Metso Neles ND9100P Operating and maintenance manual

INTELLIGENT
VALVE CONTROLLER
ND9100P
Rev. 2.2
Installation, Maintenance and
Operating Instructions
7 ND91P 70 en • 1/2009

27 ND91P 70 en
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about the safe handling and operation of the intelligent valve controller.
If you require additional assistance, please contact the manufacturer or manufacturer's representative.
Addresses and phone numbers are printed on the back cover.
SAVE THESE INSTRUCTIONS!
Subject to change without notice.
All trademarks are property of their respective owners.
Table of Contents
1 ND9000 PRODUCT FAMILY SUMMARY ....... 3
1.1 Key features........................................... 3
2 ND9100P INTELLIGENT VALVE CONTROLLER
WITH PROFIBUS PA COMMUNICATION ...... 4
2.1 General .................................................. 4
2.2 Technical description ............................ 4
2.3 Markings ................................................ 4
2.4 Technical specifications ........................ 5
2.5 Recycling and disposal ......................... 6
2.6 Safety precautions ................................. 6
3 TRANSPORTATION, RECEPTION AND
STORAGE ....................................................... 6
4 MOUNTING...................................................... 6
4.1 General .................................................. 6
4.2 Mounting on EC and EJ actuators......... 7
4.3 Mounting on Metso actuators with
VDI/VDE mounting face ......................... 7
4.4 Mounting on linear actuator of
nelesCV Globe....................................... 8
4.5 Mounting on linear actuator with IEC 60534
mounting face ........................................ 8
4.6 Piping..................................................... 9
4.7 Electrical connections.......................... 12
5 LOCAL USER INTERFACE (LUI) ................. 13
5.1 Measurement monitoring ..................... 13
5.2 Guided start-up.................................... 13
5.3 Configuration menu ............................. 14
5.4 Mode menu.......................................... 14
5.5 Configuration parameters.................... 15
5.6 Valve travel calibration......................... 17
5.7 Special displays................................... 18
5.8 Write protection.................................... 19
6 MAINTENANCE............................................. 19
6.1 Prestage............................................... 19
6.2 Spool valve assembly .......................... 20
6.3 Communication circuit board .............. 20
7 ERROR MESSAGES..................................... 21
7.1 Failsafe errors ...................................... 21
7.2 Alarms.................................................. 21
7.3 Errors ................................................... 21
7.4 Warnings.............................................. 22
7.5 Notifications ......................................... 22
8 TROUBLE SHOOTING.................................. 23
9 ND9100P/B06 (WITH LIMIT SWITCHES) ..... 24
9.1 Introduction.......................................... 24
9.2 Installing ND9100P/B06 on
a valve controller.................................. 24
9.3 Electrical connections.......................... 25
9.4 Adjustment........................................... 25
9.5 Removal of the limit switches
ND9100P/B06 ...................................... 25
9.6 Circuit diagrams .................................. 25
9.7 Maintenance ........................................ 25
10 TOOLS........................................................... 25
11 ORDERING SPARE PARTS ......................... 25
12 DRAWINGS AND PARTS LISTS .................. 26
12.1 Exploded view and parts list,
ND9100P.............................................. 26
12.2 Exploded view and parts list,
ND9100P/B06 ...................................... 27
12.3 Mounting parts for EC05-14/EJ05-14
actuators, rising signal opens valve .... 28
12.4 Mounting parts for B1C/B1J6-20
actuators .............................................. 28
12.5 Mounting parts for B1C/B1J25-50,
B1C502 and B1J322 actuators............ 29
12.6 Mounting parts for Quadra-Powr®
actuators .............................................. 29
12.7 Mounting parts for linear actuators of
nelesCV Globe ..................................... 30
12.8 Mounting parts for linear actuators ...... 31
12.9 Connection diagram ............................ 32
12.10 Control drawing ................................... 33
13 DIMENSIONS ................................................ 35
14 EC DECLARATION OF CONFORMITY ........ 36
15 TYPE CODING .............................................. 37

7 ND91P 70 en 3
1 ND9000 PRODUCT FAMILY SUMMARY
1.1 Key features
❑Benchmark control performance on rotary and
linear valves
❑Reliable and robust design
❑Ease of use
❑Language selection: English, German and French
❑Local / remote operation
❑Expandable architecture
❑Advanced device diagnostics including
❑Self-diagnostics
❑Online diagnostics
❑Performance diagnostics
❑Communication diagnostics
❑Extended off-line tests
❑Intelligent Valve Diamond
1.1.1 Options
❑Interchangeable communication options:
❑Profibus PA
❑FOUNDATION Fieldbus
❑HART
❑Limit switches
❑Position transmitter (in HART only)
❑Special corrosion resistant finish
❑Exhaust adapter
1.1.2 Total cost of ownership
❑Low energy and air consumption
❑Future proof design allows further options at a
reduced cost
❑Optimised spares program. Reduced number of spares
❑Retro-fit to existing installations (Neles or 3rd party)
1.1.3 Minimised process variability
❑Linearisation of the valve flow characteristics
❑Excellent dynamic and static control performance
❑High-speed of response
❑Accurate internal measurements
1.1.4 Easy installation and configuration
❑Same unit for linear and rotary valves, double
and single-acting actuators
❑Simple calibration and configuration
❑using Local User Interface
❑using Profibus configurator,
such as FieldCare or Simatic PDM
❑Flush mounting capability to avoid tubing and
mounting parts
❑Low power design enables installation to all com-
mon control systems
1.1.5 Open solution
Metso is committed to delivering products that freely inter-
face with software and hardware from a variety of manufac-
turers; and the ND9000 is no exception. This open
architecture allows the ND9000 to be integrated with other
field devices to give an unprecedented level of controllability.
❑FDT based multi-vendor support configuration
ND9000 DTM download page:
www.metso.com/automation/nd9000
1.1.6 ND9000 in fieldbus networks
❑Approved interoperability
❑Host interoperability ensured
❑FOUNDATION Fieldbus ITK version 5.01 certified
❑Profibus PA profile version 3.0 PNO certified
❑Easy to upgrade; can be done by replacing the
HART communication board to fieldbus commu-
nication board
❑Excellent maintainability with firmware download-
feature
❑Advanced communication diagnostics
❑Digital communication via the fieldbus includes
not only the set point, but also the position feed-
back signal from the position sensor. No special
supplementary modules for analog or digital
position feedback are needed when using the
fieldbus valve controller.
❑Back up LAS functionality available in FOUNDA-
TION Fieldbus enviroment
❑Input selector and output splitter blocks available
in FOUNDATION Fieldbus devices allowing
advanced distributed control
❑Multipurpose functionality
❑Standard function blocks enables the freedom
to use ND9000 intelligent valve controller either
in continuous or on-off control applications
❑Open and close information directly available
via the fieldbus
❑Open and close detection is based on either
position measurement (soft limit switch) or
mechanical limit switch information
❑ND9000 download page:
www.metso.com/automation/nd9000
1.1.7 ND9000 mounting on actuators and
valves
❑Mounted on single and double acting actuators
❑Both rotary and linear valves
❑Flush mounting capability
❑Ability to attach options to electronics and
mechanics later
❑Possibility to mount also on valves that are in
process with 1-point calibration feature
1.1.8 Product reliability
❑Designed to operate in harsh environmental con-
ditions
❑Rugged modular design
❑Excellent temperature characteristics
❑Vibration and impact tolerant
❑IP66 enclosure
❑Protected against humidity
❑Maintenance free operation
❑Resistant to dirty air
❑Wear resistant and sealed components
❑Contactless position measurement
1.1.9 Predictive maintenance
❑Easy access to collected data with FieldCare software
❑Ingenious Valve Diamond to visualise control
valve performance & diagnostics
❑Logical trend and histogram collection
❑Information collected on service conditions
❑Extensive set of off-line tests with accurate
key figure calculations
❑Fast notifications using on-line alarms
❑Condition monitoring tool available
❑Real time monitoring of valve control parameters.

47 ND91P 70 en
2 ND9100P INTELLIGENT VALVE
CONTROLLER WITH PROFIBUS PA
COMMUNICATION
2.1 General
This manual incorporates Installation, Maintenance and
Operation Instructions for the Metso ND9100P intelli-
gent valve controller. The ND9100P may be used with
either cylinder or diaphragm type pneumatic actuators
for rotary or linear valves.
2.2 Technical description
The ND9100P is a fieldbus powered microcontroller-
based intelligent valve controller. The ND9100P configu-
ration can be done either using local push buttons or
profibus configurator.
The powerful 32-bit microcontroller controls the valve
position. The measurements include:
❑Input signal
❑Valve position with contactless sensor
❑Actuator pressures, 2 independent measurements
❑Supply pressure
❑Spool valve position
❑Device temperature
Advanced self-diagnostics guarantees that all meas-
urements operate correctly. Failure of one measure-
ment does not cause the valve to fail if the input signal
and position measurements are operating correctly.
After connections of electric signal and pneumatic sup-
ply the micro controller (µC) reads the input signal,
position sensor (α), pressure sensors (Ps, P1, P2) and
spool position sensor (SPS). A difference between
input signal and position sensor (α) measurement is
detected by the control algorithm inside the µC. The µC
calculates a new value for prestage (PR) coil current
based on the information from the input signal and from
the sensors. Changed current to the PR changes the
pilot pressure to the spool valve. Reduced pilot pres-
sure moves the spool and the actuator pressures
change accordingly. The spool opens the flow to the
driving side of the double diaphragm actuator and
opens the flow out from the other side of the actuator.
The increasing pressure will move the diaphragm pis-
ton. The actuator and feedback shaft rotate clockwise.
The position sensor (α) measures the rotation for the
µC. The µC using control algorithm modulates the PR-
current from the steady state value until a new position
of the actuator according to the input signal is reached.
2.3 Markings
The valve controller is equipped with an identification
plate sticker (Fig. 2).
Identification plate markings from top to bottom include:
❑Type designation of the valve controller
❑Revision number
❑Enclosure class
❑Operational temperature
❑Input signal (voltage range)
❑Input resistance
❑Maximum supply voltage
❑Supply pressure range
❑Contact details of the manufacturer
❑CE mark
❑Manufacturing serial number TTYYWWNNNN*)
*) Manufacturing serial number explained:
TT= device and factory sign
YY= year of manufacturing
WW = week of manufacturing
NNNN = consecutive number
Example: PH08011234 = controller, year 2008, week 1,
consecutive number 1234.
NOTE:
The selection and use of the valve controller in a specific
application requires close consideration of detailed
aspects. Due to the nature of the product, this manual
cannot cover all the likely situations that may occur when
installing, using or servicing the valve controller.
If you are uncertain about the use of the controller or its
suitability for your intended use, please contact Metso’s
Automation business for more information.
Fig. 1 The principle of operation
Fig. 2 Identification plate

7 ND91P 70 en 5
2.4 Technical specifications
ND9100P INTELLIGENT VALVE CONTROLLER
General
Bus powered, no external power supply required.
Suitable for rotary and sliding-stem valves.
Actuator connections in accordance with VDI/VDE 3845
and IEC 60534-6 standards.
Flush mounting on NelesCV™ control valves.
Action: Double or single acting
Travel range: Linear; 10–120 mm with standard IEC parts.
Larger strokes possible with suitable kits
Rotary: 45–95°.
Measurement range 110° with freely
rotating feedback shaft.
Environmental influence
Standard temperature range:
-40° – +85 °C / -40° – +185 °F
Influence of temperature on valve position:
< 0.5 % / 10 °K
Influence of vibration on valve position:
< 1 % under 2g 5–150 Hz,
1g 150–300 Hz, 0.5g 300–2000 Hz
Enclosure
Material: Anodised aluminium alloy and
polymer composite
Protection class: IP66, NEMA 4X
Pneumatic ports: G 1/4
Electrical connection: max. 2.5 mm2
Cable gland thread: M20 x 1.5
Weight: 1.8 kg / 4.0 lbs
Mechanical and digital position indicator visible
through the main cover
Special corrosion resistant finish available
Pneumatics
Supply pressure: 1.4–8 bar / 20–115 psi
Effect of supply pressure on valve position:
<0.1 % at 10 % difference in inlet pressure
Air quality: According to ISO 8573-1:2001
Solid particles: Class 5
(3–5 µm filtration is recommended)
Humidity: Class 1
(dew point 10 °C/50 °F below minimum
temperature is recommended)
Oil class: 3 (or <1 ppm))
Capacity with 4 bar / 60 psi supply:
5.5 Nm3/h / 3.3 scfm (spool valve 2)
12 Nm3/h / 7.1 scfm (spool valve 3)
38 Nm3/h / 22.4 scfm (spool valve 6)
Consumption with 4 bar / 60 psi supply
in steady state position:
< 0.6 Nm3/h / 0.35 scfm (spool valves 2 & 3
< 1.0 Nm3/h / 0.6 scfm (spool valve 6)
Electronics
Power supply: taken from bus
Bus voltage: 9 to 32 V DC, reverse polarity protection
Max basic current:17.2 mA
Fault current (FDE):3.9 mA
EEx ia IIC T6: Ui ≤24 V
Ii ≤380 mA
Pi ≤5.32 W
Ci < 5 nF
Li < 10 µH
EEx nL IIC: Ui ≤32 V
Ii ≤380 mA
Pi ≤5.32 W
Ci < 5 nF
Li < 10 µH
(ATEX approval is valid under these conditions)
Performance with moderate constant-load,
actuators EC05-EC10
Values at 20 °C / 68 °F and without any additional instru-
ments, such as boosters or quick exhaust valves etc.
Dead band acc. to IEC 61514:
≤0.1 %
Hysteresis acc. to IEC 61514:
<0.5 %
Local user interface functions
❑Local control of the valve
❑Monitoring of valve position, input signal, temper-
ature, supply and actuator pressure difference
❑Guided start-up function
❑LUI may be locked remotely to prevent unauthor-
ised access
❑Calibration: Automatic / Manual
❑1-point calibration
❑Limit switch state monitoring
❑Control configuration: aggressive, fast, optimum,
stable, maximum stability
❑Mode selection: Automatic/Manual
❑Rotation: valve rotation clockwise or counter-
clockwise to close
❑Dead angle
❑Low cut-off, cut-off safety range (default 2 %)
❑Positioner fail action, open/close
❑Actuator type, double/single acting
❑Valve type, rotary/linear IEC/nelesCV Globe/FLI
❑Language selection: English, German and French
Approvals
Intrinsically safe and non incendive
ATEX EC-Directive 94/9/EC;
EN 50014
EN 50020: 2 G EEx ia IIC T4...T6
EN 50284: 1 G EEx ia IIC T4...T6
EN50021: 3 G EEx nA II T4...T6
IEC 60079-27: EEx nL IIC
EN 50281-1-1: D T90 °C
CSA CAN/CSA-C22.2-0,-142, -157;
CAN/CSA-E60079-0,-11, -15
IS Class I, Div. 1, Groups A, B, C, D T4...T6
IS Class I, Zone 0, Ex ia IIC T4...T6
NI Class I, Div. 2, Groups A, B, C, D T4...T6
FM FM Class 3600, 3610, 3611, 3810:
IS Class I, Div. 1, Groups A, B, C, D T4...T6
IS Class I, Zone 0, AEx ia IIC T4...T6
NI Class I, Div. 2, Groups A, B, C, D T4...T6
NI Class I, Zone 2, Ex nA II T4...T6

67 ND91P 70 en
Electromagnetic Protection
Electromagnetic compatibility
Emission acc. to EN 61000-6-4 (2001)
and FCC 47 CFR PART 15,
SUBPART B, CLASS B (1994)
Immunity acc. to EN 61000-6-2 (2001)
CE Marking
89/336/EEC
Electromagnetic compatibility
94/9/EC
ATEX (when applicable)
MICRO SWITCHES, 2 PIECES
(OPTIONAL WITH EXTENSION MODULE)
Code B06 Omron D2VW-01 gold plated micro switch,
Bus powered, no external power and cabling needed.
Code I02 P+F NJ2-12GK-SN
Code I09 P+F; NCB2-12GM35-N0
Code I56 IFC 2002-ARKG/UP
Code K05 Omron D2VW-5, micro switch
Code K06 Omron D2VW-01 gold plated, micro switch
2.5 Recycling and disposal
Most valve controller parts can be recycled if sorted
according to material.
Most parts have material marking. A material list is supplied
with the valve controller. In addition, separate recycling and
disposal instructions are available from the manufacturer.
A valve controller may also be returned to the manufac-
turer for recycling and disposal. There will be a charge for
this.
2.6 Safety precautions
3 TRANSPORTATION, RECEPTION
AND STORAGE
The valve controller is a sophisticated instrument, han-
dle it with care.
❑Check the controller for any damage that may
have occurred during transportation.
❑Store the uninstalled controller preferably
indoors, keep it away from rain and dust.
❑Do not unpack the device until installing it.
❑Do not drop or knock the controller.
❑Keep the flow ports and cable glands plugged
until installing.
❑Follow instructions elsewhere in this manual.
4 MOUNTING
4.1 General
CAUTION:
Do not exceed the permitted values!
Exceeding the permitted values marked on the valve
controller may cause damage to the controller and to
equipment attached to the controller and could lead to
uncontrolled pressure release in the worst case. Dam-
age to the equipment and personal injury may result.
CAUTION:
Do not remove or dismantle a pressurized controller!
Removing or dismantling a pressurized prestage or
spool valve of an ND9100 leads to uncontrolled pressure
release. Always shut off the supply air and release the
pressure from the pipelines and equipment before
removing or dismantling the controller. Otherwise per-
sonal injury and damage to equipment may result.
WARNING:
During automatic or manual calibration and tuning
the valve operates between open and closed posi-
tions. Make sure that the operation does not
endanger people or processes!
WARNING:
Do not operate the device with electronics cover
(39) removed!
Electromagnetic immunity is reduced, valve may
stroke. Explosion protection may be impaired.
Intrinsic Safety (Ex i) WARNING:
Ensure that the complete installation and wiring is
intrinsically safe before operating the device!
The equipment must be connected via a certified
Zener barrier placed outside the hazardous area.
ATEX WARNING:
Electrostatic charge hazard!
The pointer and display windows are non-conductive.
Clean with a damp cloth only!
Spark hazard!
Protect the aluminium housing from impacts and fric-
tion!
ATEX WARNING:
For use in the presence of combustible dust.
Ignition protection relies on the enclosure. Protect the
cover of the valve controller from impacts. When tem-
perature is higher than 70 °C the temperature rating of
the cable shall be higher than the temperature.
NOTE:
Avoid earthing a welding machine in close proximity to
an ND9100H valve controller.
Damage to the equipment may result.
NOTE:
The enclosure of ND9100P intelligent valve controller meets
the IP66 protection class according to EN 60529 in any posi-
tion when the cable entry is plugged according to IP66.
Based on good mounting practice, the recommended
mounting position is electrical connections placed down-
wards. This recommendation is shown in our mounting
position coding for control valves.
If these requirements are not fulfilled, and the cable gland
is leaking and the leakage is damaging valve controller or
other electrical instrumentation, our warranty is not valid.

7 ND91P 70 en 7
If the ND9100P is supplied with valve and actuator, the
tubes are mounted and the ND9100P adjusted in
accordance with the customer’s specifications. If the
controller is ordered separately, the mounting parts for
the assembly must be ordered at the same time.
Sample order: (B1CU13)-Z-ND9106PN
The controller is equipped with the Metso flush mounting
face, the old Neles mounting face and for connection
according to VDI/VDE 3845.
Shaft coupling alternatives for the controller for Metso
actuators are shown in Fig. 5.
For mounting parts for Metso actuators, see 12.3 - 12.7.
4.2 Mounting on EC and EJ actuators
See figure in Section 12.3.
❑Mount the U-shaped coupling (47) to the shaft.
Apply thread-locking compound to the screws
(48) and tighten firmly.
❑Remove all protective plastic plugs (5 pcs.) from all
pneumatic connections. Mount the metal plugs (53)
to the unused controller connections with sealant.
For EJ (single acting, spring to close) and EJA (sin-
gle acting, spring to open) actuators, mount a
metal plug (54) with sealant to the C1 connection at
the bottom of the controller.
❑Mount the O-rings (38, 2 pcs.) into the air con-
nections in the bottom of the controller.
❑Mount the O-ring (49) into the square groove in
the bottom of the controller.
❑Place the valve controller on top of the actuator
so that the pointer of the shaft washer (16) is
located in the position shown in Fig.5.
❑Fasten the screws (4).
4.3 Mounting on Metso actuators with
VDI/VDE mounting face
See figures in Section 12.4 -12.6.
❑Mount the H-shaped coupling (47) to the shaft.
Apply the thread-locking compound to the screw
(48) and tighten firmly.
❑Remove all protective plastic plugs from the pneu-
matic connections (5 pcs.). Mount the metal plugs
(54) with sealant to the unused controller connections
at the bottom of the controller.
❑BJ and other single acting actuators: mount a
metal plug (53) with sealant to the C1 connection.
❑Set the direction arrow of the actuator in the
direction of the valve closure member and attach
the ear (2) to the indicator cover in the position
shown in Section 12.4. Secure the screw of the
ear using e.g. Loctite and tighten firmly.
❑Attach the bracket (1) to the ND9100P.
❑Attach the bracket (1) to the actuator. The shaft
coupling of the ND9100P must fit into the ear (2) so
that the pointer of the shaft washer (16) is located in
the position shown in Fig. 5.
Fig. 3 Mounting on EC and EJ actuators
O-rings
Fig. 4 Mounting on Metso actuator with VDI/VDE
mounting face
C2
S
C1
The pointer on the coupling must
stay in this sector
11

87 ND91P 70 en
4.4 Mounting on linear actuator of
nelesCV Globe
See figure in Section 12.7.
❑Attach the J-shaped feedback lever (47) to the
valve controller shaft. Apply the thread-locking
compound to the screws and tighten firmly.
❑Remove all plastic plugs from all actuator connections
(5 pcs.). Mount the metal plugs (53) to the unused
controller connections with sealant.
❑Mount the metal plug (54) with sealant to the connec-
tion C1 at the bottom of the controller and mount the
O-rings (38, 2 pcs.) to the connections.
❑Attach the mounting plate (39) to the valve con-
troller with screws (28).
❑Mount the the conical plug (16) to the lever and
select the position on the scale according to the
valve stroke.
❑Install the O-ring (31) to the actuator. Place the con-
ical plug into the frame on the stem and tighten the
screws (4).
4.5 Mounting on linear actuator with IEC
60534 mounting face
See figure in Section 12.8.
❑Attach the feedback arm with spacer to the valve
controller shaft. Note the position of the mark on the
shaft as in 12.8. Apply thread locking compound to
the screws and tighten firmly. Attach the spring to
the feedback arm as shown in Section 12.8.
❑Mount the valve controller mounting bracket
loosely to the yoke of the actuator.
❑Remove all plastic plugs from all actuator connec-
tions (5 pcs.). Mount the metal plugs (54) with seal-
ant to the unused controller connections at the
bottom of the controller.
❑Mount the valve controller loosely to the mount-
ing bracket guiding the pin on the actuator stem
to the slot of the feedback arm.
❑Align the bracket and the valve controller with the
actuator stem and adjust their position so that the
feedback arm is approximately at a 90° angle to
the actuator stem (in the mid-stroke position).
❑Tighten the valve controller mounting bracket
screws.
❑Adjust the distance of the valve controller to the pin
on the actuator stem so that the pin stays in the lever
slot at full stroke. Ensure also that the maximum
angle of the lever does not exceed 45° in either
direction. Maximum allowed travel of the lever is
shown in Section 12.8. Best control performance is
achieved when the feedback lever utilises the maxi-
mum allowed angle (±45° from horizontal position).
The whole range should be at least 45°.
❑Make sure that the valve controller is in right
angle and tighten all the mounting bolts.
❑Ensure that the valve controller complies with
previous steps. Check that the actuator pin does
not touch the valve controller case throughout
the entire stroke of the actuator. If the actuator
pin is too long it may be cut to size.
❑Apply grease (Molykote or equivalent) to the con-
tact surfaces of the actuator pin and the feed-
back arm to reduce wear.
Fig. 5 Shaft coupling alternatives
VDI/VDE 3845 mounting
45°
nelesCV Globe mounting
pointer
mark on housing
45°
pointer
mark on housing
45
EC/EJ flush mounting
pointer
mark on housing
45°
45°
IEC 60534 mounting
pointer
mark on housing
shaft end
shaft end
shaft end
shaft end

7 ND91P 70 en 9
4.6 Piping
Table 2 provides the recommended tube sizes in
accordance with actuator sizes. Tube sizes are the mini-
mum values allowed. Operating times may be tested by
the FieldCare software.
Connect the air supply to S (G1/4 ).
Connect C1 and C2 (G1/4) to the actuator, see Fig. 6.
ND9100P is connected direct to the EC or EJ actuator.
Connections C1 and C2 (G1/4) must be plugged, see
12.3.
Liquid sealants, such as Loctite 577 are recommended
for the pipe threads.
The air supply must be clean, dry and oil-free instrument
air, see Section 2.4.
CAUTION:
Do not exceed the permitted supply pressure of
the ND9100P!
NOTE:
A valve controller mounted on a spring actuator must
be connected only as single-acting. See Fig. 6.
NOTE:
An excess of sealant may result in faulty operation of
the controller.
Sealing tape is not recommended.
Ensure that the air piping is clean.
Table 1 Spring rates
Actuator type Spring rate (bar/psi)
B1JK 3 / 43
B1J 4.2 / 61
B1JV 5.5 / 80
QPB 3 / 43
QPC 4.3 / 62
QPD 5.6 / 81
EJK 3 / 43
EJ 4 / 57
EJV 5 / 72
Adjust regulator pressure to a level that is max 1 bar (14.5
psi) + spring rate.

10 7 ND91P 70 en
Table 2 Piping
Actuator Actuator piping Spool valve
EC Stroke vol.
dm3/ in3G 6 10 1/4 3/8
05 0.09 / 5 1/4 x x 2
07 0.2 / 12 1/4 x x 2
10 0.5 / 31 1/4 x x 3
12 1.2 / 73 1/4 x x 3
14 3.0 / 183 1/4 x x 6
16 7.7 / 470 3/8 x x 6
25 20.5 / 1250 3/8 x x 6
EJ Stroke vol.
dm3 /in3G 6 10 1/4 3/8 Spool valve
05 0.18 / 11 1/4 x x 2
07 0.4 / 24 1/4 x x 2, 3*
10 1 / 61 1/4 x x 3
12 2.4 / 145 1/4 x x 3
14 6 / 366 1/4 x x 6
16 15 / 915 3/8 x x 6
25 41 / 2500 3/8 x x 6
B1C Stroke vol.
dm3/ in3NPT 6 10 1/4 3/8 Spool valve
6 0.3 / 18 1/4 x x 2, 3*
9 0.6 / 37 1/4 x x 3
11 1.1 / 67 3/8 (x) x (x) x 3
13 2.3 / 140 3/8 x x 3
17 4.3 / 262 1/2 x x 6
20 5.4 / 330 1/2 x x 6
25 10.5 / 610 1/2 x x 6
32 21 / 1282 3/4 x x 6
40 43 / 2624 3/4 x x 6
50 84 / 5126 1 x x 6
502 195 / 11900 1 x x 6
B1J
B1JA
Stroke vol.
dm3/ in3NPT 6 10 1/4 3/8 Spool valve
8 0.9 / 55 3/8 (x) x (x) x 3
10 1.8 / 110 3/8 x x 3
12 3.6 / 220 1/2 x x 6
16 6.7 / 409 1/2 x x 6
20 13 / 793 3/4 x x 6
25 27 / 1648 3/4 x x 6
32 53 / 3234 1 x x 6
322 106 / 6468 1 x x 6
QP Stroke vol.
dm3/ in3NPT 6 10 1/4 3/8 Spool valve
1 0.62 / 37 3/8 (x) x (x) x 2, 3*
2 1.08 / 66 3/8 (x) x (x) x 3
3 2.18 / 133 3/8 x x 3
4 4.34 / 265 3/8 x x 6
5 8.7 / 531 3/8 x x 6
6 17.5 / 1068 3/4 x x 6
Air supply piping 10 mm or 3/8" for all actuators.
Pipe sizes are nominal, i.e. approximately outer diameter. Inner diameter is typically 2 mm smaller.
x = Standard pipe size used in Neles control valves.
(x) = Minimum pipe size (if smaller than standard).
*) Spool size 2 is preferred for accurate control and standard for Neles control valves.
Spool size 3 can be used if fast full stroke times are required.

7 ND91P 70 en 11
Fig. 6 Operation directions and air connections
SINGLE-ACTING ACTUATOR, SPRING TO OPEN
SINGLE-ACTING ACTUATOR, SPRING TO CLOSE
DOUBLE-ACTING ACTUATOR
Self closing
Default setting:
ROT = cC (close valve to clockwise)
ATYP = 2-A
PFA = CLO
A0, CUTL and VTYP according to valve type
3.Self closing
Default setting:
ROT = cC (close valve to clockwise)
ATYP = 1-A
PFA = CLO (must be in the spring direction)
A0, CUTL and VTYP according to valve type
4.Self opening
Default setting:
ROT = cC (close valve to clockwise)
ATYP = 1-A
PFA = OPE (must be in the spring direction)
A0, CUTL and VTYP according to valve type
C1
C2
S
C1
C2
S
C1
C2
S
1.
DOUBLE-ACTING ACTUATOR, REVERSED PIPING
Self opening
Default setting:
ROT = cC (close valve to clockwise)
ATYP = 2-A
PFA = OPE
A0, CUTL and VTYP according to valve type
C1
C2
S
2.

12 7 ND91P 70 en
4.7 Electrical connections
The ND9100P is powered by Profibus PA (IEC 61158-2).
The same bus cable is used also for the fieldbus com-
munication.
The bus cable is led through a M20 x 1.5 cable gland.
Connect the conductors to the terminal strip as shown in
Fig. 7.
Reverse polarity protection permits connection of the
bus cables in any order.
The cable shield can be grounded by connecting the
shield to the earth connection screw. The shield can be
left unconnected by using the empty terminal.
Please note following before mounting the cover of
the valve controller:
❑Attach the LUI (223) cabling to the sticker on the
reverse side of the LUI.
Check that the cabling does not get squeezed by
the electronics cover (39) or the device cover
(100).
❑Check using a feeler gauge that the clearance
between the position indicator (109) and the
electronics cover is 1 mm.
Fig. 7 Terminals
Fig. 8 Control wiring
HAZARDOUS LOCATION
ND9100PU1/U2
NONHAZARDOUS LOCATION
Entity Parameters:
Ui ≤24.0 V
Ii ≤380 mA
Pi ≤5.32 W
Ci < 5 nF
Li < 10 µH
Entity Parameters:
Uo ≤Ui
Io ≤Ii
Po ≤Pi
connect the cable
shield to earth ground
Associated
apparatus

7 ND91P 70 en 13
5 LOCAL USER INTERFACE (LUI)
The local user interface may be used to monitor the
device behaviour as well as configuring and commis-
sioning the controller during installation and normal
operation. The local user interface consists of 2 row LCD
and 4 button keypad interface. There are also custom
graphical characters for special conditions.
5.1 Measurement monitoring
When the device is powered, it enters the measurement
monitoring view. The following measurements may be
viewed from the display. The Table 3 identifies the default
unit and also optional unit of the measurement.
If the unit selection is altered from the FieldCare software
to US units, the pressure default unit will automatically be
changed to psi and temperature unit to Fahrenheit.
The active unit may be changed by pressing the ?key
constantly. The display shows the current unit selection
on the top row of the display. You may change the selec-
tion by pressing +or -while keeping the ?key
pressed down. When the buttons are released the cur-
rent selection will be activated.
If the device has been idle for 1 hour, and there is no
user activity on the local user interface, the measure-
ments will start scrolling on the display. This enables the
user to view all the measurements through the window of
the main cover.
5.2 Guided start-up
Guided startup offers a fast view of the most critical
parameters of the ND9100P controller, actuator and
valve configuration. After verifying the parameters the
valve travel calibration is recommended. The guided
start-up is entered by pressing the =and ?keys
simultaneously.
The configuration parameters are listed in following
order, see explanation from 5.5:
Valve type VTYP
Actuator type ATYP
Positioner fail action PFA
Valve rotation direction ROT
Valve dead angle A0
PA address ADR
If you modify any of the parameters you will also need to
calibrate and tune the device. See 5.6 for detailed
description.
Fig. 9 Local user interface (LUI)
Table 3 Default / optional units of measurements
Measurement Default unit Optional unit
valve position Percentage of full
scale Angle, where 0 % refers to 0 (angle)
target position Percentage of full
scale none
setpoint Percentage of full
scale
actuator
pressure
difference
bar psi
supply pressure bar psi
device
temperature ° Celcius ° Fahrenheit
Fig. 10 Measurement unit change
— continuous push
— brief push

14 7 ND91P 70 en
5.3 Configuration menu
The local user interface is organised in a menu struc-
ture. To enter the menus press +and -simultaneously
in the measurement monitoring view panel. To move to
the next or previous selection by pressing +or -
accordingly.
5.4 Mode menu
If the user wants to change the valve operating mode,
press the ?key at the MODE selection. The mode will
start to flash and by pressing +or -you may alter the
operation mode selection. User accepts the current
selection by pressing the ? key.
There are two options for the operating mode.
5.4.1 AUTO
During the auto mode, the controller controls the valve
position according to the incoming setpoint signal from
the bus. This mode is used during the normal process
control service.
5.4.2 MAN
During this mode the valve position may be controlled man-
ually by using the keyboard and pressing the +or -but-
tons. The position of the manually driven valve is not saved
in the memory of the controller, i.e. the valve will not return to
the same position after signal failure. However, the valve
may be driven back into position after signal failure by
using +and -keys.The manual control starts from the
current position of the valve after the MAN-mode is acti-
vated. In order to change the manual setpoint return to the
measurement monitoring view and go to target position
measurement. Press the ?key shortly to activate the tar-
get position editing, text TPOS starts to blink and now you
are able to edit the setpoint by pressing +or -button.
The setpoint changes in 0.1 % increments/decrements in
spite of the selected unit and the valve starts to move
immediately. A continuous push changes the setpoint
faster. In order to view other measurements, press the ?
or = keys and select a measurement. Repeat the previ-
ous steps if you would like to alter the setpoint value again.
Fig. 11 Guided start-up
NOTE:
You may cancel any action by pressing the =button.
Cancelling of operation returns user interface view one
level up in menu hierarchy.
— brief push
Fig. 12 Configuration
— brief push

7 ND91P 70 en 15
5.5 Configuration parameters
When PAR is on the display you may enter the configura-
tion menu by pressing the ?key. In this menu the most
important configuration and signal modification parame-
ters are viewable. You may view the current value and edit
them by pressing the ?key at the relevant parameter.
The name of the parameter will appear on the upper row
of the display and the current value is on the lower row.
5.5.1 Performance level, PERF
If you want to change the tuning of the valve position
control, the PERF selection is available. The default fac-
tory value is C.
❑Once PERF is displayed press the ?key to
enter the edit state and PERF starts to blink.
❑Select between five values by pressing the +or
-key.
❑After the desired value is displayed, press the
key ?to conclude the operation
5.5.2 Low cut-off, CUTL
Low cut-off safety range CUTL ensures the valve closing
against mechanical travel stops. The factory default
value is 2 %.
❑Once CUTL is displayed press the ?key to
enter the edit state and the CUTL will start to
blink. The currently selected value appears as a
percentage (%) on the display.
❑Modify the parameter value by pressing +or -
keys alternately until the desired value appears
on the display.
❑After the desired value is displayed, press the
key ?to conclude the operation.
5.5.3 Valve type, VTYP
To compensate for nonlinearity of the position feedback
caused by the actuator linkage mechanism of a linear
control valve, the appropriate selection must be made on
the VTYP display.
❑After selecting VTYP on the display, press the ?
key to enter the edit state and the VTYP starts to
blink.
❑Select between four values rot, LIn, nCG or FLI
using the +and -keys. The value rot indi-
cates a rotary valve and LIn a linear valve. Use
nCG only for nelesCV Globe valves to accommo-
date special linkage geometry. Use FLI only for
linear valves when linkage geometry is not needed
to be corrected by valve controller firmware.
❑To conclude press the ?key when the desired
value is shown on the display.
5.5.4 Actuator type, ATYP
In order to optimise the control performance the device
needs to be informed about the actuator type.
❑After selecting ATYP on the display, press the ?
key to enter the edit state and ATYP starts to blink.
❑Select between two values 2-Aor 1-Ausing the +
and -keys. The value 2-Aindicates a double
acting actuator and 1-Aa single acting actuator.
❑To conclude press the ?key when the desired
value is shown on the display.
5.5.5 Positioner fail action, PFA
Positioner fail action will take place in case of signal
failure or when the controller software discovers a fatal
device failure. For single acting actuators set value in
the spring direction. For double acting actuators see
Fig. 6 for correct settings.
❑Once PFA is displayed, press the ?key to enter
the edit state and the PFA will start blinking.
❑You may select between two values by pressing
the +or -key. The CLO value indicates that the
valve ought to be closed in fail action situations.
The OPE value indicates the valve to be opened in
fail action situations.
Fig. 13 Setpoint change in MAN mode
Table 4 Performance level
Selection Meaning Description
AAggressive Immediate response to
signal changes, overshoots
bFast Fast response to signal
changes, small overshooting
COptimum Very small overshoot with
minimum step response
time
dStable No overshooting, slow
response to input signal
changes
EMaximum stability No overshooting, deadband
may increase, slow but
stable behaviour
For use with volume boosters and/or very fast actuators,
additional performance levels A1 to D1 can be used.
Characteristics of these extended levels are the same as
those in the table above. However, with performance level
settings A1 to D1, adaptive properties of the ND9000 control
algorithm are disabled.
NOTE:
Perform valve calibration and tuning always when
VTYP has been changed.
NOTE:
Perform valve calibration and tuning always when
ATYP has been changed.

16 7 ND91P 70 en
❑After the desired value is displayed, press the
key ?to conclude the operation.
5.5.6 Valve rotation direction, ROT
The application-specific parameter ROT defines the rela-
tionship between position sensor rotation and valve action.
❑Once ROT is displayed press the ?key to enter
the edit state and ROT starts to blink.
❑Now you may select between two values by
pressing the +or -key. The value cC indicates
clockwise rotation for closing the valve and ccC
means counterclockwise to close.
❑After the desired value is displayed, press the
key ?to conclude the operation.
5.5.7 Valve dead angle, A0
The α0setting is made for Metso segment and ball valves.
This setting takes into account the "dead angle" α0of the
ball valves. The entire signal range is then used for effec-
tive valve opening 90° - α0. Use 0 % as the "dead angle"
for the valves not mentioned in Table 5. ❑After selecting A0 on the display, press the ?
key to enter the edit state and A0 starts to blink.
The value currently selected appears as a per-
centage (%) on the display.
❑Modify the parameter value by pressing +or -
keys alternately until the desired value appears
on the display.
❑Press the ?key to make your selection and
return to the setting state.
5.5.8 Profibus slave address setting
❑You can modify the Profibus slave address by
pressing +and -keys. Range is 0-126, default
value is 126.
❑Press the ?key to make your selection and
return to the setting state.
5.5.9 Language selection, LANG
❑Select between three languages EnG, GEr or FrE
using the +and -keys.
❑To conclude press the ?key when the desired
value is shown on the display.
5.5.10Low limit, high cutoff, high limit
ND9100P supports signal cutoff and limiting in both
ends of the operating range. The configuration parame-
ters are; low cutoff, low limit, high cutoff and high limit.
❑If the input signal is smaller than low cutoff,
the valve will be fully closed.
❑If the input signal is smaller than low limit,
the valve stays in the low limit.
❑If the input signal is greater than high cutoff,
the valve will be fully opened.
NOTE:
Perform valve calibration and tuning always when con-
troller fail action parameter has been changed.
NOTE:
Perform valve calibration and tuning always when ROT
has been changed.
Taulukko 5 Dead angle in percentage
Valve
size
Valve series
MBV
QMBV
1)
MBV
QMBV
2)
D,
P,
C
T5,
QT5
QX-
T5
T25,
QT25
QX-
T25
R,
QR
ER-
SOFT
3)
FL
4)
ZX
mm in Dead angle, %
15 1/2 15
20 3/4 15
25 1 14 - - 25.5 19.5 - - 15 25.5 27 12.5
25/1 1/1 14.5 11
25/2 1/2 8 11
25/3 1/3 8 10
25/4 8
40 1 1/2 12 - - 24.5 12.5 - - 12 16 21 12.5
50 2 10 9 13.5 24.5 12.5 18 8 17 20.5 23 12.5
65 2 1/2 9 - - - - - - 13 - 18
8031081218816.58.598.515.5
100 4 10 8 12 16.5 8.5 16 9 8 7 14.5
125 5 12 - - - - 12 6.5 8 -
150 6 10 8 11.5 16 9 13.5 8 13.5 13
200 8 9 7 8.5 12 6.5 9.5 7 11.5
250 10 9 7 7.5 13.5 9.5 7 10.5
300 12 8 6 6.5 9.5 7.5 6 9.5
350 14 6 6 - 5 9.5
400 16 5 5.5 9.5
(14")
59.5
450 18 6 7.5
(16")
500 20 6 4.5
600 24 5.5 6
650 26 7
700 28 7 6
750 30 6
800 32 -
900 36 5.5
1) Seat supported 2) Trunnion 3) Soft seated R-valve 4) Low Cv Finetrol
Fig. 14 Principle of setting
Fig. 15 Dead angle
100
80
60
40
20
00 20 40 60 80 100
α0
Position
Input signal
low cut-off safety range 2 ±0.5 %
Basic setting α0setting

7 ND91P 70 en 17
❑If the input signal is greater than high limit,
the valve stays in the high limit.
The cutoff overrides the limit as follows:
❑If the low cutoff > low limit, the low limit is not
active.
❑If the low cutoff < low limit, both low cutoff and
limit are active.
❑If the low cutoff is set to zero, the low cutoff is not
active.
❑If the high cutoff < high limit, the high limit is not
active.
❑If the high cutoff > high limit, both high cutoff and
limit are active.
❑If the high cutoff is set to 100%, the high cutoff is
not active.
Only the low cutoff is adjustable using the LUI. Low limit,
high cutoff and high limit are configurable via fieldbus.
5.6 Valve travel calibration
Select CAL from the menu by using +or -keys and
press the ?key. Define the calibration type AUTO, MAN
or TUNE. You may also select TUNE after AUTO and MAN
calibration separately as seen in Fig.16.
5.6.1 AUTO calibration function
During the calibration process the display will show the fol-
lowing text: CALrun. After calibration the ND9100P scrolls
CALIBRATION SUCCESSFUL text. You may interrupt the cali-
bration sequences at any time by pressing the =key.
After the calibration sequence is finished, press the =
key twice to get back to the measurement view.
Please refer to Chapter 6 if this sequence has failed
and an error message is displayed.
If you cannot drive the valve into a fully open position or
if there is no mechanical limit stop, a manual calibration
is required.
5.6.2 MAN calibration function
After selecting the MAN calibration function from the
menu press the ?key to activate the procedure. With
the +or -keys drive the valve manually to the closed
(0 %) position and then press the ?key. If you cancel
the operation, the old values of the previous calibration
will be restored. Drive the valve into the desired maxi-
mum opening position (100 %) with the +and -keys
and press the ?key.
If this sequence has failed and an error message is
shown, see Chapter 6.
5.6.3 TUNE function
During the tuning the ND9100P controller searches for
optimum internal control parameters for the valve posi-
tion control. At any time you may interrupt the tuning
sequence by pressing the =key. The tuning will not
alter the PERF parameter.
If calibration and tuning are performed in sequence, the
cancelling of tuning does not restore the old calibration
values.
5.6.4 1-Point Calibration
1-point calibration is useful in cases in which the valve
controller needs to be changed but it is not possible to
run the normal calibration and the valve is not allowed
to change position (the valve is active, for example).
This procedure does not ensure the best possible
control performance, and it is always recommended
to run either AUTO or MAN calibration and tuning,
as soon as possible. The primary way to calibrate
valve position is to use either AUTO or MAN calibration.
Before starting 1-point calibration, read the warnings
and notes below and check that the valve is mechan-
ically locked. Before starting 1-point calibration,
adjust the TPOS value in the MAN mode (see sec-
tion 5.4.2) to correspond with the physical position
of the valve.
Once the 1-point calibration is started, the first view
shows ANG above and NN.Nbelow (see Fig. 16). NN.N
presents the maximum turning angle (in degrees) that
the valve can perform.
To change the value:
❑Press ?, NN.Nbegins blink
❑Press +and --buttons to change the value
After the correct valve operation angle is set, press ?-
button.
During the calibration process the display will show the fol-
lowing text: CALrun. After calibration the ND9100P scrolls
CALIBRATION SUCCESSFUL text. You may interrupt the cal-
ibration sequences at any time by pressing the =key.
After the calibration sequence is finished, press the =
key twice to get back to the measurement view.
Please refer to Chapter 7 if this sequence has failed
and an error message is displayed.
The valve can be unlocked when the calibration is suc-
cesfully finished.
NOTE:
If AUTO CAL or MAN CAL is selected, the valve controller
must be in AUTO mode. 1-point calibration may run in
both AUTO and MAN mode.
Fig. 16 Calibration selection
WARNING:
Automatic calibration drives the valve against the
mechanical open and closed travel limits of the
valve-actuator assembly and a tuning procedure is
performed. Make sure that these procedures can
be safely executed.

18 7 ND91P 70 en
5.6.5 LS status
LS shows the status of limit switches:
--- No LS active
CLO LS "Closed" active
OPE LS "Open" active
LSE LS Error, both switches activated
at the same time
5.7 Special displays
5.7.1 User interface locked
In order to prevent unauthorised access, the Local User
Interface may be locked. In this mode measurements
may be viewed but configurations and calibrations are
prohibited. You may lock and unlock the device only via
dip switch, see Fig. 20. When the Local User Interface is
locked the lock symbol will be activated on the display.
5.7.2 Online-alarm active
If an online alarm has been detected the solid &symbol
is activated. This symbol will disappear after the recov-
ery from online alarm. You may view the reason for the
alarm by viewing the latest event while pushing the =
and -keys simultaneously or by using FieldCare soft-
ware where all events may be viewed.
5.7.3 Viewing of latest event
You may view the latest event by pressing the =and -
keys simultaneously in the measurement monitoring
view. The message is scrolled on the top row of the dis-
play twice. You may stop the scrolling by pressing the ?
key. By pressing the =key, the message will disappear.
For the list of events see Chapter 6.
5.7.4 Fail-safe active
When the ND9100P detects serious device failure (set-
point, valve position and control signals) it enters fail-
safe mode, which drives the control valve into the posi-
tion defined in the parameter controller fail action (PFA).
Fail-safe mode is indicated by the display as seen in
Fig. 19. The error message is displayed until the cause
of error is eliminated and the ND9100P unit is restarted,
i.e. the power loop is momentarily disconnected.
5.7.5 Reduced Performance
When the ND9100P detects spool valve measurement
failure, it enters reduced performance mode.This is
indicated by the blinking &in the display, see Fig. 20.
In reduced performance mode valve control can not be
optimized. To correct the problem replace the spool
valve assembly and perform auto calibration.
WARNING:
Supply pressure can be connected to the valve
controller only after 1-point calibration is success-
fully completed. If supply pressure is connected to
the valve controller before successful 1-point cali-
bration, the valve may move and cause danger.
NOTE:
If an incorrect valve operation angle is given to the
valve controller during 1-point calibration, valve oper-
ation will be incorrect. In this case, you must perform
1-point calibration again with correct valve operation
angle value.
NOTE:
If the valve position is not stable (due to heavy vibra-
tion etc) during 1-point calibration, the calibration will
not end successfully. Check that the valve position is
fully stable during this operation.
Fig. 17 LUI locked
Fig. 18 Online alarm message
Fig. 19 Failsafe display
Fig. 20 Reduced performance display
scrolling text
scrolling text

7 ND91P 70 en 19
5.8 Write protection
The ND9100P is delivered from the factory with HW write
protection OFF as the default setting. Reading and
changing parameters is thus allowed. Write protection
can be enabled with the switch (DIP1) located on the cir-
cuit board (Fig. 21).
Write protection protects all write access to all writeable
parameters of the device. Changing the parameters
from the LUI or profibus configurator is thus not allowed.
6 MAINTENANCE
The maintenance requirements of the ND9100P valve
controller depend on the service conditions, for
instance, the quality of instrument air. Under normal
service conditions there is no requirement for regular
maintenance.
When maintaining the ND9100P ensure that the supply
air is shut off and pressure is released. In the following
text the numbers in brackets ( ) correspond to the part
numbers in the exploded view as shown in Chapter 12,
unless otherwise stated.
The ND9100P valve controller includes the following
interchangeable modules: prestage unit (120), spool
valve unit with sensor (193), communication circuit
board (215).
The modules are located below the covers (39) and (43).
In the event of failure the whole module must be
changed. The module retrofit must be assembled in a
clean, dry environment. In reassembly apply thread-
locking compound (for instance, Loctite 243) and tighten
the screws firmly.
6.1 Prestage
6.1.1 Removal
❑Open the prestage cover (43) attached with M4
screw (44). Unplug the prestage wire connector
on the spool sensor board. Unscrew the M4
screws (139, 2 pcs.) and lift up the prestage
module. Remove the O-ring (140).
6.1.2 Installation
❑Place a new O-ring (140) into the groove on the
spool valve and press the prestage into place.
Make sure the nozzle is guided into the O-ring
properly. The screws guide the prestage body
into the correct position. Tighten the screws
(139) evenly.
❑Push the prestage 2-pole wire connector into the
socket on the spool sensor board. The wire con-
nector may only be fitted in the correct position.
Replace the prestage cover (43) and tighten the
M4 screw (44).
Fig. 21 Write protection
12
ON
NOTE:
Whenever any maintenance operations have been
done for the ND9100P, the device should be cali-
brated and tuned.
NOTE:
The prestage must be handled carefully. In particular
the moving parts of the prestage should not be
touched when the protective cover is not in place.

20 7 ND91P 70 en
6.2 Spool valve assembly
Before removing the spool valve assembly (193) the
prestage (120) must be removed. See 6.1.
6.2.1 Removal
❑Unscrew the M4 screws (47, 3 pcs.), M3 screws
(48, 2 pcs.) and M3 screw (49). Remove the
spool valve assembly.
❑The spool valve may be cleaned if special atten-
tion is paid to a clean environment and proper
procedure. After unscrewing the M4 screws (47,
3 pcs.) the spool valve may be lifted from the fix-
ture. Hold the ends of the body with your fingers
to avoid dropping the spool from the body. Clean
the spool and the bore of the body with care. Do
not leave any fibres from cleaning materials in
the bore or on the spool. Do not scratch the mat-
ing surfaces of the spool and body. The restrictor
is located under the spool valve in the fixture. It
may be cleaned when the spool valve is
removed.
6.2.2 Installation
❑Ensure that the gasket (174) is properly located
in the groove on the bottom of the spool valve
assembly. Mount the spool valve assembly on to
the housing and tighten the M3 and M4 screws
evenly. Ensure the O-ring (140) slots inside the
groove fully. Mount the prestage unit directly on
the spool valve unit as in 6.1.
6.3 Communication circuit board
6.3.1 Removal
❑Loosen the M8 grub screw (110) off the position
indicator (109) and turn the position indicator
from the shaft. Remove the cover off the prestage
(43). Remove the cover of the circuit boards
attached with M3 screws (42, 4 pcs.).
❑Remove the M3 screws (217, 4 pcs.). Hold the
sides of the circuit board and lift it directly
upwards and outwards. Handle the board care-
fully, touching only the sides.
6.3.2 Installation
❑Mount the new communication circuit board
carefully.
❑Locate the pins with the matching connector on
the board. Tighten the M3 screws (217) evenly.
❑Install the cover of the circuit boards and the
cover of the prestage (43).
❑Mount the position indicator (109) on the shaft
and tighten the M8 screw (110) temporarily. The
final orientation and locking of the position indi-
cator should be done after installation of the
valve controller to the actuator.
NOTE:
Each spool valve body has an individual correspond-
ing spool which cannot be replaced by any other
spool. Never alter the orientation of the spool.
The orientation of the spool is marked on the spool
valve body, see Fig. 22.
Fig. 22 Spool valve assembly
NOTE:
If the maintenance operations have been done for the
spool valve assembly, the device must always be cal-
ibrated and tuned.
195 194140 160 174 175
0327000170
Assembly direction of spool
Sticker on fastener (160)
NOTE:
Ground yourself on the body of the device before
touching the circuit board.
NOTE:
Do not remove the Valve Controller Board (210)!
Removing the board will void the warranty.
Fig. 23 Communication board
215