Metso Neles ValvGuard VG9000F Operating and maintenance manual

Neles ValvGuard™
VG9000F
Rev. 1.1
Installation, Maintenance and
Operating Instructions
7 VG9F 70 en • 7/2011

27 VG9F 70 en
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about the safe handling and operation of the intelligent safety 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 VG9000F VALVGUARD
INTELLIGENT SAFETY VALVE CONTROLLER
WITH FOUNDATION FIELDBUS
COMMUNICATION.......................................... 3
1.1 General.................................................. 3
1.2 Technical description............................. 3
1.3 Markings ................................................ 3
1.4 Technical specifications......................... 4
1.5 Recycling and disposal.......................... 5
1.6 Safety precautions................................. 5
2 TRANSPORTATION, RECEPTION AND
STORAGE ....................................................... 6
3 MOUNTING...................................................... 6
3.1 General.................................................. 6
3.2 Mounting on Metso actuators with
VDI/VDE mounting face......................... 6
3.3 Mounting on linear actuator with IEC 60534
mounting face ........................................ 7
3.4 Mounting and installation of VG9300..... 7
3.5 Piping..................................................... 8
3.6 Electrical connections.......................... 11
4 LOCAL USER INTERFACE (LUI) ................. 12
4.1 Measurement monitoring..................... 12
4.2 Guided start-up.................................... 13
4.3 Configuration menu.............................. 13
4.4 Configuration parameters .................... 13
4.5 Valve travel calibration......................... 16
4.6 Testing................................................. 16
4.7 Limit Switch LS status.......................... 17
4.8 Advance parameters............................ 17
4.9 Special displays................................... 18
5 MAINTENANCE............................................. 18
5.1 Opening and closing of the cover........ 19
5.2 Prestage .............................................. 19
5.3 Spool valve .......................................... 19
5.4 Communication circuit board ............... 20
6 MESSAGES................................................... 20
7 TROUBLE SHOOTING.................................. 22
8 VG9_/K_, VG9_/I_, VG9_F/D_, VG9_F/R_
(WITH LIMIT SWITCHES) ............................. 22
8.1 Introduction .......................................... 22
8.2 Installing VG9_F/K_, VG9_F/I_, VG9_F/D_
or VG9_F/R_ on a valve controller....... 24
8.3 Electrical connections .......................... 24
8.4 Adjustment........................................... 25
8.5 Removal of the limit switches
VG9_F/K_, VG9_F/I_, VG9_F/D_ or VG9_F/R_
for accessing the valve controller......... 25
8.6 Circuit diagrams................................... 25
8.7 Maintenance ........................................ 25
9 TOOLS........................................................... 25
10 ORDERING SPARE PARTS ......................... 25
11 DRAWINGS AND PARTS LISTS .................. 26
11.1 Exploded view and parts list, VG9000F.. 26
11.2 Exploded view and parts list,
VG9_F/K_, VG9_F/I_, VG9_F/D_,
VG9_F/R_ ............................................ 28
11.3 Mounting parts for Metso actuators
with VDI/VDE mounting face................ 30
11.4 Mounting parts for Quadra-Powr®
actuators .............................................. 30
11.5 Mounting parts for linear actuators ...... 31
11.6 Connection diagrams........................... 32
12 DIMENSIONS ................................................ 37
13 CONFIGURATION PARAMETERS .............. 41
14 EC DECLARATION OF CONFORMITY ........ 42
15 TYPE CODING .............................................. 43

7 VG9F 70 en 3
1 VG9000F VALVGUARD
INTELLIGENT SAFETY VALVE
CONTROLLER WITH FOUNDATION
FIELDBUS COMMUNICATION
1.1 General
This manual incorporates Installation, Maintenance and
Operation Instructions for the Metso’s Neles ValvGuard
VG9000F safety valve controller. The VG9000F may be
used with either cylinder or diaphragm type pneumatic
actuators for rotary or linear valves.
1.2 Technical description
Neles ValvGuard VG9000F is a microcontroller-based
safety valve controller and partial stroke test device
with FOUNDATION fieldbus communication. Addition to
FOUNDATION fieldbus there is also a separate binary
24 V DC signal needed. It is isolated from the fieldbus
and powers the safety part.
Main components of ValvGuard are spool valve (SV),
prestage unit (PR) and micro controller (µC). Spool
valve and prestage unit are the only components,
which takes part of the safety action. Spool valve con-
trols the main airflow between supply-, actuator- and
exhaust connections. The spool is operated by spring
force to fail safe position and by pneumatic force gen-
erated by the prestage valve to the normal position. The
prestage valve is coil operated flapper valve (normally
open). Coil of the prestage is energized with the safety
signal (24 V DC) and controlled by the micro controller.
Micro controller cannot prevent the safety action. Pres-
sure sensors (Px) and position sensor (α) are used to
getting the measurements for controlling the PST and
other tests. Measurements from the sensors are used
for the device diagnostics.
The device contains a Local User Interface enabling
local configuration. A PC with FieldCare software can
be used for advanced configuration and diagnostics.
The powerful 32-bit microcontroller controls the valve
position during partial stroke and other special testing.
The measurements include:
❑Safety signal
❑Valve position with contactless sensor
❑Actuator pressures, 2 independent measurements
❑Supply pressure
❑Device temperature
❑Housing pressure
Advanced self-diagnostics guarantees that all measure-
ments operate correctly. Failure of any measurement
does not cause the valve to go to fail-safe position if the
safety signal is operating correctly. After connections of
electric signals (FOUNDATION fieldbus and binary 24 V
DC) and pneumatic supply the micro controller (µC)
reads the input signal, position sensor (α) and pressure
sensors (Ps, P1, P2 and P3). This information is used to
run the partial stroke tests and other tests. .
1.3 Markings
The VG9000F safety valve controller is equipped with an
identification plate (Fig. 2).
Identification plate markings include:
❑Type designation of the safety controller
❑Enclosure class
❑Revision number
❑Input signal (voltage range)
❑Input resistance
❑Maximum supply voltage
❑Supply pressure range
❑Operational temperature
❑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: PH11011234 = controller, year 2011, 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.
NOTE:
Micro controller is only able to control the prestage if
safety signal is present (24 V DC). Micro controller can
never prevent the safety action to happen since safety
action is the same as there’s no voltage in the safety
signal line.
Fig. 1 The principle of operation
Fig. 2 Example of the identification plate
PIPING FOR DOUBLE-ACTING ACTUATORS ONLY

47 VG9F 70 en
1.4 Technical specifications
VG9000F SAFETY VALVE CONTROLLER
General
FOUNDATION fieldbus powered diagnostics, 24 V DC
power from the safety system for the safety part.
Suitable for rotary and sliding-stem valves.
Actuator connections in accordance with VDI/VDE 3845
and IEC 60534-6 standards.
Action: Double or single acting
Travel range: Linear: 10–120 mm
Rotary: 45–95°
Measurement range 110° with freely
rotating feedback shaft
Environmental influence
Standard temperature range:
-20° to +85 °C / -4° to +185 °F
Low temperature option:
-40° to +60 °C / -40° to +140 °F
Influence of temperature on valve position:
< 0,5 % / 10 °K
Influence of vibration on valve position
No effect when measured inpulse
2g 5–150 Hz, 1g 150–300 Hz,
0.5g 300–2000 Hz.
No effect on PST if max. response 4g
measured at housing.
No unintended valve movements if max.
response 15g measured at housing
Deviation from profile (only with device usage type hybrid):
<10 %
Enclosure
Material: Anodised aluminium alloy and glass
window (VG92_) or full 316 stainless
steel enclosure (VG93_)
Protection class: IP66, NEMA 4X
Mechanical position indicator and LUI visible through
the main cover (VG92_)
Pneumatic ports: VG9_15 1/4 NPT
VG9235 1/2 NPT
VG9237 1 NPT (1/2 NPT supply)
(single acting only)
Conduit entry thread:M20 x 1.5
Weight: VG9215 3.0 kg / 6.6 lb
VG9235 4.6 kg / 10.1 lb
VG9237 5.0 kg / 11 lb
VG9315 9.0 kg / 19.8 lb
VG92_ with extension housing
plus 1.0 kg / 2.2 lb
VG93_ with extension housing
plus 3.0 kg / 6.6 lb
Pneumatics
Supply pressure: 3.0–7.5 bar / 44–109 psi
Output pressure: 3.0–7.5 bar / 44–109 psi
Air quality: According to ISO 8573-1:2001
Solid particles: Class 6
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:
VG9_15 90 Nm3/h / 53 scfm (Cv = 0.7)
VG9235 380 Nm3/h / 223 scfm (Cv = 3.2)
VG9237 feed 380 Nm3/h / 223 scfm (Cv = 3.2)
exhaust 700 Nm3/h / 412 scfm (Cv = 6.4)
Consumption with 4 bar/60 psi supply:
actuator pressurized 0.22 Nm3/h / 0.13 scfm,
actuator vented 0.25 Nm3/h / 0.15 scfm
Electronics
Electrical connections: max. 0.25 - 2.5 mm2
Safety Signal (Binary input)
Connections: 24 V DC: '+' and '-'
Min voltage: 11 V DC
Max output resistance: Ro = 285 Ω
Ex d IIC T5/T6 Gb:
Ui ≤28 V
Pi ≤1.0 W
FOUNDATION fieldbus
Connections: H1: '+' and '-'
Power supply: taken from bus
Bus voltage: 9 to 32 V DC, reverse polarity protection
Max basic current: 14.2 mA
Operating current: 20.7 mA
Fault current (FDE): 6.3 mA
Ex d IIC T5/T6 Gb:
Ui ≤32 V
Ii ≤380 mA
Pi ≤5.32 W
FOUNDATION fieldbus function block execution times
MDO 15 ms
MDI 15 ms
AI 20 ms
Local user interface functions
Depends on the usage option selected (see Chapter 4
for details).
❑Monitoring of valve position, temperature, supply,
actuator pressure difference, device usage
option and binary signal (on or off)
❑Guided start-up function
❑LUI may be locked remotely to prevent unauthor-
ised access
❑Calibration
❑Parameter selection
❑Testing
❑Language selection
❑Alarm and warning state indications
❑Latest event view
See chapter 4 for details of LUI functions.
Ex NOTE:
This manual contains technical specifications for
several types of the VG9000F valve controller. If in
doubt, refer to the type approval certficate of the
respective version.
The certificate is delivered with the field device and is
also available from the manufacturer.

7 VG9F 70 en 5
APPROVALS
Safety
SIL IEC 61508 compliant up to
and including SIL 3 by TÜV
Flameproof and explosion proof
IECEx Ex d IIC T5 Gb (Ta -40°C or -25°C to +85°C)
Ex d IIC T6 Gb (Ta -40°C or -25°C to +70°C)
IEC 60079-0, IEC 60079-1
ATEX II 2G
Ex d IIC T5 Gb (Ta -40°C or -25°C to +85°C)
Ex d IIC T6 Gb (Ta -40°C or -25°C to +70°C)
EN 60079-0, EN 60079-1
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
Interoperability
FDT/DTM VG9000F DTM certified by FDT group
FF DD registered by Fieldbus FOUNDATION
1.5 Recycling and disposal
Most valve controller parts can be recycled if sorted
according to material.
Most parts have material marking. A material list is sup-
plied with the valve controller. In addition, separate recy-
cling 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.
1.6 Safety precautions
CAUTION:
Opening the cover of VG9000F field device enclosure
is allowed for authorized and trained persons only!
Misuse of powered VG9000F field device may cause
a dangerous situation.
CAUTION:
Cover should be opened only in dry places, not
when the device is vulnerable to e.g. salt water.
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.
Damage 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 ValvGuard leads to uncontrolled
pressure release. Always shut off the supply air and
release the pressure from the pipelines and equip-
ment before removing or dismantling the controller.
Otherwise personal injury and damage to equipment
may result.
WARNING:
Make sure the enclosure exhaust port will not be
clogged!
It may prevent the device to do the safety action.
CAUTION:
Make sure that during the maintenance or commis-
sioning when the device cover is open, water does
not go inside the enclosure.
WARNING:
During calibration and tuning the valve operates
between open and closed positions. Make sure
that the operation does not endanger people or
processes!
WARNING:
Do not operate the device with the cover removed!
Electromagnetic immunity is reduced, valve may
stroke.
Ex WARNING:
The locking screw (part 107) of the cover is essen-
tial to explosion protection.
The cover has to be locked in place for Ex d protec-
tion. The screw grounds the cover to the housing.
Ex WARNING:
Spark hazard!
Protect the aluminium housing and cover from impacts.
Ex WARNING:
Electrostatic charge hazard!
The pointer and display windows are non-conductive.
Clean with a damp cloth only!

67 VG9F 70 en
2 TRANSPORTATION, RECEPTION
AND STORAGE
The safety controller is a sophisticated instrument, han-
dle it with care.
❑Check the controller for any damage that may
have occurred during transportation.
❑Store the 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.
3 MOUNTING
3.1 General
If the ValvGuard is supplied with valve and actuator, the
tubes are mounted and the ValvGuard adjusted in
accordance with the customer’s specifications.
The controller is equipped for connection according to
VDI/VDE 3845.
Shaft coupling alternatives for the controller for Metso
actuators are shown in Fig. 4.
For mounting parts for Metso actuators, see 11.3 - 11.5.
3.2 Mounting on Metso actuators
with VDI/VDE mounting face
See figures in Section 11.3.
❑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
pneumatic connections.
❑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 direc-
tion of the valve closure member and attach the ear
(2) to the indicator cover in the position shown in
Section 11.3. Secure the screw of the ear using e.g.
Loctite and tighten firmly.
❑Attach the bracket (1) to the ValvGuard.
❑Attach the bracket (1) to the actuator. The shaft cou-
pling of the ValvGuard must fit into the ear (2) so that
the pointer is located in the position shown in Fig.3.
Ex WARNING:
Electrostatic charge hazard!
The paint of the device can enable charging of the
metal parts by high voltage sources. Do not install the
device in proximity of high voltage sources!
Ex i WARNING:
Ensure that the complete installation and wiring is
intrinsically safe before operating the device!
Ex i WARNING:
Do not operate the device with electronics cover
(part 39) removed!
Electromagnetic immunity is reduced, valve may
stroke. Ex i: intrinsic safety may be impaired.
Ex i WARNING:
For intrinsically safe applications, the equipment
must be connected via a certified Zener barrier
placed outside the hazardous area!
Ex d NOTE:
Only persons familiar with Ex d explosion protec-
tion are allowed to work with the device. Special
attention has to be paid to careful handling and
closing of the cover.
Ex d WARNING:
Do not open the cover when an explosive atmos-
phere may be present!
Ex d WARNING:
Use a cable gland with suitable Ex d certification.
For ambient temperature over 70 °C / 158 °F use a
heat resistant cable and cable gland suitable for at
least 90 °C / 194 °F.
ELECTRICAL SAFETY WARNING:
Use fuses for limit switch installations with
50 V AC / 75 V DC or higher.
NOTE:
Avoid earthing a welding machine in close proximity to
an VG9000F valve controller.
Damage to the equipment may result.
NOTE:
The enclosure of ValvGuard safety valve controller
meets the IP66 protection class according to
EN 60529. Cable entry needs to be plugged according
to IP66 and it is not allowed to mount the valve control-
ler in a position where the cable entry is pointing
upwards.
Based on good mounting practice, the recommended
mounting position is electrical connections placed
downwards. 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 war-
ranty is not valid.
NOTE:
Special care must be taken that the shaft position has
been set according to marking in VG9000F housing
and the pointer in the shaft. Also make sure that the
positioner fail action parameter (PFA) is set correctly
(Section 4.4.3).

7 VG9F 70 en 7
3.3 Mounting on linear actuator with IEC
60534 mounting face
See figure in Section 11.5
❑Attach the feedback arm with spacer to the con-
troller shaft. Note the position of the pointer on the
shaft as in 11.5. Apply thread locking compound
to the screws and tighten firmly. Attach the spring
to the feedback arm as shown in Section 11.5.
❑Mount the controller mounting bracket loosely to
the yoke of the actuator.
❑Remove all plastic plugs from all actuator connec-
tions (3 pcs.).
❑Mount the controller loosely to the mounting
bracket guiding the pin on the actuator stem to
the slot of the feedback arm.
❑Align the bracket and the controller with the actua-
tor stem and adjust their position so that the feed-
back arm is approximately at a 90° angle to the
actuator stem (in the mid-stroke position).
❑Tighten the controller mounting bracket screws.
❑Adjust the distance of the 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 11.5. Best control performance
is achieved when the feedback lever utilises the
maximum allowed angle (±45° from horizontal
position). The whole range should be at least 45°.
❑Make sure that the controller is in right angle and
tighten all the mounting bolts.
❑Ensure that the controller complies with previous steps.
Check that the actuator pin does not touch the control-
ler 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.
3.4 Mounting and installation of VG9300
Mounting bracket
❑Make sure the mounting bracket is suitable for
the weight of the device. See detailed weight
information in Section 1.5.
❑Three extra M8 mounting holes exist in the stand-
ard mounting face of the housing for additional
support. See dimension drawings for VG9300 in
pages 40-41 (Section 12). The use of this extra
support is mandatory in addition to the standard
mounting face.
❑There are also two 6.5 mm holes for additional
support when needed. See dimension drawings
for VG9300 in pages 40-41 (Section 12).
Pipeline support
❑Due to the extra weight of stainless steel version
and/or possible heavy vibration, make sure there
are proper supports in the pipeline to hold the
weight of the valve assembly.
Spool valve protective cover
❑The spool valve protective cover (454) has 2 pcs.
of 1/2” NPT threaded openings.
❑Openings allow an adequate exhaust capacity
and breathing of the spool valve.
❑Openings have breathers (456) installed, but
they can be replaced with protective piping if
needed and when necessary.
❑If VG is installed vertically, it is recommended to
replace the breather with protective piping in the
opening pointing upwards.
Exhaust adapter
❑The exhaust adapter (8) has a 1/2” NPT threaded
opening.
❑Opening allows an excess air to be released from
the housing and to prevent overpressurization.
❑Exhaust adapter has a breather (456) installed,
but it can be replaced with protective piping if
needed and when necessary.
❑Opening in the exhaust adapter shall not be
plugged!
Protective piping
❑Piping of the spool valve cover and/or exhaust
adapter shall be done in cases where it is
assumed that water can go inside the spool valve
cover or into the exhaust adapter in spite of
breathers.
❑Piping shall be done so that the blowing of the
exhaust air is downwards and to prevent water to go
inside the protective cover or the exhaust adapter.
❑Minimum inside diameter of the piping is 13 mm.
❑Exhaust adapter piping shall not be connected
to the spool valve cover piping!
Fig. 3 Mounting on Metso actuator with VDI/VDE
mounting face
NOTE:
Special care must be taken that the shaft position has
been set according to marking in VG9000F housing
and the pointer in the shaft. Also make sure that the
positioner fail action parameter (PFA) is set correctly
(Section 4.4.3).
C2
S
C1
The pointer on the coupling must
stay in this sector
11
NOTE:
These instructions are only for the mounting and instal-
lation of VG9300, i.e. stainless steel version of VG9000F.

87 VG9F 70 en
3.5 Piping
Table 2 provides the recommended tube sizes in accord-
ance with actuator sizes. Tube sizes are the minimum val-
ues allowed. For supply air choose a tube one size bigger.
Connect the air supply to S. Connect C1 and C2 to the
actuator, see Fig. 5. C1 must be plugged if single-act-
ing actuator.
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 1.4.
Fig. 4 Shaft coupling alternatives
45°
45°
45°
45°
VG93
VG92
VDI/VDE 3845 mounting IEC 60534 mounting
SHAFT ENDS
pointer
pointer
marks
on housing
marks
on housing
CAUTION:
Do not exceed the permitted supply pressure of
the ValvGuard!
CAUTION:
The stroking times mentioned in Table 2 are trend-
setting. They are measured with 5 bar supply air
pressure, but may vary significantly due to different
factors such as, but not limited to, pressure differ-
ence of the valve, the stiction of the actuator, supply
air pressure, the capacity of the supply air system
and the dimensions of the supply air pipeline.
NOTE:
When opening/closing times are defined in the Table 2,
the specified spool valve size can be used with that
actuator size. If there is '-' sign in the table or if smaller
actuators than shown in the table are used, please con-
tact Metso.
NOTE:
When faster speeds are needed than shown in the
table, QEV or volume booster can be used. Bypass
valve is mandatory with volume boosters and QEV.
Contact Metso for separate instrumentation diagrams
and instructions.
NOTE:
When QEV or volume booster is used, VG with small
spool valve (VG9_15_) is required.
NOTE:
An excess of sealant may result in faulty operation of
the controller.
Sealing tape is not recommended.
Do not exceed torque of 30 Nm/22 lbf ft when fitting
1/4" NPT connectors to C1, C2 and S (VG9_15).
Ensure that the air piping is clean.
NOTE:
A valve controller mounted on a spring actuator must
be connected only as single-acting. See Fig. 5.
Table 1 Spring rates
Actuator type Spring rate (bar/psi)
B1JK 3 / 43
B1J 4.2 / 61
B1JV 5.5 / 80
QPX_A 1.4 / 20
QPX_B 2.8 / 41
QPX_C 4.1 / 60
QPX_D 5.5 / 80
Adjust regulator pressure to a level that is max 1 bar (14.5 psi)
+ spring rate.
CAUTION:
The air supply system must be of sufficient size and
capacity to ensure that at maximum flow during valve
movement the pressure at the ValvGuard must not fall
below 3 bar. Also note that if the air supply system
allows the pressure at the ValvGuard to fall below the
actuator minimum supply pressure during valve move-
ment the stoke speed will be affected.

7 VG9F 70 en 9
Table 2 Piping and stroke times
Actuator
VG_15_
Supply 1/4" NPT
Actuator 1/4" NPT
VG_35_
Supply 1/2" NPT
Actuator 1/2" NPT
VG_37_ (Single acting only)
Supply 1/2" NPT
Actuator 1" NPT
B1C Stroke vol.
dm3/ in3NPT Piping Open
(s)
Close
(s)
Piping Open
(s)
Close
(s)
Piping Open
(s)
Close
(s)
40 43 2624 3/4 10 mm or 3/8" 19 19 16 mm or 5/8" 4.9 5.6 - - -
50 84 5126 1 10 mm or 3/8" 38 38 16 mm or 5/8" 9.6 11 - - -
60 121 7380 1 10 mm or 3/8" 54 54 16 mm or 5/8" 14 16 - - -
75 189 11500 1 10 mm or 3/8" 85 85 16 mm or 5/8" 22 25 - - -
502 195 11900 1 10 mm or 3/8" 87 87 16 mm or 5/8" 22 25 - - -
602 282 17200 1 10 mm or 3/8" 126 126 16 mm or 5/8" 32 37 - - -
752 441 26900 1 10 mm or 3/8" 197 197 16 mm or 5/8" 50 57 - - -
B1J
B1JA
Stroke vol.
dm3/ in3NPT Piping Air
(s)
Spring
(s)
Piping Air
(s)
Spring
(s)
Piping Air
(s)
Spring
(s)
80.9 55 3/8 10 mm or 3/8" 0.5 1.0 - - - - - -
10 1.8 110 3/8 10 mm or 3/8" 0.7 1.4 - - - - - -
12 3.6 220 1/2 10 mm or 3/8" 1.2 2.7 16 mm or 5/8" See Note 1 See Note 1 - - -
16 6.7 409 1/2 10 mm or 3/8" 3.2 4.8 16 mm or 5/8" 0.7 1.3 25 mm or 1" See Note 1 See Note 1
20 13 793 3/4 10 mm or 3/8" 4.6 9.3 16 mm or 5/8" 1.4 2.6 25 mm or 1" See Note 1 See Note 1
25 27 2048 3/4 10 mm or 3/8" 8.9 18 16 mm or 5/8" 2.9 5.4 25 mm or 1" 2.5 2.9
32 53 3234 1 10 mm or 3/8" 15 38 16 mm or 5/8" 4.9 11 25 mm or 1" 4.3 5.3
322 106 6468 1 10 mm or 3/8" 31 77 16 mm or 5/8" 9.8 21 25 mm or 1" 8.5 11
QPX Stroke vol.
dm3/ in3NPT Piping Air
(s)
Spring
(s)
Piping Air
(s)
Spring
(s)
Piping Air
(s)
Spring
(s)
10.62 38 3/8 10 mm or 3/8" See Note 1 See Note 1 - - - - - -
21.08 66 3/8 10 mm or 3/8" See Note 1 See Note 1 - - - - - -
32.18 133 3/8 10 mm or 3/8" See Note 1 See Note 1 - - - - - -
44.34 265 3/8 10 mm or 3/8" See Note 1 See Note 1 - - - - - -
VPVL Stroke vol.
dm3/ in3NPT Piping Air
(s)
Spring
(s)
Piping Air
(s)
Spring
(s)
Piping Air
(s)
Spring
(s)
350 0.7 43.8 1/4 10 mm or 3/8" See Note 1 See Note 1 - - - - - -
400 0.9 56 1/4 10 mm or 3/8" See Note 1 See Note 1 - - - - - -
450 1.5 89 1/4 10 mm or 3/8" See Note 1 See Note 1 - - - - - -
Note 1: Times to be defined later

10 7 VG9F 70 en
Fig. 5 Operation directions, air connections and assembly related parameters
DOUBLE-ACTING ACTUATOR
Self closing
Default setting:
ATYP = 2-A
PFA = CLO
VTYP according to valve type
C1
C2
S
3.
DOUBLE-ACTING ACTUATOR, REVERSED PIPING
Self opening
Default setting:
ATYP = 2-A
PFA = OPE
VTYP according to valve type
C1
C2
S
4 .
SINGLE-ACTING ACTUATOR, SPRING TO OPEN
SINGLE-ACTING ACTUATOR, SPRING TO CLOSE
1. Self closing
Default setting:
ATYP = 1-A
PFA = CLO (must be in the spring direction)
VTYP according to valve type
2. Self opening
Default setting:
ATYP = 1-A
PFA = OPE (must be in the spring direction)
VTYP according to valve type
C1
C2
S
C1
C2
S

7 VG9F 70 en 11
3.6 Electrical connections
The VG9000F diagnostics part is powered by FOUN-
DATION fieldbus (IEC 61158-2). The same bus cable is
used also for the fieldbus communication. (Connec-
tions H1: '+' and '-', see Section 1.4 for electrical rat-
ings).
Output from the safety system is used to power the
safety part. (Connections 24 V DC: '+' and '-').
See Section 11.6. for detailed connections.
The signal cables are led through M20 x 1.5 cable
glands.
Conductors to the terminal strip are prewired as shown
in Fig. 6. See Section 11.6 for detailed electric connec-
tions. The earthing of the cables shall be carried out at
the DCS end only.
Fig. 6 Prewired terminals in the circuit board
Fig. 7 VG9000F Connection diagram. See Section 11.6. for further details..
6
5
4
3
VG9000F
Safety
system
DO
(0/24 V DC)
DCS
FF H1
FF
H1
24
V DC

12 7 VG9F 70 en
4 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 two row
LCD and four button keypad interface. There are also
custom graphical characters for special conditions.
4.1 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.
Valve position (POS) shows the valve travel position in
percentage (%) of full scale. Optional unit is angle.
Input signal (INP) shows if the 24 V DC input signal is
connected (On) or not (OFF).
Actuator pressure difference (PDIF) shows the actua-
tor pressure in single acting actuators or pressure dif-
ference in double acting actuators in bars (BAR).
Optional unit is psi (PSI).
Housing pressure (Pint) shows the pressure inside
the enclosure in bars (BAR). This is not in use in rev 1.1.
Supply pressure (SUPL) shows the air supply pressure
value in bars (BAR). Optional unit is psi (PSI).
Fig. 8 Local user interface (LUI)
Table 3 Default / optional units of measurements
Measurement Default unit Optional unit Values
Valve position
(POS) Percentage (%) of full
scale
Angle (ANG),
where 0 %
refers to 0
(angle)
–
24 V DC input
signal (INP) ––On,OFF
Actuator
pressure
difference
(PDIF)
bar (BAR) psi (PSI) –
Housing
pressure
(Pint)*
bar (BAR) psi (PSI) –
Supply
pressure
(SUPL)
bar (BAR) psi (PSI) –
Device
temperature
(TEMP)
°Celsius (C) °Fahrenheit (F) –
Device usage
(USAG) – – Safety (SAF), On/Off (Ono),
Hybrid (HYb)
* Not in use in rev 1.1
Fig. 9 Measurement monitoring and unit change
— continuous push
— brief push

7 VG9F 70 en 13
Device temperature (TEMP) shows the temperature
inside the device in degree Celsius (C). Optional unit is
degree Fahrenheit (F).
Device usage (USAG) shows if the device is set to oper-
ate as safety (SAF) device, On/Off (Ono) device or
Hybrid (HYb) device.
❑Safety usage means that FOUNDATION fieldbus
powers up the diagnostic part of the device and
emergency action is implemented by the safety
system signal.
❑On/Off usage means that FOUNDATION fieldbus
powers up the diagnostic part of the device, and
on/off action is implemented by the 24 V DC sig-
nal from the DCS. Device not used as an emer-
gency valve controller. All closing actions are
then normal valve operations.
❑Hybrid usage means that VG9000F can perform
normal on/off valve operation (i.e. closing or
opening) or Partial Stroke Test (PST) through
FOUNDATION fieldbus communication. In this
way the DCS can control the valve opening/clos-
ing and PST implementation and the safety sys-
tem controls the safety action implementation.
NOTE: Default value is safety device.
NOTE: Device usage can only be changed via DD, i.e.
using fieldbus configurator.
4.2 Guided start-up
Guided startup offers a fast view of the most critical
parameters of the ValvGuard 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 4.4:
Actuator type ATYP
Valve type VTYP
Positioner fail action PFA
Extra Pneumatics Instrumentation EXTI
Actuator size ACTS
Spool valve type STYP
Automatic travel calibration CAL
If you modify any of the parameters you will also need to
calibrate the device. See 4.5 for detailed description.
4.3 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.
4.4 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. Depending on the device usage option
selected (safety, on/off, hybrid) the menu has different
parameters, see Figures 11–13. NOTE: Device usage
option can not be selected from LUI, only from DD. You
may view the current value and edit them by pressing the
?key at the relevant parameter. The name of the param-
eter will appear on the upper row of the display and the
current value is on the lower row. See also table in Chap-
ter 13.
NOTE:
You may cancel any action by pressing the =button.
Cancelling of operation returns user interface view one
level up in menu hierarchy.
Fig. 10 Guided start-up
NOTE:
Default values can be restored by using DTM.
— brief push

14 7 VG9F 70 en
Fig. 11 Configuration. Device usage: safety
— brief push
Fig. 12 Configuration. Device usage: on/off
— brief push

7 VG9F 70 en 15
4.4.1 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 1-Aor 2-Ausing the +
and -keys. The value 1-Aindicates a single act-
ing actuator and 2-Aa double acting actuator.
❑To conclude press the ?key when the desired
value is shown on the display.
4.4.2 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 two values rot or LIn using the
+and -keys. The value rot indicates a rotary
valve and LIn a linear valve.
To conclude press the ?key when the desired value is
shown on the display.
4.4.3 Positioner fail action, PFA
This section describes the function of the actuator.
Set value according to Fig. 5 for double acting actua-
tors. Generally set value according to the valve fail safe
position. For single acting actuators set value in the
spring direction. This action will also take place when
the controller software discovers a fatal device failure.
See Fig. 5 for correct settings.
❑Once PFA is displayed, press the ?key to enter
the edit state and the PFA will start blinking.
❑You may select between two values by pressing
the +or -key. The CLO value indicates that the
valve ought to be closed in fail action situations.
The OPE value indicates the valve to be opened in
fail action situations.
❑After the desired value is displayed, press the
key ?to conclude the operation.
4.4.4 Extra pneumatics instrumentation, EXTI
Only used when device usage type is Safety or Hybrid.
In order to optimise the control performance the device
needs to be informed about the extra pneumatics instru-
mentation, if any.
❑After selecting EXTI on the display, press the ?
key to enter the edit state and EXTI starts to blink.
❑Select between the following values:
non = no external instrumentation
bo1 = booster type 1
bo2 = booster type 2
bo3 = booster type 3
qE1 = quick exhaust type 1
qE2 = quick exhaust type 2
qE3 = quick exhaust type 3
co1 = combination type 1
co2 = combination type 2
co3 = combination type 3
Use the +and -keys to change the value.
Fig. 13 Configuration. Device usage: hybrid
— brief push

16 7 VG9F 70 en
❑To conclude press the ?key when the desired
value is shown on the display.
NOTE: If nothing else is defined, please select type 1 in
any class.
❑Select parameters as follows:
4.4.5 Actuator size, ACTS
This parameter defines the actuator size.
❑Look at e.g. the type code on the machine plate
in the Neles B1-series actuators to check the
size. If 3rd party actuator is used, please check
the actuator stroke volume.
❑After selecting ACTS on the display, press the ?
key to enter the edit state and ACTS starts to blink.
❑Select between the following values:
S 1 = Neles B1J8 actuator
(or stroke volume <1 dm3/ <61 in3)
S 3 = B1J10 (1-3 dm3/ 61-183 in3)
S10 = B1J12-16 (3-10 dm3/ 183-610 in3)
S30 = B1J20-25 (10-30 dm3/ 610-1831 in3)
L30 = B1J32- (>30 dm3/ >1831 in3)
Use the +and -keys to change the value.
❑To conclude press the ?key when the desired
value is shown on the display.
4.4.6 Spool type, STYP
This parameter defines the spool type and size in
VG9000F.
❑Look at the machine plate in the device to check
the typecode.
❑After selecting STYP on the display, press the ?
key to enter the edit state and STYP starts to blink.
❑Select between the following values:
15 = VG9_15
35 = VG9235
37 = VG9237
Use the +and -keys to change the value.
❑To conclude press the ?key when the desired
value is shown on the display.
4.4.7 Language selection, LANG
❑Select between three languages EnG, GEr or FrE
(English, German or French) using the +and -keys.
❑To conclude press the ?key when the desired
value is shown on the display.
4.5 Valve travel calibration
Select CAL from the menu by using +or -keys and
press the ?key.
NOTE: When device usage is hybrid the valve needs to
be in the normal position (not fail safe) for calibration to
be started.
4.5.1 AUTO CAL calibration function
During calibration process a blinking text "CAL run" will
be show on the display. If calibration ends successfully,
a text "CALIBRATION SUCCESSFUL" will be shown. Cali-
bration can be cancelled with the =key, which will
show a text "CALIBRATION CANCELLED". If calibration
fails, the reason will be shown, eg. "CALIBRATION
START FAILED", "POSITION SENSOR RANGE TOO
SMALL", "CALIBRATION TIMEOUT" or "CALIBRATION
FAILED". After calibration the device will return to the
main menu (measurement monitoring).
4.6 Testing, TESt
❑Select between two tests Partial Stroke Test
(PARt tst) or Pneumatics test (PNEU tst).
❑To conclude press the ?key when the desired
value is shown on the display.
4.6.1 Partial Stroke Test, PARt tst
Table 4 Selecting extra pneumatics instrumentation
parameters
Instrumentation type Parameter (EXTI)
Volume booster (VB) Booster type 1 (bo1)
Quick exhaust (QEV) Quick exhaust 1 (qE1)
Combination of VB and QEV Combination type 1 (co1)
NOTE:
When QEV or volume booster is used, VG with small
spool valve (VG_15_) is required.
NOTE:
When QEV or volume booster is used, VG with small
spool valve (VG_15_) is required.
CAUTION:
It is important to select the correct actuator size
because this parameter is used in device control.
Erroneous value may cause instability.
CAUTION:
It is important to select the correct spool type
because this parameter is used in device control.
Erroneous value may cause instability.
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.
NOTE:
Make sure to run the pneumatics test before the auto-
matic travel calibration.
Fig. 14 Calibration selection
NOTE:
Valve position needs to be in the normal operating
position, supply pressure needs to be in valid range,
no supply pressure drop is allowed and any test can-
not be active when calibration is started.
Pneumatics test needs to be performed succesfully
before the calibration.
WARNING:
Partial Stroke Test moves the valve according to
the stroke size. Make sure that this procedure can
be safely executed.

7 VG9F 70 en 17
NOTE: Only used when device usage type is Safety or
Hybrid.
Partial stroke test can be run from here. Partial stroke test
will be run according to the stroke size (MStr) described
in Section 4.8. Advance parameters.
NOTE: Max speed of the partial stroke test is always
restricted to 3 %/s.
❑Select PARt tst from the menu by using +or
-keys and press the ?key.
❑Test can be cancelled by pressing =.
4.6.2 Pneumatics test, PNEU tst
Pneumatics test can be run from here.
❑Select PNEU tst from the menu by using +or
-keys and press the ?key.
❑This will check the pneumatics function of the
device by moving the spool valve only and not
moving the actuator or the valve.
❑Test can be cancelled by pressing =.
4.7 Limit Switch LS status
LS shows the status of bus powered (VG9_/B_) mechan-
ical limit switches:
--- No limit switch active
CLO Limit switch "Closed" active
OPE Limit switch "Open" active
LSE Limit switch error, both switches activated
at the same time
4.8 Advance parameters
Only used when device usage type is Safety or Hybrid.
4.8.1 Stroke time and profile,
STOP, STCL,SPOP,SPCL
NOTE: Only used when device usage type is Hybrid.
Valve open and close profiles can be configured with
Neles ValvGuard with the limitation set by valve assem-
bly. Stroke time performance constraints can be seen
from the piping table in Section 3.4. Both stroke direc-
tions can be set without any connection to the each other.
Opening and closing times can be set with STOP (open) and
STCL (close) parameters. Parameter is given in seconds.
Stroke profile shape can be set with parameters SPOP
(open) and SPCL (close). Profile can be chosen sepa-
rately for both direction from one of the five profile
shapes: Linear (1), Slow Starting (2), Slow Starting &
Ending (3), Equal Percentage (4) and Quick Starting
(5). If valve stroke is needed to do as fast as possible,
set stroke time to 0.
4.8.2 Manual Stroke Size, MSTr
Targeted manual partial stroke test size. Range is 3.0–
100 %.
❑Once MSTr is displayed, press the ?key to enter
the edit state and the MSTr will start blinking.
❑Select values by pressing the +or -key. Hold-
ing down +or -key will start scrolling the
value show on the display faster.
❑After the desired value is displayed, press the
key ?to conclude the operation.
NOTE:
Valve position needs to be in the normal operating
position, supply pressure needs to be in valid range,
no supply pressure drop is allowed and any other test
or calibration cannot be active when testing is started.
NOTE:
When double acting actuator is used 'Actuator Low
Limit Pressure' -parameter needs to be set to negative
value, e.g. -2. It can only be changed via FOUNDATION
fieldbus, e.g. in the DTM.
NOTE:
Pneumatics test (Section 4.6.2.) will be run automati-
cally before the partial stroke test in some cases, e.g.
when supply pressure has changed. Pneumatics test
timeout parameter is valid also in this case.
NOTE:
Valve position needs to be in the normal operating
position, supply pressure needs to be in valid range
and any other test or calibration cannot be active
when testing is started.
NOTE:
Pneumatics test timeout parameter is 600 s. The value
is hardcoded and cannot be changed.
Fig. 15 Stroke profile shapes, opening
Fig. 16 Stroke profile shapes, closing
0
10
20
30
40
50
60
70
80
90
100
0 102030405060708090100
Linear Slow Starting & Ending Equal Percentage
Quick Starting Slow Starting
% of stroke time
valve travel
0
10
20
30
40
50
60
70
80
90
100
0 102030405060708090
100
Linear Slow Starting & Ending Equal Percentage
Quick Starting Slow Starting
% of stroke time
valve travel

18 7 VG9F 70 en
4.8.3 Automatic Partial Stroke Test, APSt
Selection if automatic partial stroke test is disabled (diS),
enabled (EnA) or enabled with randomized range (rnd).
❑Select between three options dis, EnA or rnd
using the +and -keys.
❑To conclude press the ?key when the desired
value is shown on the display.
NOTE: Automatic partial stroke test stroke size and other
parameters can not be changed from the LUI. They can
only be changed via FOUNDATION fieldbus, e.g. in the
DTM.
4.9 Special displays
4.9.1 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
FOUNDATION fieldbus DD. When the Local User Inter-
face is locked the lock symbol will be activated on the
display.
4.9.2 Alarm or warning state
All failure conditions and statuses in VG9000F can be
individually configured to three different classes: Alarm,
Warning or Info, or they can be ignored. This configura-
tion can be done with DTM (see separate DTM manual).
Alarm state causes a blinking & to be shown on the dis-
play. In Warning state, the &symbol is steady.
4.9.3 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.
4.9.4 Write protection
The VG9000F 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. If you need to change the setting, please
contact Metso’s Automation business for instructions.
Write protection protects all write access to all writeable
parameters of the device. Changing the parameters
from the LUI, fieldbus configurator or FieldCare is thus
not allowed.
5 MAINTENANCE
The maintenance requirements of the ValvGuard valve
controller depend on the service conditions, for instance,
the quality of instrument air. Under normal service condi-
tions there is no requirement for regular maintenance.
When maintaining the ValvGuard 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 11,
unless otherwise stated.
The ValvGuard VG9000F includes the following mod-
ules: prestage unit (120), spool valve (420), communi-
cation circuit board and controller circuit board with
position and pressure sensors (210).
The spool valve is located on the bottom side of the
device while the other modules are located below the
cover (100). In the event of failure the whole module
must be changed. The module retrofit must be assem-
Fig. 17 LUI locked
Fig. 18 Alarm and Warning states
Device in Warning state
Device in Alarm state
Fig. 19 Online alarm or warning state message
Ex d NOTE:
Maintenance of the parts of the flameproof enclo-
sure is not allowed!
Device type VG9000F_E6_:
Housing (2), Cover (100), Shaft assembly (11), Limit
switch housing (300).
NOTE:
VG9000 maintenance can be done by Metso certified
service personnel only.
scrolling text

7 VG9F 70 en 19
bled in a clean, dry environment. On reassembly apply
a thread-locking compound (for instance, Loctite 243)
and tighten the screws firmly.
5.1 Opening and closing of the cover
❑Open VG9000F cover (100) by opening the M4
screw (107) first until it is not anymore attached
to the housing (2). Then turn the cover counter-
clockwise until it can be removed.
❑Close the cover (100) in reverse order. Mount it
first on top of the housing (2) and then turn it
clockwise until threads are tight and the screw
(107) is facing the spring (111) in the housing
(2). Tighten the M4 screw (107).
5.2 Prestage
5.2.1 Removal
❑Loosen the M8 stop screw (110) in the position
indicator (109) and turn the position indicator
from the shaft (11). Remove the inner cover (39)
attached with M3 screws (42, 3 pcs.).
❑Unplug the prestage wire connector from the
connector board (182). Unscrew the M4 screws
(139, 2 pcs.) and lift up the prestage unit (120).
Remove the O-ring (140).
5.2.2 Adapter plate removal
❑Remove the screw (412) and remove the adapter
plate. Adapter plate is only needed to be
removed when replaced with new one.
5.2.3 Installation
❑Install the new adapter plate, if it has been
removed. Make sure the O-rings (411) are prop-
erly installed. Tighten the screw (412).
❑Place a new O-ring (140) into the groove in the
prestage mounting plate (400) 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 posi-
tion. Tighten the screws (139) evenly.
❑Push the prestage 2-pole wire connector into the
socket on the connector board (182). The wire
connector can only be fitted in the correct posi-
tion. Replace the inner cover (39) and tighten the
M3 screws.
5.3 Spool valve
5.3.1 Standard capacity
Standard capacity means the spool valve option 15 in
VG9_15. See type coding in the machine plate for
details.
5.3.1.1 Removal
For spool valve removal it is usually necessary to
unmount the valve controller from the actuator.
❑Before removing the spool valve assembly in
VG9315, the spool valve cover (454) needs to be
removed. Unscrew the M4 screws (4 pcs.).
❑Working from the bottom side of the valve con-
troller, unscrew the M5 screws (4 pcs.). Remove
the spool valve (420) with gasket (63). Do not
remove the spool valve adapter plate (421).
5.3.1.2 Installation
❑Mount the spool valve (420) to the housing, and
tighten the four M5 screws evenly.
❑Mount the spool valve cover (454) (only in
VG9315).Tighten the four M4 screws evenly.
5.3.2 High capacity
High capacity spool valve means the spool valve options
35 or 37 in VG9235 or VG9237. See type coding in the
machine plate for details.
5.3.2.1 Removal
❑Unscrew the M5 screws (4 pcs.). Remove the
spool valve (420) with gasket from the mounting
block (421).
5.3.2.2 Installation
❑Ensure that the gasket (63) is properly located in
the grooves in the bottom of the spool valve.
Mount the spool valve (420) to the mounting
block (421), and tighten the four M5 screws
evenly.
NOTE:
Whenever any maintenance operations have been
done for the VG9000F, the device should be calibrated.
NOTE:
Prestage cannot be changed in the field.
NOTE:
The prestage and adapted plate must be handled
carefully. In particular the moving parts of the
prestage should not be touched when the inner cover
(39) is not in place. Make sure the prestage and
adapter plate are kept clean during the maintenance.
NOTE:
Spool valve cannot be changed in the field.
NOTE:
If the maintenance operations are needed for the
spool valve, it is advised to replace the whole spool
valve assembly with a spare unit.
NOTE:
If adapter plate (421) is lifted away from its place, spe-
cial attention must be paid to ensure that gasket (174)
and pipe (431) are properly attached to the housing.
O-rings of the pipe must be handled carefully in order
to avoid breakage.

20 7 VG9F 70 en
5.4 Communication circuit board
5.4.1 Removal
❑Loosen the M8 stop screw (110) in the position
indicator (109) and turn the position indicator
from the shaft (11). Remove the inner cover (39)
attached with M3 screws (42, 3 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.
5.4.2 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 inner cover (39).
❑Mount the position indicator (109) on the shaft
and tighten the M8 stop screw (110) temporarily.
The final orientation and locking of the position
indicator should be done after installation of the
valve controller to the actuator.
6 MESSAGES
These messages may appear in the local user interface.
Fig. 20 Spool valve assembly
NOTE:
Communication circuit board cannot be changed in
the field.
NOTE:
Ground yourself on the body of the device before
touching the circuit board.
Ex WARNING:
Grounding of the circuit board is essential to
explosion protection.
The board is grounded to the housing by the mount-
ing screw next to the terminal blocks.
Fig. 21 Communication board
215
Display message Description
ACTUATOR FULL STROKES
COUNTER LIMIT EXCEEDED Actuator full stroke counter has exceeded the
configurable limit
CALIBRATION CANCELLED Calibration process has
been cancelled
CALIBRATION FAILED Position calibration process
has failed
Calibration process has
failed
Calibration process has
failed
Coil calibration process has
failed
CALIBRATION START
FAILED Calibration process could not be started
CALIBRATION
SUCCESSFUL Position calibration process has ended successfully
Pressure calibration process
has ended successfully
Coil calibration process has
ended successfully
CALIBRATION TIMEOUT Calibration process has
taken too long time
CONTINUED WATCHDOG
RESET Too many consecutive internal resets have been
generated
DEVICE USAGE CHANGED -
PLEASE REBOOT THE
DEVICE
Device usage (Safety/OnOff/
Hybrid) was changed
EMERGENCY TRIP
ACTIVATED Emergency trip was activated
ETT CLOSING TIME TOO
HIGH Too high closing time detected in emergency trip
test
ETT OPENING TIME TOO
HIGH Too high opening time detected in emergency trip
test
FACTORY DEFAULTS
ACTIVATED Device parameters were changed to factory settings
FACTORY SETTINGS
CREATE FAILURE
DETECTED
Factory settings creation
failed
FACTORY SETTINGS
RESTORE FAILURE
DETECTED
Factory settings restoration
failed, i.e. current parameter
set could not be loaded with
factory settings
FIELDBUS
COMMUNICATION FAILURE
RATE LIMIT EXCEEDED
Communication with FBI-
board was lost
PARAMETERS POOL
FAILURE DETECTED Parameter database initialization failed
PNEUMATICS FAILURE
DETECTED Actuator pressure difference has not changed even it
should have been. Spool
valve may be jammed
POSITION SENSOR FAILURE
DETECTED Position sensor defect has been detected
POSITION SENSOR RANGE
TOO SMALL Too narrow position sensor range was detected in
position calibration process
PRESSURE SENSOR 1
FAILURE DETECTED Pressure sensor #1 defect has been detected
PRESSURE SENSOR 2
FAILURE DETECTED Pressure sensor #2 defect has been detected
PRESSURE SENSOR 3
FAILURE DETECTED Pressure sensor #3 defect
has been detected
PST BREAKAWAY
PRESSURE TREND HIGH
LIMIT EXCEEDED
Too high breakaway pressure
detected in manual or
automatic partial stroke test
PST BREAKAWAY
PRESSURE TREND LOW
LIMIT EXCEEDED
Too low breakaway pressure
detected in manual or
automatic partial stroke test
PST COUNTER LIMIT
EXCEEDED Partial stroke test counter has exceeded the
configurable limit