alerts will be given. With experienceyou can tune the limits to more accurate levels.

Device Alert Settings view contains the followingparameters:

❑ Test Timeout: The time limit for a test to be com-pleted. If this time is exceeded, the test isaborted, error is generated and Error signal ofthe RCI unit is lit. The default = 90 seconds.

Cause of the test failure can be, for example, afaulty valve or field device, insufficient air supplyor improper parameter setting of the field device.The failure event is logged into non-volatile mem-ory of the field unit. If the actuator cylinder islarge and/or the pressure step setting has asmall value, it is possible that the default is tooshort causing test failures. In those casesextending the timeout will prevent unwantedalerts.

❑ Test Warning Time: Before a valve or pneumat-ics test is started, the Test signal of the RCI-unitis lit. This pre-test signal duration can beadjusted by the parameter. The default = 2 sec-onds.

❑ Position Error Tolerance: Valve position is con-stantly monitored by the field unit. If the meas-ured position change exceeds the tolerance anda valve test is not running, a position error is gen-erated. During the valve test Position error toler-ance defines how much overshoot is acceptedover test target. The error signal is lit and futureautomatic testing is disabled. Default = 10 %.

❑ Supply Pressure Limits: If the supply pressureis beyond it's specified range, a device operationfailure can occur. Limit values can be adjustedwith these parameters. If the limits are exceeded,an error is generated and RCI's Error signal is litand future automatic testing is disabled.If the pressure is restored, the device will resumenormal operating (testing will resume immedi-ately).❑ Supply Pressure Limit HIGH:

Default = 7.5 bar.

❑ Supply Pressure Limit LOW:Default = 2 bar

❑ Pressure Peak Tolerance: Pressure peak depthin pneumatics test is monitored. Pressure Peaktolerance parameter is given the tolerance foracceptable variation for Pressure Peak parame-ter. Range 0...100 %, default = 30 %.

❑ Pressure Peak: Pressure peak depth in pneu-matics test is monitored. Acceptable peak depth

Table 2 Events

VG Error/Event Code DTM Event11 Power Low Error12 Power Save Error21 Input signal measurement ADC

low limit failure22 Input signal measurement ADC

high limit failure23 Supply Voltage Failure30 Calibration performed31-37 Calibration error39 Test after Calibration Failed40 Test after Calibration succeeded41 Prestage Valve 1 Failure (E41)44 Prestage Valve 2 Failure (E44)51-52 Position Measurement Failure54-55 Pressure Sensor Failure56-57 Supply Pressure Failure58 Valve Position Error59 Position or Pressure Measurement Failure61-66 EEPROM error70-71 Valve Test Failed72 Pneumatics Test Failed73-74 Test Counter Limit Exceeded75 Load Factor High Alarm76 Load Factor Low Alarm77 Breakaway Pressure High Alarm78 Breakaway Pressure Low Alarm79 Leakage Limit Exceeded81 RAM error82 ROM error90 VC card booted91 Processor failure

NOTE:If testing is prevented by this error and error iscleared, testing will resume immediately!



NOTE:High and low limits are set and read simultaneously.When you enter a new value for one limit, check thatthe other limit also has a valid value entered. Note thatthe HIGH limit must be higher than the LOW limit.

9 VGB 70 en 21

is set by this parameter. Range 0...10 bar, default =0 bar.

❑ Pressure Recovery Time: Time for pressurerecovery in pneumatics test, default = 5 seconds.

❑ Valve Test Pressure Low Limit: Limit for thelowest allowable pressure during a valve test.Range 0...10 bar, default = 0 bar.

4.1.5.8 Statistic Alert SettingsWhen you are commissioning a new VG800 field device(device revision 1.0), or if you reset trend data, unnec-essary warnings may appear if the warning limits havebeen changed from default values. This happensbecause trend data of the field device is cleared andappears as a set of zeros. To overcome this, trend limitvalues should be adjusted after the first 24 hours ofoperation. This is valid only for device revision 1.0,which uses trend values for the limit check. Device revi-sion 2.0 uses the latest measurement value.

❑ Load Factor Limits: A load factor of an actuatoris calculated each time, a valve test is per-formed. The calculation is based on the supplyand the breakaway pressures. Too high load fac-tor can impair position control accuracy or canbe a sign of valve wear or damage. Also, a lowload factor can indicate a valve damage. Thedefault values are 100 % for high and 0 % for lowlimit. These figures should be adjusted to appli-cation.

❑ Load Factor Limit HIGH:0...100 %, default = 100 %.

❑ Load Factor Limit LOW:0...100 %, default = 0 %

❑ Breakaway Pressure Limits: Each time a valvetest is run, the cylinder pressure at which theactuator starts to turn is recorded. If the pressureis too low it can be a sign of high actuator load.On the other hand, high Breakaway pressurevalue can indicate a device failure.

❑ Breakaway Pressure Limit HIGH:8 bar

❑ Breakaway Pressure Limit LOW:0 bar

❑ Leakage Alarm Limit:0......3200 mV, default 3200 mV

❑ Test Number Limits: A number of successfulvalve and pneumatics test executions are logged.The execution numbers can be controlled by trig-gering an alert if a limit is reached. An alert willnot affect normal operation of the unit but may behelpful in scheduling maintenance actions.❑ Valve Test Number Limit:

Default = 1,000,000 tests❑ Pneumatics Test Number Limit:

Default = 1,000,000 tests

4.1.5.9 Reset StatisticsReset Statistics view allows you to choose the statisticsyou wish to reset. After you reset the statistics, old datais permanently deleted.

The following statistics can be reset:

❑ Valve Test Counter❑ Pneumatics Test Counter❑ Breakaway Pressure Trend❑ Load Factor Trend❑ Leakage Trend❑ Event Log

To reset statistics:

1. Click the checkboxes by the statistics you wish toreset.

2. Click Reset.

4.1.5.10 Reset Alerts

Reset Alerts view allows you to choose the alerts youwish to reset. After you reset the alerts, old data is per-manently deleted.

The following alerts can be reset:

❑ Valve Test Failure❑ Pneumatics Test Failure❑ Load Factor Alarm❑ Breakaway Pressure Alarm❑ Leakage High AlarmTo reset alerts:

1. Click the checkboxes by the alerts you wish to reset. 2. Click Reset. This also resets the last measurement

value from device.

4.1.6 Device Status

The overall status of the device is shown on the DTMStatus Bar in the Device Status box. The overall statusis updated every 10 seconds. Device Status is deter-mined based on the most acute alert state that exists inthe device. The statuses are as follows:

❑ Alarm❑ Warning❑ OK❑ UnknownTo view the statuses of individual parameters, go to Statusview. Status view shows the status of the device parame-ters in a tree format. The tree consists of various groupsof parameters. Fig. 24 shows a sample Status tree.

❑ The status of each group is defined by the individualparameter within it that has the most acute status.

❑ To open a group and view the statuses of theindividual parameters, click on by the groupname, or double-click on the group name.

NOTE:High and low limits are set and read simultaneously.When you enter a new value for one limit, check thatthe other limit also has a valid value entered. Note thatthe HIGH limit must be higher than the LOW limit.

NOTE:Reset Alerts view is available only for VG800 devicerevision 2.0.

NOTE:Status information is available when the DTM is online.

22 9 VGB 70 en

❑ To close a group, click on the by the groupname, or double-click on the group name. If agroup has an OK status, it closes automaticallywhenever the DTM refreshes the Status tree.

4.1.7 TestingYou can use the test results to diagnose the conditionof the valve package. These test results reveal futuremaintenance needs. Run the valve test regularly toensure optimal performance of the valve package inevery situation.

Read through the following topics to gain a thoroughunderstanding of VG800 Testing procedures.

Test Settings

Pneumatics Test

Fig. 25 shows Test Settings on Pneumatics Test view.

In the Test Settings box, you can set the Timer to deter-mine the amount of time until the next test is performed.You can also set the test Interval, which determineshow much time elapses between tests. The Interval vis-ible in Fig. 25 represents 1,000,000 hours, which is thedefault Interval.

To set the Timer,

1. Enter the number of days in the box by the d.2. Enter the number of hours: click the drop-down list by

h and click a number.3. Enter the number of minutes: click the drop-down list

by min and click a number.4. Click Download. Confirmation view opens.5. In the Confirmation view, select test settings changes

that you wish to confirm.6. Click OK to download the parameter changes to the

device.

To set the Interval,

1. If there is not a checkmark in the Interval checkbox,click the checkbox to enable the Interval.

2. Enter the number of days in the box by the d.3. Enter the number of hours: click the drop-down list by

h and click a number.4. Enter the number of minutes: click the drop-down list

by min and click a number.5. Click Download. Confirmation view opens.6. In the Confirmation view, select test settings changes


device.Valve Test

Fig. 26 shows Test Settings on Valve Test view.

In Valve Test Settings, Timer and Interval are setaccording to the instructions above. In addition, youcan set the following parameters:

❑ Test Stroke Size: Adjusts the size of the valvemovement. Enter the desired percentage (0...100)in the box. Default = 20 %.The valve test stroke size is the distance in per-centage the valve is moved during a valve test. Itis relative to a valve position when an actuatorcylinder is pressurized. Effect of an actuator typeto actuator movement is shown in Table 3.

❑ Pressure Step: Adjusts the speed of the valvemovement and thus affect for positioning accu-racy in valve test. Enter the desired number inbar (0.001...1.0) in the box. Default = 0.05 bar.The smaller the pressure step, the slower thevalve test and more accurate positioning.

To set the parameters,

1. Enter the desired values.2. Click Download. Confirmation view opens.3. In the Confirmation view, select test settings changes


device.

4.1.7.1 Pneumatics TestIn Pneumatics Test view, there are two distinct work-

Fig. 24 Status tree

NOTE:Tests cannot be started manually if HART write pro-tection is ON.

Fig. 25 Pneumatics Test Settings

Fig. 26 Valve Test Settings

Table 3 Examples of the actuator travel and test stroke sizes

Actuator type

Test strokeActuator

movementLCD display at test stroke

Fail safe close

20 % 20 % to close from open position

80

Fail safe open 20 % 20 % to open from closed position

20

9 VGB 70 en 23

flows. Each of the following workflows is explained inmore detail below.

❑ Edit test settings❑ Perform an individual testEdit test settings

Explained in the previous section Test Settings.

Perform an individual test

1. To begin Pneumatics Test, click Start Individual Test.2. The graph is automatically uploaded after a suc-

cessful test.

Pneumatics Test Graph Information

Fig. 27 shows sample Pneumatics test results.

❑ Units are changed and scaled according to cur-rent unit settings

❑ X-axis: Time in seconds❑ Y-axis: Maximum and minimum are taken from

Supply Pressure High or Low default scale❑ You can zoom horizontally and vertically.

4.1.7.2 Valve TestIn Valve Test view, there are three distinct workflows.Each of the following workflows is explained in moredetail below.

❑ Edit test settings❑ View previous test results❑ Perform an individual testEdit test settings

❑ Explained in detail in section Test Settings❑ Remember to click Set after editing test settings.View previous test results

If the device is programmed to perform tests at variousintervals, you can view the results of the previous testas follows:

1. Check that Valve Test view is visible in DTM.2. On DTM toolbar, click Upload.

Perform an individual test

1. To begin Valve Test, click Start Individual Test.2. The graph is automatically uploaded after a suc-

cessful test.

Valve Test Graph Information

Fig. 28 shows sample Valve test results.

❑ Units are changed and scaled according to cur-rent unit settings.

❑ NOTE: Alarm limits and Target Stroke Size aredisplayed if uploaded. If some of these parame-ters are changed and downloaded, the graphmust also be updated. To update the graph, click

Upload.❑ Breakaway Pressure HIGH and LOW in Statistic

Alert Settings view determine the red alarm limitlines.

❑ Test Target Line is displayed as a vertical blueline.

❑ You can zoom horizontally and vertically.❑ Load Factor: Load factor value from last

uploaded valve test.❑ Breakaway Pressure: Breakaway pressure

value from last uploaded valve test.❑ Next Test Time: Shows the time to the next

timed valve test at the moment you last uploadedthis valve test view.

4.1.8 CalibrationRead through the following topic to gain a thoroughunderstanding of VG800 Calibration techniques.

4.1.8.1 Automatic TravelAutomatic Travel calibration performs a calibration rou-tine in VG800 that calibrates valve travel according tothe mechanical limits of the actuator.

Fig. 27 Pneumatics test results

NOTE:Automatic scheduled pneumatics test is not saved inthe field device memory and thus cannot be uploadedfor viewing.

NOTE:If, however, the DTM has most recently performed aPneumatics Test and not a Valve Test, then you cannot upload Pneumatics Test information. In that case,perform an individual Valve Test (instructions below)to view the most recent test results.

Fig. 28 Valve test results

CAUTION:During calibration, the valve moves between fullyopen and fully closed positions. Make sure that thevalve operation endangers neither people norprocesses.

24 9 VGB 70 en

To perform Automatic Travel calibration,

1. Set device to the OFF mode (choose Configuration/General/Target mode)

2. On Automatic Travel view, click Start.3. During Calibration, click Stop to stop calibration.Flashing C on Status Bar of user interface indicates thatcalibration is in process.

4.1.9 Advanced

4.1.9.1 HART Configuration1st Dynamic Variable Code

Code for the dynamic variable that is mapped to Pri-mary Variable in HART Communication. Possible codesare as follows:

❑ 0 = Actual Travel❑ 1 = Leakage Signal❑ 2 = Actuator Pressure❑ 3 = Device Temperaturedefault = 0

2nd Dynamic Variable Code

Code for the dynamic variable that is mapped to Sec-ondary Variable (SV) in HART Communication. Possiblecodes are as follows:


3rd Dynamic Variable Code

Code for the dynamic variable that is mapped to Tertia-try Variable (TV) in HART Communication. Possiblecodes are as follows:


4th Dynamic Variable Code

Code for the dynamic variable that is mapped to Qua-ternary Variable (QV) in HART Communication. Possiblecodes are as follows:


Response Preambles

The number of preambles in slave device response inHART communication. The valid range for this parame-ter is 5...20, default = 5.

4.2 DecommissioningBefore de-commissioning ensure that you have theauthority to make the change to the safety instrumentedsystem, and that the safety instrumented functions stillremain appropriate. It is also recommended that theconfiguration parameters of ValvGuard, such as the

automatic start-up function, valve test stroke size andinterval are set to safe values to ensure a possible re-commissioning in a safe manner. Also to avoid unnec-essary alarms after re-commissioning, it is recom-mended that the statistics (trends) and thecorresponding alarm limits are reset.

5 MAINTENANCE

The maintenance requirements of the VG800B dependon the service conditions, for instance, the quality ofinstrument air. In normal service conditions no regularmaintenance is required.

The filter (110) needs to be checked and possiblycleaned regularly depending on the service conditions.

5.1 RCI unitBefore removing the RCI unit you must disconnect allthe connectors or wires from the unit. See connectionsfrom Fig. 8.

Disassembly

❑ Lift unit from one corner and pull RCI unit outfrom DIN rail.

Reassembly

❑ Select correct rail width from selector. Place unitto DIN rail from one side and then push it to theplace. Make sure the unit is locked and firmly onrail.

❑ Connect all the connectors or wires and makesure they are on the right places, see Fig. 8.

NOTE:VG800 maintenance can be done by Metso certifiedservice personnel only.

NOTE:If the detailed maintenance instructions for the fielddevice VG800B is required, please see the separateMaintenance Instructions for Neles ValvGuard.

NOTE:Changing the RCI unit will disconnect VG800B fromoperation and causes the valve to move to fail-safeposition.

Fig. 29 RCI unit

9 VGB 70 en 25

6 SAFETY MANUALNeles ValvGuard is a safety related product. Extraattention is required to make sure it is used in a way it isintended to be used and in a safe manner. The follow-ing checklist provides assistance to this. Every itemmentioned in the checklist should be compared againstthe installation, and if any deviations exist the safety ofthe installation cannot be guaranteed.

De-energized is the safe state of the installation. Thismeans that no electronic or software fault within theValvGuard system can lead to a dangerous failure incase of a demand.

The required hardware fault tolerance of the installationis zero. If hardware fault tolerance of 1 is required (forexample in a furnace isolation application), then a dualredundant configuration should be used (see Fig. 30).

The ValvGuard system must be configured before com-missioning. The parameters configured to the VG800Bmust be read back and verified using the Metso DTMfor Neles ValvGuard software package before commis-sioning.

To obtain the best possible diagnostic coverage, the auto-matic test intervals and the various alarm limits in theVG800B must be set, see Section 4.1. The diagnostic cov-erage factor for an ESD-valve (a fail to close valve) can beassumed to be around 75 % (valve + actuator), and thediagnostic coverage factor of an ESV-valve (fail to openvalve) around 90 % (valve + actuator). For more accurateestimates contact Metso’s Automation business.

The diagnostic coverage of the pneumatic unit withinValvGuard can be assumed to be > 90 % only if a pres-sure regulator is installed in the air supply to the VG800(see Sections 2.5 and 2.7).

Both relay outputs in the RCI unit must be used (con-nected to an external system, see Section 2.6). Anyinconsistencies (faults) in the relay outputs have to bedetected by the external system (e.g. a DCS or a PLC).For example if the "test" -relay output is not indicating atest according to the programmed automatic test inter-val and the status of the valve is still "ok", then either the"test" -relay or the "ok/alarm" -relay output might havefailed, i.e. there could be a critical alarm which is inhibit-ing automatic testing, but is not indicated because of afailed relay output. NOTE: The relay outputs are inde-pendent of the DTM software and HART communication.

The parameters programmed in the VG800B must be pro-tected. If the organizational procedures are established, thiscan be done using the user access levels in the Metso DTMfor Neles ValvGuard software package (see "DTM User'sguide"). Otherwise the HART write protection in the VG800Bhas to be utilized (see Section 3.1.1.7).

Fig. 30 Dual redundant configurations

Dual redundant block valves

(normally open)

Dual redundant block valves

(normally closed)

Safety

system

26 9 VGB 70 en

7 TROUBLE SHOOTINGMechanical/electrical defects

1. Connecting the input voltage does not affect theposition of the actuator

❑ Supply pressure too low❑ Spool valve sticks❑ Tubing between VG800B and actuator are incor-

rect, see Fig. 11❑ Actuator and/or valve jammed❑ Signal wires incorrectly connected, no value on

display❑ Circuit board is defective❑ Calibration has not been carried out❑ Prestage is defective❑ Position sensor is defective2. Inaccurate positioning ❑ Spool valve dirty❑ Dirt in permanent air gap❑ Actuator too small❑ Supply pressure too small❑ Pressure sensor is defective❑ Loose in coupling between actuator and VG800B❑ Actuator and/or valve sticks3. Positioning too slow❑ Spool valve dirty❑ Supply air line too small or supply air filter dirty❑ Valve and/or actuator sticks❑ Check leakages in tubing between VG800B and

actuator❑ Check leakages in mechanical stop screws4. Err is shown during calibration❑ VG800B is in a mode❑ The parameter setting rot is incorrectly selected,

see Section 3.1.1.6 and Figs. 10 and 15❑ The actuator did not move or was stuck during

calibration❑ Input signal voltage is not according to the spec-

ification❑ VG800B - actuator mounting is incorrect, see

Fig. 7 and Sections 11.2...11.5❑ Spool valve sticks❑ Prestage is defective5. RCI unit shows error❑ Calibration was not successful❑ There is mechanical and/or electrical problem

with VG800B❑ VG800B has detect problem with valve, for more

information see DTM User's guide6. RCI unit does not show anything❑ Check power supply connection❑ Supply voltage is not according to the specifica-

tion❑ Power connector is not firmly in place

8 ERROR CODESWhen the VG800B detects a serious device failure(analogue inputs, analogue outputs or electronics) itenters the fail-safe mode. Fail-safe mode is indicatedby the LCD as message Exx, where xx is a numberbetween 1...99, or by the HART master software (e.g.Metso DTM). The error message is displayed until thecause of the error is eliminated, Enter button on LUI ispushed or alarm is reset by Metso DTM software.

When the VG800B detects an error during the travelcalibration, the error message Err is displayed. It dis-appears when any key is pressed.

The VG800B stores error messages in its non-volatilememory, which saves the 20 most recent error codes.The memory can be read out with HART communica-tion by using DTM for Neles ValvGuard.

Table 4 lists the error messages shown on the LCD dis-play and their explanations.

9 TOOLSNo special tools needed.

10 ORDERING SPARE PARTS

There are no spare parts for VG800B field device. Ifservice is needed, please contact Metso’s Automationbusiness for further instructions.

NOTE:In the case of an error as described above the valvestays in the normal position.

NOTE:Only the RCI (Remote Communication Interface) unitcan be ordered as a spare part.

9 VGB 70 en 27

Table 4 Error messages shown on LCD display

Error code Reason ActionE33 * Position sensor error in

calibrationCheck device mode, device must be in OFF-mode.Check position sensor, the mark on the shaft must stay in the right sector, see Fig. 7.

E34 * Calibration timed out Check the pressure supply.Check actuator piping.

E39 *Reference test timed out

Check test time out parameter.Check the pressure supply.Check actuator piping.

E51 ** Position feedback ADC low limit failure.

Check the mounting of VG800B; the mark on the shaft must stay in the right sector, see Fig. 7.Check wires, connector and position sensor rotation range or change circuit board.Rotate the position feedback shaft 10 degrees counterclockwise and cold-start the device.

E52 ** Position feedback ADC low limit failure.

Check the mounting of VG800B; the mark on the shaft must stay in the right sector, see Fig. 7.Check wires, connector and position sensor rotation range or change circuit board.Rotate the position feedback shaft 10 degrees clockwise and cold-start the device.

E56

Supply pressure level is low.

Check pressure supply.Check actuator piping.Check pressure sensor.Check/adjust supply pressure alarm limit.

E57Supply pressure level is high.

Check pressure supply.Check pressure sensor.Check/adjust supply pressure alarm limit.

E58

Position error.

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

E61 ** Memory (EEPROM) failure. Change circuit board.

E65 ** Memory (EEPROM) failure. Change circuit board.

E71

Partial stroke test failure.

Check valve-actuator assembly.Check field device connection.Check actuator piping.Check pressure sensor.Check position sensor.Check prestage unit operation.Check spool valve unit operation.

E72

Pneumatics test failure

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

E73 Valve test counter limit Check/adjust test counter limit.

E74 Pneumatics test counter limit Check/adjust test counter limit.

E75

Load factor high limit

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

E76

Load factor low limit

Check actuator operation.Check valve operation.Check/adjust load factor alert limit.Please note in VG SW rev 1.0, that this error is generated, if load factor trend data has been reset and alert limit value > 0. In this case, to override error message set the alert limit to 0 and readjust after 24 hours device operation.Error message will be removed automatically when some trend data has been recorded

E77Breakaway pressure high limit

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

E78

Breakaway pressure low limit

Check actuator piping.Check actuator operation.Check valve operation.Check/adjust breakaway pressure alert limit.Please note in VG SW rev 1.0, that this error is generated, if breakaway pressure trend data has been reset and alert limit value > 0. In this case, to override error message set the alert limit to 0 and readjust after 24 hours device operation. Error message will be removed automatically when some trend data has been recorded.

E79 Leakage alarm high limit Check valve.

E81 ** RAM error Change circuit board.

E82 ** ROM error Change circuit board.

E91 ** Watchdog error Change circuit board.

Err

Travel calibration fails

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

*) Shown only by Metso DTM (Err shown on LCD display)**) Fail-safe

28 9 VGB 70 en

11 DRAWINGS AND PARTS LISTS

11.1 Exploded view and parts list, VG800B

2

46

5

400

7

1

40

44

9813

3

401

6

110

Item Qty Description1 1 Housing2 1 Cover3 1 Prestage unit4 1 Spool valve assembly5 1 Circuit board, ND8006 1 Position sensor7 1 Differential pressure sensor13 1 Pneumatic block40 1 Shaft46 1 Protective cover98 1 Gasket110 1 Filter400 1 Circuit board, PSB401 1 Conduit block

9 VGB 70 en 29

11.2 Mounting parts for B1JU8-322 actuators

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

Item Qty Description1 1 Mounting bracket2 1 Draught piece3 4 Washer4 4 Screw28 4 Screw29 1 Screw36 1 Coupling’s jacket

Item Qty Description1 1 Mounting bracket2 1 Ear4 4 Screw28 4 Screw29 1 Screw30 4 Screw35 1 Adapter plug

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

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

Item Qty Description1 1 Mounting bracket2 2 Coupling half3 1 Adapter4 4 Screw5 4 Hex nut6 1 Screw7 4 Screw8 4 Washer9 4 Screw10 4 Washer

30 9 VGB 70 en

11.4 Mounting parts for linear actuators with IEC 60534 mounting face

56

1516

1718

19

84 2

1112

149 11 1

3

7

70˚

14.3

(20

mm

)

21.4

(30

mm

)

28.6

(40

mm

)

35.7

(50

mm

)

42.8

(60

mm

)

50 (

70 m

m)

57.1

(80

mm

)

64.3

(90

mm

)

71.4

(10

0 m

m)

Stroke

(20 - 100 mm)

Sca

le

Dis

tanc

e fr

om s

haft

cent

er to

car

rier

bolt

acco

rdin

g to

str

oke .

Fee

dbac

k le

ver

in h

oriz

onta

l pos

ition

at m

id tr

avel

of s

trok

e

The

mar

k on

the

shaf

t sho

uld

stay

in th

is s

ecto

r!

Str

oke

20 -

60

mm

Str

oke

60 -

100

mm

9 VGB 70 en 31

11.5 Mounting parts for limit switches for Ex d enclosure

Item Qty Description1 1 Mounting bracket1 1 Console2 1 Driver3 2 Washer4 2 Hexagon nut5 4 Hexagon nut6 4 Stud8 4 Washer9 4 Hexagon screw10 1 Thread bar11 1 Cover12 2 Pin13 2 Hexagon nut14 1 Bracket support15 3 Washer16 3 Cross rec head screw28 4 Socket head screw43 2 Connection fork44 2 Haxagon nut45 2 Snap ring46 4 Washer47 1 Link48 1 Haxagon nut49 1 Socket head screw

32 9 VGB 70 en

12 DIMENSIONS

12.1 VG800B

12.2 RCI

99.53.9240

1.57

51

2.00

48

1.89

164

6.45

4

0.16

25

0.98

M5 / 18

29

201.14

0.78M6 / 10

3x1/4 NPT

5/16 UNC / 13

OUTLET3/8 NPT

26 30

1.181.02

(35.4)

F05-ł50

(VDI/VDE 3845)

1.39

31

1.2

2

(35

.4)

(1.3

9)

34

34

1.3

41

.34

48

.5

1.9

1

VG800B_A14 0.1

6

66

17

02

.60

66

.9

27

1.0

6

ND800/B1-L = 1/2 NPT

VG800B_A

73

19

0.7

52

.87

48

5.50.21

1.89

VG800B_S12

3

14

12

4

0.5

5

0.9

0

4.8

8

17

7

6.9

78

33

.27

1/4

NP

T

VG800B-K

53

2.08

682.68

40

1.5

7

64

2.52B1: M20x1.5

B2, B3: 1/2 NPT

9 VGB 70 en 33

13 CONFIGURATION PARAMETERS

*) Default values are set in boldface type

DTM LUI*Screen Parameter (unit) Values / Range Parameter Values /

RangeDevice IdentificationOperation Unit HART Tag free text, (default = VG800) - -

Description free text - -Device Date Day.Month.Year, (default = 1.1.2003) - -Message free text, (default = VG800) - -

ConfigurationGeneral Target Mode AUTO, testing allowed / Off,

calibration allowedMODE AUTO / OFF

Power-up Mode Off / Auto / Calibration & Auto ASt OFF / On / CAL

Device Keyboard Disabled / Enabled - -- - Pro

(HART Write Protection)

OFF / On

Assembly Related Valve Acting Type Rotary / Linear Act rot / LInRotation Direction to Fail-safe Clockwise / Counter Clockwise rot cC / ccCFail Safe Action Close / Open noP (Normal Position) CLO / OPE

Leakage Measurement

Leakage Measurement Enabled / Disabled,(default = disabled)

- -

Measurement Time (s) 0.001 - inf, (default = 30) - -Stabilizing Time (s) 0 - inf, (default = 0) - -Valve Dead Angle (%) 0 - 100, (default = 1) - -

DiagnosticsDevice Alert Settings Test Timeout (s) 0 - inf, (default = 90.0) - -

Test Warning Time (s) 0 - inf, (default = 2.0) - -Position Error Tolerance (%) 0 - 100, (default = 10.0) - -Supply Pressure High Alarm Limit (bar)

0 - 10, (default = 7.5) - -

Supply Pressure Low Alarm Limit (bar)

0 - 10, (default = 2.0) - -

Pressure Peak Tolerance (%) 0 - 100, (default = 30) - -Pressure Peak (bar) 0 - 10, (default = 0) - -Pressure Recovery Time (s) 0 - inf, (default = 5,0) - -Valve Test Pressure Low Limit (bar) 0 - 7, (default = 0) - -

Statistical Alert Settings

Load Factor Limit HIGH (%) 0 - 100, (default = 100) - -Load Factor Limit LOW (%) 0 - 100, (default = 0) - -Breakaway Pressure Limit HIGH (bar) 0 - 10, (default = 8) - -Breakaway Pressure Limit LOW (bar) 0 - 10, (default = 0) - -Leakage Alarm Limit (mV) 0 - 3200, (default = 3200) - -Valve Test Number Limit 0 - inf, (default = 1000000) - -Pneumatics Test Number Limit 0 - inf, (default = 1000000) - -

TestingPneumatics Test Pneumatics Test Timer 1 min - 1000000 h - -

Pneumatics Test interval 1 min - 1000000 h(default = 41666 d 16 h 0 min = 1000000 h)

Valve Test Valve Test Timer 1 min - 1000000 hValve Test Interval 1 min - 1000000 h

(default = 41666 d 16 h 0 min = 1000000 h)

Test Stroke Size (%) 0 - 100, (default = 20.0) - -Pressure Step (bar) 0.001 - 1, (default = 0.05) - -

AdvancedHART Configuration 1st Dynamic Variable Code 0 = Actual Travel, 1 = Leakage Signal,

2 = Actuator Pressure, 3 = Device Temperature, (default = 0)

- -

2nd Dynamic Variable Code 0 = Actual Travel, 1 = Leakage Signal, 2 = Actuator Pressure, 3 = Device Temperature, (default = 1)

- -

3rd Dynamic Variable Code 0 = Actual Travel, 1 = Leakage Signal, 2 = Actuator Pressure, 3 = Device Temperature, (default = 2)

- -

4th Dynamic Variable Code 0 = Actual Travel, 1 = Leakage Signal, 2 = Actuator Pressure, 3 = Device Temperature, (default = 3)

- -

Response Preambles 5 - 20, (default = 5) - -

34 9 VGB 70 en

14 EC DECLARATION OF CONFORMITY

EC DECLARATION OF CONFORMITYManufacturer:Metso Automation Oy00811 HelsinkiFinland

Product: Intelligent Safety Valve Controller Neles ValvGuard VG800-series

Approvals:Type Approval EC Type examination CertificateVG8_B1_ ATEX II 2G Ex d IIC T5/T6 DEMKO 07 ATEX 143372XVG8_X_ ATEX II 1G EEx ia IIC T5/T6 DEMKO 03 ATEX 133502X

Applicable directives:EMC 89/336/EC and 93/68/EC Electrical componentsATEX 94/9/EC Electrical and non-electrical components

As the products within our sole responsibility of design and manufacture may be used as parts or components in machinery and are notalone performing functions as described in Article 6(2) in the Machinery Directive (2006/42/EC), we declare that our product(s) to whichthis Declaration of Conformity relates must NOT be put into service until the relevant machinery into which it is to be incorporated hasbeen declared in conformity with the provisions of the Machinery Directive.

The product above is manufactured in compliance with the applicable European directives and technical specifications/standards.

Protection from e.g. static electricity caused by the process or connected equipment must be considered by the user ( EN 60079-14 §6 ).

The product do not possess any residual risk according to hazard analyses made under the applicable directives providing that theprocedures stated by the Installation, Operation and Maintenance manual are followed and the product is used under conditionsmentioned in the technical specifications.

Manufacturer’s certificates:Standard / Directive Notified Body Certificate No.ISO 9001:2000 DNV 24888-2008-AQ-FIN-FINAATEX 94/9/EC Annex IV DNV 0575 DNV-2006-OSL-ATEX-0260Q

Helsinki 2 December 2009

Ralf Liljestrand, Quality ManagerAuthorized person of the manufacturer within the European Community

9 VGB 70 en 35

15 TYPE CODING

Neles ValvGuard

1. 2. 3. 4. 5. 6. 7. 8.

VG 8 5 68 B1 S1 A SL

1. PRODUCT GROUP

VGNeles ValvGuard for emergency shutdown valves, including only the smart safety valve controller. The Remote Communication Interface module (RCI) has to be specified separately.

2. SERIES CODE

8

3. INPUT SIGNAL RANGE

5 0/24 V DC binary on/off-signal

4. SPOOL VALVE CONNECTIONS (S, C2)

68 Single action 1/4 NPT

5. ELECTRICAL CLASSIFICATION

B1

Flameproof enclosure.ATEX II 2 G Ex d IIC T5/T6 certification according toEN 60079-0, EN 60079-1.Temperature range:T5: -40° to +80 °C / -40° to +176 °F.T6 -40° to +75 °C / -40° to +167 °F.Supply voltage 21...30 V DC.M20x1.5 conduit entry.

B2

Flameproof enclosure.FM certification, Class I, Division 1 and 2, Groups B, C and D,Class II and Class III, Groups E, F and G, FM 3615.Temperature range:T5: -40° to +80 °C /-40° to +176 °FT6: -40° to +75 °C /-40° to +167 °FSupply voltage 21...30 V DC.1/2" NPT conduit entry.

B3

Flameproof enclosure.CSA certification,Class I, Divisions 1 and 2, Groups B, C, D,Class II, Division 2, Groups E, F and G and Class III.CSA C22.2 no142-M1987/CSA C22.2 no30-M1986/CSA C22.2 no 25-1966.Temperature range -40° to +80 °C / -40° to +176 °F.Supply voltage 21...30 V DC.1/2'' NPT conduit entry.

6. ACTUATOR CONNECTION

S1Rotary motion.Attachment face according to standard VDI/VDE 3845, equipped with an H-clip. When separate deliveries,VDI/VDE 3845 ear is supplied.

A1Linear motion.Applicable to linear actuators according to IEC 60534-6-1 with own linkage set.

Y Special construction

7. PRESSURE GAUGES

N No pressure gauges.

APressure gauges, scale bar/psi/kPa, basic material brass, nickel plated housing stainless steel. Glycerine filled.Temperature range for gauges -40° to +80 °C / -40° to +176 °F.

8. LEAKAGE SENSOR

SLAcoustic leakage sensor. Voltage: 3.3 VDC, I < 10 mAElectrical classification shall be B1 ( 5.sign)Temperature range for B1: T5; -40° to +60 °C / -40° to +140 °F. T6; +40 °C / +104 °F.

ADDITIONAL ACCESSORIES

FILTER REGULATOR

K

Filter regulator for supply air. Filter size 5 µm.Pressure gauge, scale bar/psi/kPa, basic material brass, nickel plated, housing stainless steel, glycerine filled.Temperature range -40º to +82 ºC / -40º to +180 ºF.If large capacity filter regulator is required please contact Metso.

CONDUIT ENTRY NIPPLES

CE091/2" NPT conduit entry nipple.M20x1,5 / 1/2 NPT, Exd approved.Applicable with 5. sign "B1"

ADDITIONAL DEVICES FOR VG800

RCI24V

RCI, Remote Communication Interface.SIL 3 certified according to IEC61508 together with VG800.Input 0/24 V DC. For other input voltages contact Metso.

NOTE: RCI24V is always needed with VG800

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

North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, MA 01545, USA. Tel. +1 508 852 0200. Fax +1 508 852 8172Latin America, Av. Independéncia, 2500-Iporanga, 18087-101, Sorocaba-São Paulo, Brazil. Tel. +55 15 3235 9700. Fax +55 15 3235 9748/49

Asia Pacific, 238A Thomson Road, #25-09 Novena Square Tower A, 307684 Singapore. Tel. +65 6511 1011. Fax +65 6250 0830China, 19/F, the Exchange Beijing, No. 118, Jianguo Lu Yi, Chaoyang Dist, 100022 Beijing, China. Tel. +86-10-6566-6600. Fax +86-10-6566-2575

Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai, United Arab Emirates.Tel. +971 4 883 6974. Fax +971 4 883 6836

www.metso.com/automation

36 9 VGB 70 en

neles valvguard™ system series vg800b -...

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