ND9000 Valve Controller

Pocket Reference Guide

For Revision 2, 2.x
 Table of Contents
ND9000 Type Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Neles Actuator to ND9000 Combinations . . . . . . . . . . . . . . . 2
Error Messages on LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Failsafe Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Notifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mounting Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measurement Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Guided Start-Up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Configuring the Positioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting the Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Valve Travel Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Additional Information & Support Files. . . . . . . . . . . . . . . . 25

ND9000 Valve Controller I

 ND9000 Type Coding
1. Sign Product Group
ND Intelligent Valve Controller

2. Sign Series Code

9

3. Sign Enclosure
10 Standard IP66 / NEMA 4X
20 Flameproof (Ex d) IP66 / NEMA 4X

4. Sign Spool Valve

2 Low Capacity. Actuator < 1 dm3
3 Medium Capacity. Actuator 1…3 dm3
6 High Capacity. Actuator > 3 dm3

5. Sign Communication/Input Signal Range

H 4-20 mA, HART Communication
F Foundation Fieldbus
P Profibus PA

(Signs 6, 7, 8, & 9 are Options; see IMO for details)

ND9000 Valve Controller 1

 Neles Actuator to ND9000
Combinations
ND9102: EC05, 07, & 10, EJ05, & 07, B1C6, 9, B1J(A)8, QP1
ND9103: EC10, 12, EJ07, 10, 12, B1C6, 9, 11, 13, B1J(A)8, &
10, QP1, 2, & 3
ND9106: EC14, 16, & 25, EJ14, 16, & 25, B1C17, 20, 25, 32,
40, 50, & 502, B1J(A)12, 16, 20, 25, 32, & 322,
QP4, 5, & 6

Error Messages on LCD

Failsafe Errors
Display Message Action
Position Sensor Failure Change the ND9000 device
to a new one.
Setpoint Sensor Failure Change the ND9000 device
to a new one.
Prestage Shortcut Error Shortcut in prestage unit.
Replace prestage unit.
FAE nnn Fatal malfunction in the
device. Nnn is a number
between 001 - 004. Change
the ND9000 device to a new
one.

ND9000 Valve Controller 2

Alarms
Display Message Description/Action
Deviation Alarm Valve deviation out of limits
Stiction low alarm Stiction has exceeded the
low limit
Stiction high alarm Stiction has exceeded the
high limit
Load for opening low Load for opening has
exceeded the low limit
Load for opening high Load for opening has
exceeded the high limit
Load for closing too low Load for closing has exceed-
ed the low limit.
Load for closing too high Load for closing has exceed-
ed the high limit.
Spool valve problem Check the spool valve unit
and replace if necessary.
Pneumatics problem Check pneumatic connec-
tions and actuator leakage.
Friction problem Valve is not moving correct-
ly. Check load factor.

ND9000 Valve Controller 3

Errors
Display Message Description/Action
Prestage Cut Error Prestage wire is cut or con-
nector is loose.
Pressure Sensor 1 Failure The device performance is
reduced. Change the
ND9000 device to a new
one during next mainte-
nance activity.
Pressure Sensor 2 Failure The device performance is
reduced. Change the
ND9000 device to a new
one during next mainte-
nance activity.
Pressure Sensor 3 Failure Supply pressure sensor
failed. No affect on perform-
ance.
Spool Valve Sensor Failure Check the sensor connec-
tions. Device performance
level is reduced. Change the
ND9000 device to a new
one during next mainte-
nance activity.
Temp. Sensor Failure The accuracy of the meas-
urements is reduced.
Change the ND9000 device
to a new one during next
maintenance activity.

ND9000 Valve Controller 4

Statistics Database Error Failed to store statistics.
New measurements will be
lost.
Event Database Error Failed to store events. New
events will be lost.
Pos. Calibration Failed Check the configuration
parameters and controller
mounting. Check that the
controller shaft is properly
aligned.
Tuning failed Check that the valve is mov-
ing properly. Check the
prestage and spool unit.
Pos. Sensor Range Error Position sensor range failed
during calibration. Valve
controller shaft failed to
rotate minimum 45 deg.
Check the configuration
parameters and controller
mounting. Check that the
controller shaft is correctly
aligned.
Calibration Timeout Check configuration and
installation.
Calibration start Failed Check the supply pressure.
Tuning Range Error Check the prestage and
spool valve unit.

ND9000 Valve Controller 5

Spool Sensor Range Err Spool sensor range failed
during position calibration.
Check the configuration
parameters. Check the
prestage and spool valve
unit.

Warnings
Display Message Description/Action
Total Operation Time Operating Time Exceeded
Limit
Valve Full Strokes Warn. Valve Stroke Counter Limit
Reached
Valve Reversals Warn. Valve Reversals counter limit
reached.
Act. Full Strokes Warn. Actuator Stroke counter
limit reached.
Actuator Reversals Warn. Actuator Reversals counter
limit reached
Spool Full Strokes Warn. Spool stroke counter limit
reached
Spool Reversal Warn. Spool reversals counter limit
reached
Steady State Dev. Warn. Steady State deviation has
increased
Dyn. State Dev. Warn. Dynamic State deviation has
increased
Stiction Low Warning Stiction has exceeded the
low limit

ND9000 Valve Controller 6

Stiction High Warning Stiction has exceeded the
high limit
Ld. for Opening too Low Load for opening has
exceeded the low limit
Ld. for Opening too High Load for opening has
exceeded the high limit
Supp. Press. Out of Limit Supply pressure has exceed-
ed the specified operating
conditions
Temperature Out of Limit Temperature has exceeded
the specified operating con-
ditions
Hunting Detection Warn. Change performance level
to less aggressive to stabi-
lize valve. Check that the
spool valve capacity is suit-
able for the actuator.
Reduced Perform Activ. Performance is reduced due
to defective spool valve sen-
sor. Change the spool valve
assembly
Too Low Supply press for 1-Act actuator
Increase supply pressure.
Valve Rev. Trend Warn. Travel setpoint per day has
exceeded the limit
Valve Rev. while Stable SP Valve reversals while set-
point is stable, per day, has
exceeded the limit

ND9000 Valve Controller 7

Load for closing too Low Load for closing has
exceeded the low limit
Load for closing too high Load for closing has
exceeded the high limit

ND9000 Valve Controller 8

Notifications
Display Message Description
Calibration Successful Position Calibration
Successfully performed.
Test Cancelled Off-line test has been can-
celled.
Test Done Off-line test has been suc-
cessfully performed.
Test Failed Off-line test failed. Repeat
the test sequence.
Calibration Cancelled Calibration has been can-
celled.
Param Backup Restored Parameter backup database
has been activated.
PT Not Activated (Only with position transmit-
ter option). The position
transmitter is not energized.
1PT Cal Failed 1-point calibration failed.
Check the mounting of the
valve controller. Verify input
parameter (range) value.
Check rotation parameter
(ROT).
Tune Ok Tuning has been successful-
ly performed.
Reduced Perf Deactivated Spool valve measurement
and normal valve control is
recovered.

ND9000 Valve Controller 9

 Mounting Tips
The ND9000 will only function in the pre-set 90° quad-
rant, see below photo. If this is done incorrectly, errors
“Position Calibration Failed” and “Position Sensor
Range Error” can occur during calibration.
• Be sure air supply is connected and a minimum of 3.6
mA power is supplied.
• Set Filter Regulator: For D/A actuators, set approx. 10 PSI
below minimum expected air supply pressure. For S/A
actuators, set at no more than 14.5 psi higher than
spring rating. (For spring ratings below 45 psi, set at 60
psi.) Do not exceed the actuator’s pressure rating
and do not exceed 115 psi.
• When inserting the H-Clip into the bracket, ensure that
the H-Clip is straight as seen in #11 on the following
page.
• Once the mounting has been completed, per the IMO,
the air supply and power can be connected to begin
the commissioning.

ND9000 Valve Controller 10

 Mounting for Clockwise-to-Close 90°
Rotary

50%
Open
Closed

Pointer must stay within the arc.

Turn over & mount, per IMO

110 deg max range

ND9000 Valve Controller 11

 Measurement Monitoring
Remove cover.
Notice the function menu on the
inside of the exterior cover.

LCD indicates POS, valve position

(% [DEFAULT], ANG).

Press the [+] key once.

The LCD displays TPOS,
target position (%).

Press the [+] key once.

The LCD displays SETP, setpoint (mA
[DEFAULT], %)

Press the [+] key once.

The LCD displays PDIF, actuator
pressure differential
(BAR [DEFAULT], PSI)

ND9000 Valve Controller 12

 Press the [+] key once.
The LCD displays SUPL, supply
pressure (BAR [DEFAULT], PSI)

Press the [+] once.

The LCD display TEMP, temperature
(C [DEFAULT], F)

ND9000 Valve Controller 13

 Changing the Units in Measurement
Monitoring

ND9000 Valve Controller 14

 Guided Start-Up Menu
Press [C] and [↵] keys simultaneously.

VTYPE (Valve Type)*

Rot – Rotary valve
Lin – Linear valve (corrected for nonlinearity)
nCG – NelesCV Globe valve
FLI – Linear valve (not corrected)

ATYPE (Actuator Type)*

2-A – double-acting
1-A – single-acting

PFA (Positioner Fail Action)*

CLO – fail closed
OPE – fail open

ROT (Valve Rotation Direction)*

cC – clockwise to close
ccC – counterclockwise to close

A0 (Valve Dead Angle)

A0 – 0% - (Default), set as required by valve type

CAL (Calibration)
AUTO CAL – Automatic Calibration
TUNE – YES or NO
MAN CAL – Manual Calibration
TUNE – YES or NO

* Modifying this parameter requires calibrating and tuning of

the device.

ND9000 Valve Controller 15

1-PT CAL – 1 Point Calibration
ANG – Maximum Tuning Angle

Configuration Menu
Press [+] and [−] keys simultaneously

MODE (Mode Menu):

AUTO – Controlled by 4-20mA input signal
MAN - Manually controlled by keypad

PAR (Configuration Parameters):

PERF (Performance Level)
A(1) – Agressive
B(1) – Fast
C(1) – Optimum
D(1) – Stable
E – Maximum Stability
(1) is for volume boosted and/or very fast actuators
CUTL (Low cut-off )
2.0% - (Default), adjust as necessary
DIR (Signal Direction)
OPE – rising signal to Open
CLO – rising signal to Close
VTYP (Valve Type)*
Rot – Rotary valve
Lin – Linear valve (corrected for nonlinearity)
nCG – NelesCV Globe Valve
FLI – Linear valve (not corrected)

* Modifying this parameter requires calibrating and tuning of

the device.
ND9000 Valve Controller 16
ATYP (Actuator Type)*
1-A – Single Acting Actuator
2-A – Double Acting Actuator
PFA (Positioner Fail Action)*
CLO – Closed
OPE – Open
ROT (Valve Rotation Direction)*
cC – Clockwise to Close
ccC – Counterclockwise to Close
A0 (Valve Dead Angle)
0% - (Default), set as required by valve type
LANG
EnG – English
GEr – German
FrE – French

CAL (Valve Travel Calibration)

AUTO CAL – Automatic Calibration
TUNE – YES or NO
MAN CAL – Manual Calibration
TUNE – YES or NO
1-PT CAL – 1 Point Calibration
ANG – Maximum Tuning Angle
As a general rule: [↵] selects anything so it is blinking and
enters menus. [+] and [−] change anything that is blink-
ing and move between menus/settings. [C] cancels any
action and returns the user interface view up one level.

* Modifying this parameter requires calibrating and tuning of

the device.

ND9000 Valve Controller 17

 Configuring the Positioner
Press the [+] and [−] simultaneously
to access the Configuration Menu
(refer to chart on pg. 16/17). This
menu will allow access to all config-
uration settings available from the
Local User Interface (LUI).

Setting the Mode

The mode menu (MODE) screen will
be displayed. Pressing [↵] will cause
MODE to start blinking. Use the [+]
and [−] keys to move between AUTO
(automatic operation) and MAN
(adjust TPOS using the [+] and [−]
keys). Press [↵] to select the desired
mode.

Configuration Parameters
Press [+] to display the configuration
parameters (PAR) screen. Pressing
[↵] will enter the parameters menu.

ND9000 Valve Controller 18

 The first parameter in the menu is
performance level (PERF) setting.
Pressing [↵] will cause PERF to start
blinking. Use the [+] and [−] keys to
move between performance levels
(A…E, A1…D1). Press [↵] to select
the desired performance level.

Press [+] to display the Low cut-off

(CUTL) setting. Pressing [↵] will
cause CUTL to start blinking. Use
the [+] and [−] keys to change the
signal percentage that forces the
valve closed (Default = 2%). Press [↵]
to select the desired value.

ND9000 Valve Controller 19

 Press [+] to display the Signal
Direction (DIR) setting. Pressing [↵]
will cause DIR to start blinking. Use
the [+] and [−] keys to move
between rising signal to open (OPE),
and rising signal to close (CLO). Press
[↵] to select the desired value.

Press [+] to display the Valve Type

(VTYP) setting. Pressing [↵] will
cause VTYP to start blinking. Use
the [+] and [−] keys to move
between Rotary valve (Rot), Linear
valve (Lin), NelesCV Globe Valve
(nCG), and Linear valve, not correct-
ed, (FLI). Press [↵] to select the
desired setting.

Press [+] to display the Actuator

Type (ATYP) setting. Pressing [↵] will
cause ATYP to start blinking. Use
the [+] and [−] keys to move
between single-acting (1-A) and
double-acting (2-A). Press [↵] to
select the desired setting.

ND9000 Valve Controller 20

 Press [+] to display the Positioner
Fail Action (PFA) setting. Pressing [↵]
will cause PFA to start blinking. Use
the [+] and [−] keys to move
between fail open (OPE) and fail
close (CLO). Set in spring direction
for single-acting actuators. For dou-
ble-acting actuators, set CLO for
direct piping and OPE for reversed
piping. Press [↵] to select the
desired setting.

Press [+] to display the Valve

Rotation Direction (ROT) setting.
Pressing [↵] will cause ROT to start
blinking. Use the [+] and [−] keys to
move between clockwise to close
(cC) and counterclockwise to close
(ccC). Press [↵] to select the desired
setting.

Press [+] to display the Dead Angle

(A0) setting. Pressing [↵] will cause
A0 to start blinking. Use the [+] and
[−] keys to enter the correct value
from the below table. This value will
compensate for the inherent “dead
angle” of segmented and ball valves.
This allows for the entire signal
range to be used for control. Press
[↵] to select the desired setting.

ND9000 Valve Controller 21

 Press [+] to display the Language
Selection (LANG) setting. Pressing
[↵] will cause LANG to start blinking.
Use the [+] and [−] keys to move
between English (EnG), German
(GEr), and French (FrE). Press [↵] to
select the desired setting.

ND9000 Valve Controller 22

Valve Travel Calibration
Press [C] to exit the parameters
menu. Then press [+] to view the
valve travel calibration (CAL) screen.
Press [↵] to enter the calibration
menu.

The Automatic calibration (AUTO

CAL) will be flashing.
Use AUTO Calibration for actuators
that have both Open & Close
mechanical stops. Pressing [↵] will
display TUNE with YES flashing. Use
the [+] and [−] keys to move
between YES and NO. Press [↵] to
start the calibration with or without
the tuning function.

Press [+] to display manual calibra-

tion (MAN CAL) flashing.
Select MANUAL Calibration if you
cannot drive the valve into a fully
open position or of there is no
mechanical limit stop. Pressing [↵]
will display TUNE with YES flashing.
Use the [+] and [−] keys to move
between YES and NO. Press [↵] to
start the calibration with or without
the tuning function.

ND9000 Valve Controller 23

 First use the [+] and [−] keys to drive
the valve to the closed position,
then press [↵].
Next use the [+] and [−] keys to drive
the valve to the open position, then
press [↵]. The rest of the calibration
will run automatically.

Press [+] to display tune (TUNE)

flashing.
Selecting TUNE will cause the con-
troller to search for the optimum
internal control parameters for the
valve position control. Press [↵] to
execute the TUNE function.

Press [+] to display 1-point calibra-

tion (1PT CAL) flashing.
Select 1-Point Calibration if the valve
controller needs to be changed but
the valve is not allowed to change
position (i.e. the valve is active). This
procedure does not ensure the best
possible control performance, and it
is always recommended to run
either AUTO or MAN calibration with
tuning as soon as possible.

ND9000 Valve Controller 24

 Before starting 1-point calibration
ensure that the valve is mechanical-
ly locked. Change the MODE to
manual (MAN) and adjust target
position (TPOS) so that it matches
the physical position of the valve.
Do not connect supply pressure
until 1-point calibration is
successfully complete.

Press [↵] to display ANG which will

be flashing. Use the [+] and [−] keys
to enter the maximum tuning angle
that the valve can perform, then
press [↵].

After a successful calibration the

LCD will display CALIBRATION SUC-
CESSFUL. Press [C] twice to get back
to measurement view.

Additional Information & Support Files

Visit our web site for access to IMO’s, Technical Bulletins,
DTM files, HART DD files, Foundation Fieldbus and
Profibus-PA support files w/ manuals, and more.
http://www.metsoautomation.com/ND9000

ND9000 Valve Controller 25

Metso Automation

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

North America
44 Bowditch Drive, P.O. Box 8044
Shrewsbury, Massachusetts
01545-8044 U.S.A.
Tel. int. +1 508 852 0200
Fax int. +1 508 393 0978

Europe
6-8 rue du Maine
68271 Wittenheim Cedex, France
Tel. int. +33 (0)3 89 50 64 00
Fax int. +33 (0)3 89 50 64 40

Latin America
Avenida Independencia, 2500 – Iporanga
18087-101, Sorocaba – São Paulo
BRAZIL
Tel. int. +55 15 2102-9700
Fax int. +55 15 2102-9748/49

Middle East
Jebel Ali Freezone, P.O. Box 17175
Dubai
United Arab Emirates
Tel. int. +971 4 883 6974
Fax int. +971 4 883 6836

Asia Pacific
238 A Thomson Road
#25 - 09 Novena Square Tower A
307684 Singapore
Tel. int. +65 6511 1011
Fax int. +65 6250 0830

www.metsoautomation.com

PG-ND9000 6/08