7 ND 70 en

Rev. 4
Issue 10/97

VALVE CONTROLLER
Series ND800

INSTALLATION, MAINTENANCE
AND OPERATING INSTRUCTIONS
2

Table of Contents
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 3 9 ORDERING SPARE PARTS. . . . . . . . . . . . 15
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 10 DRAWINGS AND PARTS LISTS . . . . . . . 16
1.2 Principle of operation . . . . . . . . . . . . . . . . . . . . 3 10.1 Exploded view and parts list . . . . . . . . . . . . . . 16
1.3 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 10.2 Mounting parts for B1C/B1J 6-20
1.4 Technical specifications . . . . . . . . . . . . . . . . . . . 3 actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . 5 10.3 Mounting parts for B1C/B1J 25-50,
2 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . 5 B1C 502 and B1J322 actuators. . . . . . . . . . . . 17
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 10.4 Mounting parts for Quadra-Powr®, ST,
2.2 Mounting on Neles-Jamesbury actuators SP and Valv-Powr® actuators . . . . . . . . . . . . . 18
with VDI/VDE mounting face (S1) . . . . . . . . . 5 10.5 Mounting parts for D/R linear actuators . . . . 18
2.3 Mounting on Neles-Jamesbury actuators 11 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . 19
with old mounting face (S2). . . . . . . . . . . . . . . 5 12 TYPE CODING . . . . . . . . . . . . . . . . . . . . . . 20
2.4 Mounting on Neles-Jamesbury
linear actuators. . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Piping of supply air. . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Electrical connections . . . . . . . . . . . . . . . . . . . . 7
3 USER INTERFACE . . . . . . . . . . . . . . . . . . . . 9
3.1 Keyboard and display . . . . . . . . . . . . . . . . . . . . 9
3.2 Keyboard functions . . . . . . . . . . . . . . . . . . . . . . 9
3.3 HART communication . . . . . . . . . . . . . . . . . . . 9
4 CONFIGURATION. . . . . . . . . . . . . . . . . . . 11
4.1 Zero and range . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Position control . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Control valve related settings. . . . . . . . . . . . . 11
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 12
5.1 Prestage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Spool valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4 Position sensor . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.5 Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . 14
6 ERROR MESSAGES. . . . . . . . . . . . . . . . . . . 14
7 TROUBLE SHOOTING . . . . . . . . . . . . . . . 14
8 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

READ THESE INSTRUCTIONS FIRST!

These instructions provide information about safe handling and operation of the 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!

Quadra-Powr and Valv-Powr are registered trademarks and Valve Manager is a trademark of Neles-Jamesbury.
All other brand or product names are trademarks or registered trademarks of their respective owners.
Subject to change without notice.
 3

1 INTRODUCTION 1.3 Markings

The valve controller is provided with an identification plate sticker,
1.1 General see Fig. 2. Identification plate markings from top to bottom are:
These instructions describe the digital Neles-Jamesbury ND800 Type designation of the valve controller
valve position controller. The ND800 can be used with either Revision number
cylinder or diaphragm type pneumatic actuators for rotary or linear Enclosure class
valves. Input signal (voltage range)
Input resistance
1.2 Principle of operation Max supply voltage
Supply pressure range
The ND800 is a 4-20 mA loop-powered microcontroller based
Operational temperature
valve controller. A 3.84 mA input signal will allow energy enough to
start communication via push buttons on the circuit board or HART. Manufacturing series number
A 275 HART hand-held terminal or a PC with HART modem (Valve CE mark
Manager ) can be connected to the terminal strip located in the
ND800 itself or in the DCS. The maximum load voltage is 12.8 V
with 20 mA.
Using push buttons or HART the configuration parameters can be
set according to the actuator and valve in question. Then auto-cali-
bration can be started via push buttons or HART. Display with three
digits and text labels shows the operation.
In control service the microcontroller (µC) reads input signal (mA),
position sensor (α) and pressure sensor (p). A change in input signal Fig. 2. Identification plate
will be detected by control algorithm inside the µC. The microcon-
troller will change the pilot current to one of prestage (PR) coils. Alternative markings on the optional plate, Fig. 3:
Prestage valve lowers the pilot pressure at the end of the spool Filter-regulator (-K)
valve (SV). The spool moves in direction of low pressure to open Operational temperature of regulator
the flow to the top of the actuator cylinder and to open the flow Conduit entries (-L, -I or -NJ)
out from other side of the piston. Increasing pressure difference
over the piston moves the piston and rotates the feedback shaft.
Position sensor (α) measures the rotation for the µC. The micro-
controller calculates in control algorithm a new pilot current until a
new position of the actuator proportional to the input signal (mA)
is reached. In steady state position the spool valve (SV) and prestage (PR)
valves are closed.

Fig. 3. Optional plate

1.4 Technical specifications

SV
General
PR
ND800 valve controller is suitable for rotary and sliding stem valves.
µC Actuator connection In accordance with VDI/VDE 3845
α
C2
P
standard (S1) or optionally other NE-series
C1 compatibility (S2).
S
To replace an existing NE/NP positioner,
specify existing valve assembly
HART
Action: Double or single acting
1 2 3 4

Turning angle: 45°- 95°

Environmental influence
Operational temp.: -20 - +85 °C (-4 - +185 °F)
4-20 m A + HART
option -40 - +85 °C (-40 - +185 °F)
Influence of temperature on valve position
< 0.05%/°C
Fig. 1. Schematic diagram Influence of vibration on valve position
< 1% under 2g 5-150 Hz and
1g 150-300 Hz
0.5g 300-2000 Hz
4

Enclosure Sensors
Material: Anodized aluminium alloy Position sensor
Protection class: IP65, NEMA 4X linear range: 110 °
Mechanical position Actuator pressure
indicator: on cover sensor linear range: 7 bar (differential pressure)
Pneumatics ports: 1/4 NPT
Electrical connection: Screw terminals internals for 2.5 mm2 Position transmitter
and 1 PG 13.5 conduit entry Output signal: 4-20 mA (galvanic isolation, 2500 VDC,
(1/2 NPT, M20x1.5 and R 1/2 as option, passive device)
see optional plate) Supply voltage: 12-36 VDC, 2-wire
Weight: 2.1 kg (4.6 lbs) 12-24 VDC, EExi...
Pneumatics Power from external supply
Load resistance: max 0-1200 Ω
Supply pressure: 2.5-8 bar (36-115 psi)
max 0-600 Ω, EExi...
Effect of supply
Approvals: Intrinsically safe as option
pressure: < 0.2 %/10 kPa (0.14%/psi)
Air quality: As defined by ISA S7.3 standard User interfaces
Capacity: Max 30 Nm3/h (18 scfm)
Local: 3 keys + LCD display
at 4 bar (60 psi) supply
HART: Universal 275 HART hand-held terminal
Consumption: 0.3 Nm3/h (0.18 scfm) or PC with a HART modem (RS 232 or
at 4 bar (60 psi) supply PCMCIA interface) together with
Electronics Valve Manager program.
Connection points are on the screw
Supply power: Taken from the 4-20 mA input signal. terminal strip
No external power needed
Minimum signal: 3.84 mA Additional HART functions
Load voltage: up to 12.8 VDC at 20 mA / 640 Ω Flow characterization: Linear, equal percentage, custom
(max voltage drop) Split range: 4-12 mA, 12-20 mA, custom
Supply voltage: max 30 VDC Ident. information: HW/SW rev., serial numbers, actuator type etc.
Polarity protection: -30 VDC Monitoring: Input signal, valve travel setpoint, actual travel,
Overcurrent actuator pressure and temperature
protection: active over 25 mA Diagnostics: Travel deviation, travel duration, load factor,
operation time, valve/actuator travel counters,
Performance with moderate constant load actuators failure information
Testing: Step response, hysteresis loop
Hysteresis + dead band: < 1 %
Module calibration: Position sensor, pressure sensor, tempera-
Linearity error : < ±2%
ture measurement, input signal measurement,
Local keypad functions prestage trim
Calibration: Automatic / Manual Electromagnetic protection
Feedback parameters: 0-100 (d and b) Protection standards: EN50081-1 and EN50082-2
Gain configuration: 0-100 (gain) IEC 801-2 ESD, level 4,
Mode Selection: Auto/Man/Off IEC 801-3 Electro Magnetic Field, level 3
Signal, DIR: - direct (default) IEC 801-4 Fast Transients, level 4
- reverse
Rotation, ROT: - clockwise (default) CE marking
- counterclockwise Electromagnetic
Dead angle, A0: acc. to valve (0 % default) compatibility: 89/336/EEC
Cut-off-safety range, SAF:
2 % (default)
Electrical connections
Input signal: 4-20 mA, 2-wire.
acc. to ANSI/ISA S50.1
Approvals: Intrinsically safe
Cenelec EEx ia IIC T5/T6,
temp. ≤ +75 °C/+67 °F; T5
temp. ≤ +50 °C/+122 °F; T6
CSA Class 1 Groups A, B, C and D (pending)
 5

1.5 Safety precautions S1 Shaft alternatives S2

CAUTION: mark
Do not exceed the permitted values!
Exceeding the permitted values marked on the valve control- 40 40
ler may cause damage to the controller and equipments mark = yellow dot
attached to controller and lead to uncontrolled pressure C2
release in the worst case.
S
Damage to the equipment and personal injury may result.
C1 The mark on the shaft
should stay in this sector
CAUTION:
Do not remove or dismantle a pressurized controller!
Removing or dismantling a pressurized prestage, spool valve or
pressure sensor of ND800 leads to uncontrolled pressure release.
Always shut off the supply air and release pressure from the pipelines
and equipment before removing or dismantling the controller. Fig. 4. Mounting on Neles-Jamesbury actuator with
Otherwise personal injury and damage to equipment may result. VDI/VDE mounting face
2.3 Mounting on Neles-Jamesbury actuators
CAUTION: with old mounting face (S2)
During the automatic or manual calibration the valve Run the actuator until the piston is in the top position (spring
is operated to open and closed positions. Make sure return actuators in the position determined by the spring).
that operation does not danger people or process! Set the direction arrow in the direction of the valve closure
member and attach the draught piece (2) to the indicator
NOTE: cover in the position shown in Fig. 5. Secure the screw of
Avoid earthing a welding machine close to ND800. the draught piece e.g. with Loctite and tighten it sufficiently.
Damage to the equipment may result. Attach the bracket (1) to the ND800.
Attach the bracket (1) to the actuator. The shaft (40) of
NOTE: ND800 must find it’s place to the draught piece (2) shown
The display may become unreadable in ambient temperatures in Fig. 5. See also drawings in Sections 10.2 and 10.3.
below -20 °C/-4 °F. Note the differences in the installation between the BC, BJ actuator
Heating, for instance with thumb, may be necessary. and BJA actuators.

2 MOUNTING
bracket (1) BC, BJ
2.1 General
When the ND800 is supplied together with the valve and actuator, the
tubes are mounted and the ND800 adjusted in accordance with the
customer’s specificatons. When the controller is ordered separately, the coupling
mounting parts for the assembly must be ordered at the same time. draught piece (2)
Example order: (B1C13)-Z-ND826/S1. coupling
The controller has the new Neles-Jamesbury mounting face bracket (1)
for connection according to VDI/VDE 3845 (S1) and also the BJA
old Neles-Jamesbury mounting face (NE) (S2).
For mounting parts for Neles-Jamesbury actuators, see Sections 10.2-10.4.

2.2 Mounting on Neles-Jamesbury actuators

with VDI/VDE mounting face (S1) Fig. 5. Mounting on Neles-Jamesbury actuator
Run the actuator until the piston is in the top position (spring
return actuators in the position determined by the spring).
Set the direction arrow in the direction of the valve closure 2.4 Mounting on Neles-Jamesbury
member and attach the draught piece (2) to the indicator linear actuators
cover in the position shown in Fig. 4. Secure the screw of See Section 10.5
the draught piece e.g. with Loctite and tighten it sufficiently. Connect an airset directly to the actuator and position the
Attach the bracket (1) to the ND800. actuator at its mid stroke position (see serial plate for
Attach the bracket (1) to the actuator. The shaft (40) of actuator stroke lenght).
ND800 must find it’s place to the draught piece (2) shown Assemble the feedback arm to the controller input shaft.
in Fig. 4. See also drawings in Sections 10.2, 10.3 and 10.4. Make sure the lettering on the feed back arm faces up
Note the differences in the installation between the BC, BJ actuator towards the controller.
and BJA actuators.
6

Assemble the controller mounting bracket loosely to the
slotted leg of the actuator. Make sure mark on shaft and
feedback arm operate in the quadrant shown.
Measure the distance from the center of the feedback
lever shaft to the slot on the feedback lever and mark this
distance with a pencil or other marking instrument. Use
dimensions given in Section 10.5.
Mount the controller loosely onto the controller mounting
bracket.
Adjust the controller mounting bracket and the controller so
that the controller is 90° to the center line of the actuator
and so that the controller feedback lever is horizontal and
90° to the counter line of the actuator.
Tighten the controller mounting bracket screws.
Adjust the controller on the controller mounting bracket so that
the measured distance is maintained between the center of the
feedback lever shaft and the actuator pin (pre-measured mark
on the feedback lever). Note the controller must still
conform to the specifications in previous steps.
Tighten all of the mounting bolts and then re-check that the
controller complies with previous steps. Check that the
actuator pin does not touch the controller case through out
the entire stroke of the actuator. If the actuator pin is too
long it may be trimmed to lenght. (1.125" or less stroke
actuators will require the pin to be trimmed).
Assemble the spring to the feedback arm as shown.
Apply grease (Molykote or equivalent) to the contact surfaces of
the actuator pin and the feedback lever to reduce wear.
Increase and/or decrease air pressure to the actuator to stroke
the actuator full stroke and check that nothing binds and that
the rotation of the feedback lever is 70° for 1"-3.5" stroke and
60° for 3⁄4" stroke. See Section 10.5.

Table 1. Piping and parameters

Actuator Piping Controller

Plastic/Cu/SS (") Plastic/Cu/SS (mm) Gain *) Gain *) Gain *)
BC Stroke vol. NPT 1/4 3/8 1/2 6/4 10/8 12/10 Spool 4 bar / 6 bar / 8 bar / d b
dm3/in3 valve 60 psi 90 psi 115 psi
6 0.3/18 1/4 x x 2 9.5 7 4.5 3 2
9 0.6/37 1/4 x x 2 15 12.5 10 2 1.5
11 1.1/67 3/8 x x 6 10 8 6 2 1
13 2.3/140 3/8 x x 6 13 11 9 1.5 1
17 4.3/262 1/2 x x 6 16 14 12 1 0.5
20 5.4/330 x x 6 17 15 13 1 0.5
25 10.5/610 1/2 x (x) x (x) 6 19 17 15 0.5 0
32 21/1282 3/4 x (x) x (x) 6 20 18 16 0.2 0
40 43/2624 3/4 (x) x x 6 22 20 18 0.2 0
50 84/5126 1 (x) x x 6 24 22 20 0.2 0
502 195/11900 1 x x 6 24 22 20 0.2 0
BJ Stroke vol. NPT 1/4 3/8 1/2 6/4 10/8 12/10 Spool Gain d b
BJA dm3/in3 valve **)
8 0.9/55 3/8 x x 21 12 3 1
10 1.8/110 x x 61 12 3 1
12 3.6/220 1/2 x x 61 14 3 0.5
16 6.7/409 x x 61 18 2 0.5
20 13/793 3/4 x (x) x (x) 61 20 1.5 0
25 27/1648 x (x) x (x) 61 22 1 0
32 53/3234 1 (x) x x 61 25 1 0
322 106/6468 x x 61 25 1 0
QP Stroke vol. NPT 1/4 3/8 1/2 6/4 10/8 12/10 Spool Gain d b
dm3/in3 valve **)
1 0.62/37 3/8 x x 21 9 3 1.5
2 1.08/66 3/8 x x 21 12 3 1
3 2.18/133 3/8 x x 61 10 3 1
4 4.34/265 3/8 x x 61 14 2 0.5
5 8.7/531 3/8 x x 61 18 2 0
6 17.5/1068 3/4 x x 61 20 1.5 0
*) Gain values are linear related what concerns other pressures.
**) In order to achieve symmetrical operation, use always filter regulator in connection with spring return actuators.
RA and DA actuators: use spool 21A. RB, RC, RD, RE and DB, DC, DE actuators: use spool 61A.
NOTE: Use QP values for diapharagm pneumatic linear actuators..
Use BJ values for spring return cylinder actuators. Use BC values for double acting cylinder actuators
 7

2.5 Piping of supply air 2.6 Electrical connections

Do not exceed the permitted supply pressure
of ND800!
Table 1 provides the recommended tube sizes in accordance with
the actuator sizes. Tube sizes are minimum values allowed. For
supply air choose one size bigger tube. Operating times can be
tested by Valve Manager.
Connect air supply to S (1/4 NPT).
Connect C1 and C2 (1/4 NPT) to the actuator.
For pipe threads are liquid sealants, e.g. Loctite, recommended.
NOTE:
A single action connection alone is permitted for controllers
mounted on the spring actuator. Place a plug in connection
C1. See Fig. 8.
NOTE:
Excessive sealant may cause faulty operation of the controller.
Sealing tape is not recommended.
Ensure the cleaness of the air piping.
ND800 is powered by a standard 4 - 20 mA current loop.
HART is carried over the current loop too.
The input signal cable is lead through a PG13,5 cable gland. Connect
the conductors to the terminal strip according to Fig. 6.
Check the wire polarity before connection. The controller has 30 V
polarity protection. EMC requirements require earthing.
NOTE:
ND800 equals a load of 640 Ω in the current loop.
NOTE:
Without earthing the valve position may vary in a strong
magnetic field.
Connect the cables for the optional position transmitter acc. to
Fig. 6. The position transmitter needs an external power supply.
ND800 and position transmitter circuits are galvanically isolated,
isolation voltage is 2500 VDC.

1 2 3 4
The supply air must be clean, dry and oil-free instrument air, e.g. Position signal 4...20 mA

5 6 7
according to standard ISA S7.3-81.
Input signal 4...20 mA

HART-connection (ø2,3 mm)

Fig. 6. Terminals

HART

LCD
DC power input

max. +12.8 V Valve

4...20 mA Coils
Current Pneumatic
Measurement
µController block control

Push-buttons Pressure
measurement

Position
Transmitter EEPROM
+12...36 V (12...24 V)
4...20 mA Option
Position
Measurement

Fig. 7. Operation blocks

8

C2
S DOUBLE-ACTING ACTUATOR
C1

1. Increasing input signal to open valve.

Default setting:
DIR = OPE
ROT = cC (close valve to c lockwise)
A0 = % (acc. to valve type)
SAF = 2 %
C2
2. Increasing input signal to close valve.
S
C1 Setting:
DIR = CLO
ROT = cC (close valve to c lockwise)
A0 = % (acc. to valve type)
SAF = 2 %

C2
S SINGLE-ACTING ACTUATOR (SPRING TO CLOSE)
C1

3. Increasing input signal to open valve.

Spring to close valve.
Default setting:
DIR = OPE
ROT = cC (close valve to c lockwise)
C2 A0 = % (acc. to valve type)
SAF = 2 %
S
C1
4. Increasing input signal to close valve.
Spring to open valve.
Setting:
DIR = CLO
ROT = ccC (close valve to c ounterclockwise)
A0 = % (acc. to valve type)
SAF = 2 %
CAUTION: Valve closes exceptionally counterclockwise.
Unsuitable for Q-, R-, T5-, F- and L-series valves.

C2
S SINGLE-ACTING ACTUATOR (SPRING TO OPEN)
C1

5. Increasing input signal to close valve.

Spring to open valve.

Default setting:
DIR = CLO
ROT = cC (close valve to c lockwise)
A0 = % (acc. to valve type)
SAF = 2 %

Fig. 8. Operation directions and air connections


3 USER INTERFACE
3.1 Keyboard and display
The keyboard and the display of ND800 are shown in Fig. 9. Only
the applicable information is shown on the display in each mode.
The operations and display are controlled by +, - and r keys.
Four setting functions are available: m, g, d or
c. Each of these names refer the function to be adjusted or
changed.
In a or M mode the display indicates 0-100 % as the valve
travel. In o mode the display shows two horizontal lines (--)
instead of digits. By pressing r key the display shows input signal in
mA within about 5 seconds. Under other situations the digit display
indicates the selected adjustable parameter value.
MODE: AUTO MAN OFF
GAIN
DB
CALIB
Fig. 9. LCD-display and keyboard
3.2 Keyboard functions
See keyboard operations from Fig. 11.
The keyboard setting state is initiated by pressing + and - keys for
5 seconds. The blinking text item m and one of the previously
selected operation modes, a, M or o, will be shown
on the display. If you want to change the operation mode, press r
first. a, M or o will start to blink showing that the
changing of the mode is enabled. Choose with + or - key the
desired mode, a, M or o. After the mode has been
selected, press the r key.
The m function provides three alternative ND800 operation
modes as follows:
a:
During a mode the ND800 controls the valve position
according to the incoming 4-20 mA signal. This mode is used during
normal process control service. After signal failure the ND800
follows input signal in a mode.
M:
During this mode the valve position can be manually controlled from
the keyboard + or - keys. The position of the valve driven manually
is not saved into non-volatile memory of ND800, e.g. the position
does not recover after signal failure. However, the valve can be
driven back to it’s position after signal failure by + and - keys.
o:
When o mode is activated the ND800 drives the valve to the
4 mA related position and does not respond to incoming signal.
Accept the selected mode with r key which returns you automat-
ically back to the setting state.
9
Move to the next setting by pressing + key. g starts to flash.
The needed positioner gain for different size of actuators is set with
the g parameter. By pressing r key allows you to change a
gain value shown in the display with + and - keys. Accept a changed
value with r key, which returns you automatically back to the setting
state.
d includes positioner feedback parameters d and b. By pressing
r key you can select one of the above mentioned parameters with
+ and - keys. Accept your choice with r key and change values
with + and - keys. Accept the value with r. Default values are
mentioned in Table 1.
The next setting to move on with + key is c. By pressing the
r key you can start zero and travel range calibration. More detailed
information about c is given in Section 4.1.
You can move within different options with + key forwards and -
key backwards.
In addition, there are four control valve related configuration
parameters: di r. rot, A0 and SAF, which are explained in Section 4.3
You can return from any setting point back to the operation state
by pressing simultaneously + and - keys < 1 second, repeat pressing
if needed.
3.3 HART communication
The ND800 is delivered from factory with HART write protection
OFF as default. Reading and changing of parameters is thus allowed.
The protection can be enabled with a switch (DIP1) located on the
circuit board, Fig. 10. The changes, which may influence the valve
position, cannot be made using Valve Manager program when the
switch no. 1 (on the left-hand side of the switch block) is ON. For
detailed information see Valve Manager User’s Guide. HART con-
nection at the ND800 terminal strip is shown in Fig.6.
DIP1 DIP1
OFF ON
ON ON
1 1 2
1 1 2
DIP1
ON
1 2
1
Fig. 10. DIP switch
10
Operation

% = input signal (mA)

state

& >5s
Setting state

DB DB

DB DB

PREVIOUS SETTING
>5s >5s & FACTORY = 90°

&

KEY STROKES

& = Escape < 1 s

Fig. 11. Keyboard operations


4 CONFIGURATION
4.1 Zero and range
The ND800 position sensor operational range is factory adjusted
to suit Neles-Jamesbury actuators. In case the ND800 shall be fitted
into other manufacturer’s actuator, there may be a need to readjust
the sensor as explained in Section 5.4.
Connect the air supply and input signal. Make sure that the
voltage is max 12.8 VDC with 20 mA, measured from the
+ and - terminals.
Select c function from the keyboard according to 3.2.
Now you can select from the display a or M
calibration mode by pressing + or - keys.
CAUTION:
The automatic calibration drives the valve against
mechanical open and closed travel limits of the
valve-actuator assembly. Make sure that this proce-
dure can be safely executed.
a calibration function:
Due to safety precautions the r key needs to be pressed
for 5 seconds to activate a calibration function.
During calibration the display shows CAL text. After cali-
bration the ND800 returns automatically to its setting
function.
At any instance you may interrupt the calibration se-
quences by pressing simultaneously the + and - keys.
After the a calibration sequence is concluded press
simultaneously the + and - keys to get back to operation
state. If this sequence is terminated and an error indication
Err is shown on the display, see Chapter 7.
Now the ND800 works with basic settings including 2 ± 0.5 % signal
cutoff margins to secure full closing of the valve.
In case you can not drive the valve fully open position or if there is
no mechanical limit stop available, act as follows:
M calibration function:
After selecting from the display the M calibration
function press the r key to activate the procedure.
Drive the valve manually from the + or - keys to the
closed (0 %) position and after this press the r key.
In case you cannot drive the valve into open position, then
you may skip this sequence now by pressing + and - keys
simultaneously. Now the ND800 assumes that the maxi-
mum valve opening is the latest calibrated value, the
factory setting is 90°.
Drive the valve to the desired maximum opening position
(100 %) with + and - keys and press the r key.
Press simultaneously + and - keys to return into operation
state.
Now the valve controller works with basic settings including
2 ± 0.5 % signal cutoff margins.
4.2 Position control
g is gain parameter, d is actuator pressure feedback parameter
and b is valve velocity feedback parameter. The default values for
different actuator sizes are given in Table 1. Values are defined at a
moderate load in the actuator. However, because of the large range
in pressure drop and temperature at the different processes, variety
11
in supply air pressure and large variety of valve constructions,
actuator load may differ considerably from the default value. For
that reason g, d and b may have to be adjusted to meet
optimum control performance. Use the following guideline to adjust
g, d and b.
Set d and b values as specified in Table 1.
Set initial value for g as specified in Table 1.
If valve is unstable, lower g until valve is stable at the
constant input signal. If higher g is needed, increase
d to dampen unstability.
If valve is slow, increase g or if valve is overshooting,
decrease g. Adjust g for slightly overshooting
and then increase b to dampen it.
If deviation between input signal and actual valve position
is high, increase g to decrease deviation. However,
avoid unstable operation.
g setting:
Select g function from the keyboard acc. to Section 3.2.
Now the display should indicate the current parameter
value. If you want to change it, press the r key.
Increase the parameter value by pressing the + key or
decrease the value by pressing the - key.
Press the r key when a desired value is shown on the
display.
Press the + and - keys simultaneously to return into the
operation state.
d setting:
The d parameters can also be adjusted in the same manner,
see Fig. 11.
ND800 stays in the selected operation mode during the g
and d settings.
4.3 Control valve related settings
The basic factory settings of ND800 assumes raising signal to open
the valve and clockwise closing direction for the position sensor as
well as sets the signal cutoff safety margin to 2 ± 0.5 % to guarantee
full closing of the valve against mechanical travel stops.
Increasing input signal closes valve Increasing input signal opens valve
POSITION %
α0 α0
cut-off safety range 2 ± 0.5 % INPUT SIGNAL %
Basic setting α0-setting
Fig. 12. Principle of setting
To modify the settings proceed as follows:
Select c function from the keyboard according to
Section 3.2.
Select settings by pressing simultaneously the keys + and r.
You can return back to operation state by pressing + and
- keys simultaneously once, alternatively press + or -
repeatedly.
12

Now you can modify the four parameters as follows: Table 2. Dead angle as percentage
Direction of signal
When letters di r appear on the display you may read the Valve series
signal action direction by first pressing the key r and then Valve size MBV, D, T5, T25, R, QR
selecting between two values OPE or CLO by pressing + and QMBV, QT5,
- keys. The value OPE signifies raising signal 4-20 mA to open QD QT25
the valve and CLO means raising signal to close the valve. mm in Dead angle as %
To conclude press the key r when the desired value is 25 1 18 21 15
shown on the display. See default values from Fig. 8 and 40 1 1⁄2 18 21 12
functions from Fig. 11. 50 2 18 21 17
Valve action 65 2 1⁄2 16 - 13
80 3 14 15 9
The next application specific parameter rot defines relationship be- 100 4 14 15 8
tween the position sensor rotation and valve action.
125 5 14 15 8
After getting rot displayed press the key r and the current
150 6 12 14 8
parameter value is shown on the display. Now you may select
200 8 10 11 7
between two values by pressing the + or - keys. The value
250 10 9 11 7
cC means clockwise rotation for closing valve and ccC signifies 300 12 9 11 6
counterclockwise to close. 350 14 9 11 5
After the desired value is displayed press the key r to 400 16 9 11 5
conclude this operation. See default values and tubings 450 18 9 11 -
from Fig. 8 and functions from Fig. 11. 500-800 20-32 8 - -
α0 setting (dead angle) 900-1000 36-40 6 - -
α0 setting is made to segment and ball valves of Neles-Jamesbury.
This setting takes into account the "dead angle" α0 of the ball valves. 5 MAINTENANCE
The entire signal range is then used for effective valve opening 90° - α0,
see Figure 13 and Table 2. Use 0 % as the "dead angle for the valves The maintenance requirements of ND800 valve controller depends
not mentioned in the Table 2. on the service conditions like for instance the quality of instrument
air. In normal service conditions no regular maintenance is required.
The best reliability is achieved following these instructions.
In the following text the numbers inside parenthesis ( ) refer to the part
numbers of assembly drawing in Chapter 10, unless otherwise stated.
The ND800 valve controller includes the following interchangeable
modules: prestage (3), spool valve (4), circuit board (5), position
sensor (6), and differential pressure sensor (7).
The modules are located underneath protective cover (46) which
is attached with M3-screws (48, 4 pcs.). If a module fails it must be
changed. The module retrofit must be made in clean and dry
α0 = dead angle environment. After replacement apply locking glue (like for instance
Loctite 243) and tighten the screws firmly.
Fig. 13. Dead angle
5.1 Prestage
After selecting A0 on the display, press the key r and the NOTE:
currently selected parameter value in percent (%) appears The prestage must be handled very carefully. Especially the moving
on the display. parts on both ends of prestage should not be touched when the
Modify the parameter value by pressing sequentially + or prestage is functional and the protective cover is not in place.
- keys until the desired value appears on the display.
Press the r key to finalize the selection and return into
Disassembly
setting state. See Fig. 11 for functions.
Unplug the prestage (3) wire connectors from the circuit
Cut-off safety range board (5). Unscrew the M4 screws (92, 2 pcs.) and
When SAF appears on the display, press the key r and the remove the prestage module.
current default value in percentage (%) from input range
Reassembly
appears on the display. The standard default value of Place the O-rings (91) into the respective grooves and
Neles-Jamesbury is 2 % (2.0). Now modify this value to press the prestage into place. Make sure that the nozzles
the desired number and press the key r to return into are properly guided on top of the O-rings. The screws
setting state. See Fig. 11 for functions. guide the prestage body into the correct position.
After all the control valve related parameters are correctly Push the prestage 2-pole wire connectors into sockets on
set, return to operational state by pressing simultaneously circuit board. Make sure that the wires do not cross each
the + and - keys for a short time. other. The wire connectors can be fitted only in correct way.

Tighten the screws (92) evenly with a torque of approx.
0.8 Nm/0.6 ft.lb..
Mount the protective cover (46) carefully in place and
tighten the screws (48).
Prestage trimming
Changing of prestage module requires updating of prestage trim-
ming values by using HART communication. Automatic prestage
trimming requires connecting the supply pressure and plugging
pressure connections C1 and C2. Automatic trimming can be
activated via HART and it lasts approx. 5-10 minutes. See detailed 5.3
instructions from the user’s manual of ND800 HART master Disassembly
software, e.g. Valve Manager (v. 2.0 or later) or ND800 DD
(= Device Description) for HART handheld (rev. 4 or later).
NOTE:
If the supply pressure at the assembly location differs from
that of trimming location, the trimming should be adjusted
manually via HART in order to get optimal control perform-
ance. See detailed instructions from the user’s manual of
ND800 HART master software, e.g., Valve Manager (v. 2.0 or
later) or ND800 DD for HART handheld (rev. 4 or later).
5.2 Spool valve
Before removing the spool valve (4) the prestage (3) must be taken
off, see Section 5.1.
Reassembly
Disassembly
Unscrew the M4 screws (99, 4 pcs.) and remove the spool
valve assembly.
The spool valve cleaning can be done by following especially clean
and careful procedures. The seal (106), filter (105), restriction (104)
and spring (100) are located at the end pieces of the spool valve (102)
and (103). Also the spool (97) can be removed for cleaning.
NOTE:
Each spool valve body has an individual matching spool which
cannot be replaced with any other spool piece. Never ex-
change the location of the spool springs.
Reassembly
Place a new gasket (98) in location determined by the fitting
screw holes. Mount the spool valve on top of the seal in
corresponding position and tighten the M4 screws (99) evenly.
The O-rings must be mounted first to their grooves located
in the spool valve unit. While mounting the O-rings to their
grooves the O-rings must be compressed because the sealing
is done radially. Make sure that the O-rings are evenly
compressed and that they are fully inside the grooves. The
102 96 103
104
105
106 108 109 97 100 101 107
Fig. 14. Spool valve Fig. 15.
13
O-rings must be in perfect condition, no defects are
allowed. If a tool is used it must be blunt.
Mount the prestage unit directly on the spool valve unit.
The ends of the nozzles will guide the prestage unit on
right location. The prestage unit must fit by pushing gently
with no excessive force. Ensure that the spool valve unit
and the prestage unit have an even surface connection
before tightening the screws.
Circuit board
Loosen the M8 screw (66) and turn the position indicator (65)
out from the feedback shaft.
Unplug all wire connectors from the circuit board (5) and
the signal wires from the terminal block (35).
Remove the M3 screws (111, 5 pcs.).
NOTE:
Ground yourself on the device body before touching the
circuit board.
Take hold of the sides of circuit board and lift it directly
upwards and out. Handle the board carefully, touching
only on the sides.
Remount the circuit board carefully. Don’t let the feed-
back shaft touch the circuit board.
Locate the pins of the pressure sensor on the matching
connections located on the board.
Tighten the M3 screws (111) evenly.
Push the rubber grommet on the slot located on the
intermediate wall of the body and connect the wires on
the terminal block as shown in Fig. 15. Plug the prestage
wire connectors into the board making sure that the wires
don’t cross each other. Plug the position sensor (6) wire
connector into the board.
Mount the protective cover (46).
Mount the position indicator (65) to the shaft and tighten
M8 screw (66) temporary. The final locking of position
indicator is made during the installation for actuator.
NOTE:
Changing of new circuit board requires updating of module
parameters by using HART communication. See instructions
from the user’s manual of ND800 HART master software (e.g.
Valve Manager (v. 2.0 or later) or ND800 for HART handheld
(rev. 4 or later).
5 red circuit board
6 yellow
7 blue
8 black
8
1 2 3 4
5 6 7
grommet
Circuit board
14

5.4 Position sensor Reassembly

Before loosening the position sensor (6) you have to first loosen
the circuit board according to 5.3.
The assembly of position sensor (6) consists of the MR-sensor (114)
which is fixed to the housing and the spiral (117) which is fixed to
the main shaft.
Disassembly
Loosen M3 screws (116, 2 pcs.) and lift the sensor out
from the housing.
Loosen the lock ring (119) on the shaft and open the
hexagon socket screw (118, 2 pcs.). Mark the top of the spiral
before removing. Slide the spiral out from the shaft.
Reassembly
Mount the new sensor and spiral as a pair. Slide the spiral back
to the shaft and instal the lock ring back to the shaft. Turn the
spiral and the shaft to the position shown in the Fig. 16,
corresponding 45° opening of valve. Tighten the M3 screws.
Mount the O-rings (123, 2 pcs.) to their grooves located
in the housing. Push the pressure sensor back to its place
oriented by the O-rings. The final location is shown in the
Fig. 17. Tighten the M3 screws evenly.
Mount back the circuit board and the protective cover
according to 5.3.
NOTE:
Changing of new pressure sensor requires updating of calibration
values of sensor using HART communication. See instructions
from the user’s manual of ND800 HART master software (e.g.
Valve Manager, ND800 DD for HART handheld).

NOTE:
The position sensor and the spiral constitute a pair, and must
not be replaced separately.

Install 0,1 mm thick strip (delivered with the sensor)

between the sensor and the spiral. Press the sensor against
the spiral, not using unnecessary high force, and tighten
the screws (116) evenly. Remove the strip. Fig. 17. Pressure sensor
Mount the circuit board and the protective cover (46)
according to 5.3. 6 ERROR MESSAGES

When ND800 detects serious device failure (analogue inputs,

NOTE:
analogue outputs or electronics) it enters fail-safe mode which drives
Changing of new position sensor requires updating of calibration control valve into 4 mA position. Fail-safe mode is indicated by LCD
values of sensor using HART communication. See instructions as message Exx, where xx is a number between 1-99 or by HART
from the user’s manual of ND800 HART master software (e.g. master software (e.g. Valve Manager). Error message is displayed
Valve Manager (v. 2.0 or later) or ND800 DD (= Device until the cause of error is eliminated and the ND800 unit is
Description) for HART handheld (rev. 4 or later). cold-started, i.e. input signal disconnected momentarily.
When ND800 detects error during travel calibration, en error
Shaft alternatives message Err is displayed. It disappears when any key is pressed.
yellow
ND800 stores error messages to its non-volatile memory, which
45°
mark holds 20 latest error codes. The memory can be read out with
HART communication by using Valve Manager.
40 40
Table 3 gives the error messages shown on LCD display and their
explanations.
mark
7 TROUBLE SHOOTING
yellow 119
114
40
45° 118 116 117 Mechanical/electrical defects
mark to this 1. A change in the input signal does not affect the position of the
position actuator
mark = yellow dot supply pressure too low
mark spool valve sticks
Fig. 16. Position sensor tubes between controller and actuator are incorrect, see Fig. 8
actuator and/or valve jammed
5.5 Pressure sensor signal wires connected incorrectly, no value on display
Before loosening the pressure sensor (7) you have to loosen the circuit board is defective
circuit board according to 5.3. calibration is not carried out (a or M)
ND800 is either in M or o mode
Disassembly
Loosen M3 screws (126, 2 pcs.) and lift out the pressure incorrect load voltage, maximum is 12.8 VDC / 20 mA
sensor (7) holding from the both angle parts. prestage is defective
position sensor is defective
 15

Table 3. Error messages shown on LCD display

Error message Reason Action

Input signal measurement ADC low limit If error message occurs after cold-start within the input signal range of
E21 failure. 4-20 mA, change circuit board.
Input signal measurement ADC high limit If error message occurs after cold-start within the input signal range of
E22 failure. 4-20 mA, change circuit board.
Pneumatic prestage valve 1 (VA1) control Check wires and connectors or change circuit board.
E41 failure. Resistance of the coil is approx. 100 Ω, measured from the prestage connectors.
Pneumatic prestage valve 2 (VA2) control Check wires and connectors or change circuit board.
E44 failure. Resistance of the coil is approx. 100 Ω, measured from the prestage connectors.
Position feedback ADC low limit failure. Check wires, connector and position sensor rotation range or
E51 change circuit board.
Rotate the position feedback shaft counterclockwise and cold-start the device.
Position feedback ADC high limit failure. Check wires, connector and position sensor rotation range or
E52 change circuit board.
Rotate the position feedback shaft clockwise and cold-start the device.
E61 Memory (EEPROM) failure. Change circuit board.

E65 Memory (EEPROM) failure. Change circuit board.

E81 Memory (RAM) failure. Change circuit board.

E82 Memory (ROM) failure. Change circuit board.

E91 Processor failure. Change circuit board.

Zero and travel calibration fails. Check range of position sensor or mechanical limits of actuator.
Err Check wires and connectors.
ADC = analog/digital converter
2. The actuator goes to the final position with a small change of input signal is less than 4 mA
input signal ND800/actuator mounting is incorrect, see Figs. 4, 5, 16 and
tubes between controller and actuator are incorrect, see Fig. 8 Section 10.5
the parameter settings di r and rot are selected incor- HART trouble shooting is explained in the user’s guide of HART
rectly. See Figs. 8 and 11 master software (e.g. Valve Manager).
3. Inaccurate positioning
spool valve dirty 8 TOOLS
dirt in the permanent magnet air gap
actuator too small No special tools needed.
supply pressure too low
pressure sensor is defective 9 ORDERING SPARE PARTS
d and b parameters in the d mode are not acc. to
recommendations, shown in Table 1 When ordering spare parts, always include the following information:
g parameter is too small controller type designation (from the id plate) and serial
number
4. Overshooting or too slow positioning code of this manual, part number, name of the part and
g is too high or too low, see Table 1 quantity required
spool valve dirty serial number of the position sensor when ordering the
supply air tube too small or supply air filter dirty circuit board
valve sticks
5. Err is shown during calibration
position sensor is out of range, see Section 5.4
mechanical actuator travel exceeds position sensor linear
travel, i.e. 110°. If it fails in fully closed position, turn the
spiral (117) in 5° steps counterclockwise. If it fails in fully
open position, turn the spiral (117) in 5° steps to clock-
wise.
the parameter settings di r and rot are selected incor-
rectly, see Section 4.3 and Fig. 8
the actuator did not move or was stuck during calibration
16

10 DRAWINGS AND PARTS LISTS

10.1 Exploded view and parts list

64
66
65
92
3
46
7
99 48 126
107 106
91 116
5 6
97 111
4 109 118 123

103, 104, 105

101 100
96 119
108
98 102, 104, 105

1 35

32 31

44
40

54
52
51

Item Qty Description Recommended spare Item Qty Description Recommended spare
1 1 Housing 96 1 Spool valve body **
2 1 Cover 97 1 Spool **
3 1 Prestage unit * 98 1 Gasket x
4 1 Spool valve assembly * x 99 4 Screw
5 1 Circuit board 100 2 Spring **
6 1 Position sensor * 101 1 Back stop **
7 1 Differential pressure sensor * 102 1 End piece I **
31 1 Exhaus cover 103 1 End piece II **
32 2 Screw 104 2 Restriction **
35 4 Terminal block 105 2 Filter **
40 1 Shaft assembly 106 2 Gasket **
44 1 Washer 107 4 Screw **
46 1 Protective cover 108 1 Adjustable back stop **
48 4 Screw 109 1 O-ring **
51 1 Ear 111 5 Screw
52 1 Screw 116 2 Screw
54 1 Couplings jacket 118 2 Screw
64 4 Screw 119 1 Lock ring
65 1 Pointer 123 2 O-ring
66 1 Screw 126 2 Screw
91 2 O-ring x
92 2 Screw *) delivered as a module
**) part of the spool valve assembly
 17

10.2 Mounting parts for B1C/B1J 6-20

actuators

Item Qty Description

1 1 Mounting bracket
2 1 Draught piece
3 4 Washer
4 4 Screw
13 2 Stud (BC6)
14 2 Hexagon nut (BC)
28 4 Screw
29 1 Screw
36 1 Coupling jacket

10.3 Mounting parts for B1C/B1J 25-50,

B1C 502 and B1J322 actuators

Item Qty Description

1 1 Mounting bracket
2 1 Draught piece
3 4 Washer
4 4 Screw
27 4 Washer
28 4 Screw
18

10.4 Mounting parts for Quadra-Powr®, ST,

SP and Valv-Powr® actuators
Item Qty Description
1 1 Mounting bracket
2 1 Ear
4 4 Screw
28 4 Screw
29 1 Screw
30 4 Screw
35 1 Adapter plug
(QP II 1/S- 6/S only)
35 1 Adapter plate
(QP II 2B/K thr. 6_/K)
36 1 Coupling jacket

Item Qty Description

1 1 Mounting bracket
2 2 Coupling half
3 1 Adapter
4 4 Screw
5 4 Hex nut
6 1 Screw
7 4 Screw
8 4 Washer
9 4 Screw
10 4 Washer

10.5 Mounting parts for D/R linear actuators

STROKE
88.9 [3-1/2]

5 6 3 57.2 [2-1/4]
38.1 [1-1/2]
9 28.6 [1-1/8]
25.4 [1.0]
10 19.1 [0.75]
11 LEVERARM IN HORIZONTAL
12 POSITION (MID-STROKE).

60°
FOR 3/4" STROKE
MAKE SURE THIS MARK ON THE VALVES 70°
7 8 LEVER ARM IS IN THE SAME
QUADRANT AS THE MARK ON
THE FLAT OF THE SHAFT. ACTUATOR PIN

16.5[0.65]
18.1[0.71]
20.4[0.80]
27.2[1.07]
40.8[1.61]
63.5[2.50]
DISTANCE FROM FEEDBACK ARM CENTER
TO ACTUATOR PIN CENTER.
1
Item Qty Description
2 1 1 Mounting bracket
4 2 1 Feedback leverarm
3 1 Clamp
2-1/4
3-1/2

STROKE IN INCHES
4 1 Leverarm spring
STROKE IN INCHES
5 1 M5 hex screw
6 1 Lockwasher
MARK ON SHAFT SHOULD 7 4 M6 hex screw
STAY IN THIS QUADRANT
8 4 Flatwasher
9 2 5/16 hex screw
10 4 Flatwasher
11 2 Lockwasher
12 2 Hex nut
 19

11 DIMENSIONS

ND800/S1
21 1/4NPT
0.83

1.30 0.90
23

C2
PG13.5

33
4.60
117

S
1.30
33
0.93
23.5

C1
0.98
25
(0.12)
(3)
M6x12 4
0.16 F05-¯50(VDI/VDE3845)
23 (35.4)
0.90 (1.39)

(35.4)
(1.39)
M6/10

ND800/S2
25
47.5 0.98
1.87
39.5
1.55

1.10
28

C2
0.59
5.39
15

S
137

¯6
¯0.23
C1
1.02
(26)

26 30 5/16UNC/13
137 -/L=1/2NPT 1.02 1.18
5.39 -/I=M20x1.5
-/NJ=R1/2
1.22
31
20
12 TYPE CODING
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A MEMBER OF RAUMA CORPORATION