7 ND 70 enRev. 4

Issue 10/97

VALVE CONTROLLERSeries ND800

INSTALLATION, MAINTENANCEAND OPERATING INSTRUCTIONS

Table of Contents

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 31.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 Principle of operation . . . . . . . . . . . . . . . . . . . . 31.3 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4 Technical specifications . . . . . . . . . . . . . . . . . . . 31.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . 5

2 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . 52.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2 Mounting on Neles-Jamesbury actuators

with VDI/VDE mounting face (S1) . . . . . . . . . 52.3 Mounting on Neles-Jamesbury actuators

with old mounting face (S2) . . . . . . . . . . . . . . . 52.4 Mounting on Neles-Jamesbury

linear actuators. . . . . . . . . . . . . . . . . . . . . . . . . . 52.5 Piping of supply air. . . . . . . . . . . . . . . . . . . . . . . 72.6 Electrical connections . . . . . . . . . . . . . . . . . . . . 7

3 USER INTERFACE . . . . . . . . . . . . . . . . . . . . 93.1 Keyboard and display . . . . . . . . . . . . . . . . . . . . 93.2 Keyboard functions . . . . . . . . . . . . . . . . . . . . . . 93.3 HART communication . . . . . . . . . . . . . . . . . . . 9

4 CONFIGURATION. . . . . . . . . . . . . . . . . . . 114.1 Zero and range . . . . . . . . . . . . . . . . . . . . . . . . 114.2 Position control . . . . . . . . . . . . . . . . . . . . . . . . 114.3 Control valve related settings. . . . . . . . . . . . . 11

5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 125.1 Prestage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.2 Spool valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.3 Circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . 135.4 Position sensor . . . . . . . . . . . . . . . . . . . . . . . . . 145.5 Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . 14

6 ERROR MESSAGES. . . . . . . . . . . . . . . . . . . 147 TROUBLE SHOOTING . . . . . . . . . . . . . . . 148 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9 ORDERING SPARE PARTS. . . . . . . . . . . . 1510 DRAWINGS AND PARTS LISTS . . . . . . . 16

10.1 Exploded view and parts list . . . . . . . . . . . . . . 1610.2 Mounting parts for B1C/B1J 6-20

actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1710.3 Mounting parts for B1C/B1J 25-50,

B1C 502 and B1J322 actuators. . . . . . . . . . . . 1710.4 Mounting parts for Quadra-Powr®, ST,

SP and Valv-Powr® actuators . . . . . . . . . . . . . 1810.5 Mounting parts for D/R linear actuators . . . . 18

11 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . 1912 TYPE CODING. . . . . . . . . . . . . . . . . . . . . . 20

READ THESE INSTRUCTIONS FIRST!

These instructions provide information about safe handling and operation of the valve controllerIf 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.

2

1 INTRODUCTION

1.1 GeneralThese instructions describe the digital Neles-Jamesbury ND800valve position controller. The ND800 can be used with eithercylinder or diaphragm type pneumatic actuators for rotary or linearvalves.

1.2 Principle of operationThe ND800 is a 4-20 mA loop-powered microcontroller basedvalve controller. A 3.84 mA input signal will allow energy enough tostart communication via push buttons on the circuit board or HART.A 275 HART hand-held terminal or a PC with HART modem (ValveManager ) can be connected to the terminal strip located in theND800 itself or in the DCS. The maximum load voltage is 12.8 Vwith 20 mA.

Using push buttons or HART the configuration parameters can beset according to the actuator and valve in question. Then auto-cali-bration can be started via push buttons or HART. Display with threedigits 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 signalwill be detected by control algorithm inside the µC. The microcon-troller will change the pilot current to one of prestage (PR) coils.Prestage valve lowers the pilot pressure at the end of the spoolvalve (SV). The spool moves in direction of low pressure to openthe flow to the top of the actuator cylinder and to open the flowout from other side of the piston. Increasing pressure differenceover 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 anew 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.

1.3 MarkingsThe valve controller is provided with an identification plate sticker,see Fig. 2. Identification plate markings from top to bottom are:

Type designation of the valve controllerRevision numberEnclosure classInput signal (voltage range)Input resistanceMax supply voltageSupply pressure rangeOperational temperatureManufacturing series numberCE mark

Alternative markings on the optional plate, Fig. 3:Filter-regulator (-K)Operational temperature of regulatorConduit entries (-L, -I or -NJ)

1.4 Technical specificationsGeneral

ND800 valve controller is suitable for rotary and sliding stem valves.

Actuator connection In accordance with VDI/VDE 3845standard (S1) or optionally other NE-series compatibility (S2).To replace an existing NE/NP positioner,specify existing valve assembly

Action: Double or single actingTurning angle: 45°- 95°

Environmental influence

Operational temp.: -20 - +85 °C (-4 - +185 °F)option -40 - +85 °C (-40 - +185 °F)Influence of temperature on valve position

< 0.05%/°CInfluence of vibration on valve position

< 1% under 2g 5-150 Hz and1g 150-300 Hz0.5g 300-2000 Hz

C

SV

C2

C1

PR

4-20 m A

14

32

HART

+ HART

Pα

µ

S

Fig. 1. Schematic diagram

Fig. 2. Identification plate

Fig. 3. Optional plate

3

Enclosure

Material: Anodized aluminium alloyProtection class: IP65, NEMA 4XMechanical position indicator: on coverPneumatics ports: 1/4 NPTElectrical connection: Screw terminals internals for 2.5 mm2

and 1 PG 13.5 conduit entry (1/2 NPT, M20x1.5 and R 1/2 as option,see optional plate)

Weight: 2.1 kg (4.6 lbs)

Pneumatics

Supply pressure: 2.5-8 bar (36-115 psi)Effect of supplypressure: < 0.2 %/10 kPa (0.14%/psi)Air quality: As defined by ISA S7.3 standardCapacity: Max 30 Nm3/h (18 scfm)

at 4 bar (60 psi) supply

Consumption: 0.3 Nm3/h (0.18 scfm)at 4 bar (60 psi) supply

Electronics

Supply power: Taken from the 4-20 mA input signal.No external power needed

Minimum signal: 3.84 mALoad voltage: up to 12.8 VDC at 20 mA / 640 Ω

(max voltage drop)Supply voltage: max 30 VDCPolarity protection: -30 VDCOvercurrentprotection: active over 25 mA

Performance with moderate constant load actuators

Hysteresis + dead band: < 1 %Linearity error : < ±2%

Local keypad functions

Calibration: Automatic / ManualFeedback parameters: 0-100 (d and b)Gain configuration: 0-100 (gain)Mode Selection: Auto/Man/OffSignal, DIR: - direct (default)

- reverseRotation, ROT: - clockwise (default)

- counterclockwiseDead angle, A0: acc. to valve (0 % default)Cut-off-safety range, SAF:

2 % (default)

Electrical connections

Input signal: 4-20 mA, 2-wire.acc. to ANSI/ISA S50.1

Approvals: Intrinsically safeCenelec EEx ia IIC T5/T6,temp. ≤ +75 °C/+67 °F; T5 temp. ≤ +50 °C/+122 °F; T6CSA Class 1 Groups A, B, C and D (pending)

Sensors

Position sensor linear range: 110 °Actuator pressuresensor linear range: 7 bar (differential pressure)

Position transmitter

Output signal: 4-20 mA (galvanic isolation, 2500 VDC,passive device)

Supply voltage: 12-36 VDC, 2-wire12-24 VDC, EExi...Power from external supply

Load resistance: max 0-1200 Ωmax 0-600 Ω, EExi...

Approvals: Intrinsically safe as option

User interfaces

Local: 3 keys + LCD displayHART: Universal 275 HART hand-held terminal

or PC with a HART modem (RS 232 orPCMCIA interface) together with Valve Manager program.Connection points are on the screw terminal strip

Additional HART functionsFlow characterization: Linear, equal percentage, customSplit range: 4-12 mA, 12-20 mA, customIdent. information: HW/SW rev., serial numbers, actuator type etc.Monitoring: Input signal, valve travel setpoint, actual travel,

actuator pressure and temperatureDiagnostics: Travel deviation, travel duration, load factor,

operation time, valve/actuator travel counters,failure information

Testing: Step response, hysteresis loopModule calibration: Position sensor, pressure sensor, tempera-

ture measurement, input signal measurement, prestage trim

Electromagnetic protection

Protection standards: EN50081-1 and EN50082-2IEC 801-2 ESD, level 4,IEC 801-3 Electro Magnetic Field, level 3IEC 801-4 Fast Transients, level 4

CE marking

Electromagneticcompatibility: 89/336/EEC

4

1.5 Safety precautions

CAUTION:Do not exceed the permitted values!Exceeding the permitted values marked on the valve control-ler may cause damage to the controller and equipmentsattached to controller and lead to uncontrolled pressurerelease 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, spool valve orpressure sensor of ND800 leads to uncontrolled pressure release.Always shut off the supply air and release pressure from the pipelinesand equipment before removing or dismantling the controller.Otherwise personal injury and damage to equipment may result.

CAUTION:During the automatic or manual calibration the valveis operated to open and closed positions. Make surethat operation does not danger people or process!

NOTE:Avoid earthing a welding machine close to ND800.Damage to the equipment may result.

NOTE:The display may become unreadable in ambient temperaturesbelow -20 °C/-4 °F.Heating, for instance with thumb, may be necessary.

2 MOUNTING

2.1 GeneralWhen the ND800 is supplied together with the valve and actuator, thetubes are mounted and the ND800 adjusted in accordance with thecustomer’s specificatons. When the controller is ordered separately, themounting parts for the assembly must be ordered at the same time.

Example order: (B1C13)-Z-ND826/S1.

The controller has the new Neles-Jamesbury mounting facefor connection according to VDI/VDE 3845 (S1) and also theold 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 actuatorswith VDI/VDE mounting face (S1)

Run the actuator until the piston is in the top position (springreturn actuators in the position determined by the spring).Set the direction arrow in the direction of the valve closuremember and attach the draught piece (2) to the indicatorcover in the position shown in Fig. 4. Secure the screw ofthe draught piece e.g. with Loctite and tighten it sufficiently.Attach the bracket (1) to the ND800. Attach the bracket (1) to the actuator. The shaft (40) ofND800 must find it’s place to the draught piece (2) shownin Fig. 4. See also drawings in Sections 10.2, 10.3 and 10.4.

Note the differences in the installation between the BC, BJ actuatorand BJA actuators.

2.3 Mounting on Neles-Jamesbury actuatorswith old mounting face (S2)

Run the actuator until the piston is in the top position (springreturn actuators in the position determined by the spring).Set the direction arrow in the direction of the valve closuremember and attach the draught piece (2) to the indicatorcover in the position shown in Fig. 5. Secure the screw ofthe draught piece e.g. with Loctite and tighten it sufficiently.Attach the bracket (1) to the ND800. Attach the bracket (1) to the actuator. The shaft (40) ofND800 must find it’s place to the draught piece (2) shownin Fig. 5. See also drawings in Sections 10.2 and 10.3.

Note the differences in the installation between the BC, BJ actuatorand BJA actuators.

2.4 Mounting on Neles-Jamesbury linear actuators

See Section 10.5 Connect an airset directly to the actuator and position theactuator at its mid stroke position (see serial plate foractuator stroke lenght).Assemble the feedback arm to the controller input shaft.Make sure the lettering on the feed back arm faces uptowards the controller.

C2

S

C1 The mark on the shaftshould stay in this sector

Fig. 4. Mounting on Neles-Jamesbury actuator with VDI/VDE mounting face

draught piece (2)

coupling

coupling

bracket (1)

bracket (1)

BC, BJ

BJA

Fig. 5. Mounting on Neles-Jamesbury actuator

40 40

mark

Shaft alternatives

mark = yellow dot

S2S1

5

Assemble the controller mounting bracket loosely to theslotted leg of the actuator. Make sure mark on shaft andfeedback arm operate in the quadrant shown.Measure the distance from the center of the feedbacklever shaft to the slot on the feedback lever and mark thisdistance with a pencil or other marking instrument. Usedimensions given in Section 10.5.Mount the controller loosely onto the controller mountingbracket.Adjust the controller mounting bracket and the controller sothat the controller is 90° to the center line of the actuatorand so that the controller feedback lever is horizontal and90° to the counter line of the actuator.Tighten the controller mounting bracket screws.Adjust the controller on the controller mounting bracket so thatthe measured distance is maintained between the center of thefeedback lever shaft and the actuator pin (pre-measured mark

on the feedback lever). Note the controller must stillconform to the specifications in previous steps.Tighten all of the mounting bolts and then re-check that thecontroller complies with previous steps. Check that theactuator pin does not touch the controller case through outthe entire stroke of the actuator. If the actuator pin is toolong it may be trimmed to lenght. (1.125" or less strokeactuators 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 ofthe actuator pin and the feedback lever to reduce wear.Increase and/or decrease air pressure to the actuator to strokethe actuator full stroke and check that nothing binds and thatthe rotation of the feedback lever is 70° for 1"-3.5" stroke and60° for 3⁄4" stroke. See Section 10.5.

Actuator Piping ControllerPlastic/Cu/SS (") Plastic/Cu/SS (mm) Gain *)

4 bar /60 psi

Gain *)6 bar /90 psi

Gain *)8 bar /115 psi

BC Stroke vol.dm3/in3

NPT 1/4 3/8 1/2 6/4 10/8 12/10 Spoolvalve

d b

6 0.3/18 1/4 x x 2 9.5 7 4.5 3 29 0.6/37 1/4 x x 2 15 12.5 10 2 1.511 1.1/67 3/8 x x 6 10 8 6 2 113 2.3/140 3/8 x x 6 13 11 9 1.5 11720

4.3/2625.4/330

1/2 xx

xx

66

1617

1415

1213

11

0.50.5

2532

10.5/61021/1282

1/23/4

xx

(x)(x)

xx

(x)(x)

66

1920

1718

1516

0.50.2

00

4050

43/262484/5126

3/41

(x)(x)

xx

xx

66

2224

2022

1820

0.20.2

00

502 195/11900 1 x x 6 24 22 20 0.2 0BJ

BJAStroke vol.

dm3/in3NPT 1/4 3/8 1/2 6/4 10/8 12/10 Spool

valveGain**)

d b

810

0.9/551.8/110

3/8 xx

xx

2161

1212

33

11

1216

3.6/2206.7/409

1/2 xx

xx

6161

1418

32

0.50.5

2025

13/79327/1648

3/4 xx

(x)(x)

xx

(x)(x)

6161

2022

1.51

00

32322

53/3234106/6468

1 (x) xx

xx

6161

2525

11

00

QP Stroke vol.dm3/in3

NPT 1/4 3/8 1/2 6/4 10/8 12/10 Spoolvalve

Gain**)

d b

1 0.62/37 3/8 x x 21 9 3 1.52 1.08/66 3/8 x x 21 12 3 13 2.18/133 3/8 x x 61 10 3 14 4.34/265 3/8 x x 61 14 2 0.55 8.7/531 3/8 x x 61 18 2 06 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

Table 1. Piping and parameters

6

2.5 Piping of supply air

Do not exceed the permitted supply pressureof ND800!

Table 1 provides the recommended tube sizes in accordance withthe actuator sizes. Tube sizes are minimum values allowed. Forsupply air choose one size bigger tube. Operating times can betested 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 controllersmounted on the spring actuator. Place a plug in connectionC1. 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.

The supply air must be clean, dry and oil-free instrument air, e.g.according to standard ISA S7.3-81.

2.6 Electrical connectionsND800 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. Connectthe conductors to the terminal strip according to Fig. 6.

Check the wire polarity before connection. The controller has 30 Vpolarity 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 strongmagnetic field.

Connect the cables for the optional position transmitter acc. toFig. 6. The position transmitter needs an external power supply.ND800 and position transmitter circuits are galvanically isolated,isolation voltage is 2500 VDC.

87

65 1

23

4

Position signal 4...20 mA

Input signal 4...20 mA

HART-connection (ø2,3 mm)

Fig. 6. Terminals

HART

max. +12.8 V4...20 mA

+12...36 V (12...24 V)4...20 mA

EEPROM

LCD

CurrentMeasurement

Push-buttons

PositionTransmitter

Option

µController

ValveCoils

Pneumaticblock control

Pressuremeasurement

PositionMeasurement

DC power input

Fig. 7. Operation blocks

7

SINGLE-ACTING ACTUATOR (SPRING TO OPEN)

SINGLE-ACTING ACTUATOR (SPRING TO CLOSE)

DOUBLE-ACTING ACTUATOR

1. Increasing input signal to open valve.

Default setting:DIR = OPEROT = cC ( lose valve to lockwise)A0 = % (acc. to valve type)SAF = 2 %

c c

3. Increasing input signal to open valve.Spring to close valve.

Default setting:DIR = OPEROT = cC ( lose valve to lockwise)A0 = % (acc. to valve type)SAF = 2 %

c c

5. Increasing input signal to close valve.Spring to open valve.

Default setting:DIR = CLOROT = cC ( lose valve to lockwise)A0 = % (acc. to valve type)SAF = 2 %

c c

4. Increasing input signal to close valve.Spring to open valve.

Setting:DIR = CLOROT = ccC ( lose valve to ounter lockwise)A0 = % (acc. to valve type)SAF = 2 %

c c c

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

2. Increasing input signal to close valve.

Setting:DIR = CLOROT = cC ( lose valve to lockwise)A0 = % (acc. to valve type)SAF = 2 %

c c

C1

C2

S

C1

C2

S

C1

C2

S

C1

C2

S

C1

C2

S

Fig. 8. Operation directions and air connections

8

3 USER INTERFACE

3.1 Keyboard and displayThe keyboard and the display of ND800 are shown in Fig. 9. Onlythe 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 orc. Each of these names refer the function to be adjusted orchanged.

In a or M mode the display indicates 0-100 % as the valvetravel. In o mode the display shows two horizontal lines (--)instead of digits. By pressing r key the display shows input signal inmA within about 5 seconds. Under other situations the digit displayindicates the selected adjustable parameter value.

3.2 Keyboard functionsSee keyboard operations from Fig. 11.

The keyboard setting state is initiated by pressing + and - keys for5 seconds. The blinking text item m and one of the previouslyselected operation modes, a, M or o, will be shownon the display. If you want to change the operation mode, press rfirst. a, M or o will start to blink showing that thechanging of the mode is enabled. Choose with + or - key thedesired mode, a, M or o. After the mode has beenselected, press the r key.

The m function provides three alternative ND800 operationmodes as follows:

a:During a mode the ND800 controls the valve positionaccording to the incoming 4-20 mA signal. This mode is used duringnormal process control service. After signal failure the ND800follows input signal in a mode.

M:During this mode the valve position can be manually controlled fromthe keyboard + or - keys. The position of the valve driven manuallyis not saved into non-volatile memory of ND800, e.g. the positiondoes not recover after signal failure. However, the valve can bedriven back to it’s position after signal failure by + and - keys.

o:When o mode is activated the ND800 drives the valve to the4 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.

Move to the next setting by pressing + key. g starts to flash.The needed positioner gain for different size of actuators is set withthe g parameter. By pressing r key allows you to change again value shown in the display with + and - keys. Accept a changedvalue with r key, which returns you automatically back to the settingstate.

d includes positioner feedback parameters

d and

b. By pressingr key you can select one of the above mentioned parameters with+ and - keys. Accept your choice with r key and change valueswith + and - keys. Accept the value with r. Default values arementioned in Table 1.

The next setting to move on with + key is c. By pressing ther key you can start zero and travel range calibration. More detailedinformation 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 configurationparameters:

di r.

rot,

A0 and

SAF, which are explained in Section 4.3

You can return from any setting point back to the operation stateby pressing simultaneously + and - keys < 1 second, repeat pressingif needed.

3.3 HART communicationThe ND800 is delivered from factory with HART write protectionOFF as default. Reading and changing of parameters is thus allowed.The protection can be enabled with a switch (DIP1) located on thecircuit board, Fig. 10. The changes, which may influence the valveposition, cannot be made using Valve Manager program when theswitch no. 1 (on the left-hand side of the switch block) is ON. Fordetailed information see Valve Manager User’s Guide. HART con-nection at the ND800 terminal strip is shown in Fig.6.

MODE:GAINDBCALIB

AUTO MAN OFF

Fig. 9. LCD-display and keyboard

1

DIP1

DIP1OFF

1 1 2

ON

1 2

ON

DIP1ON

1 1 2

ON

Fig. 10. DIP switch

9

DB

&

%

> 5 s > 5 s FACTORY = 90°

&

&

DBDB

DB

&PREVIOUS SETTING

> 5 s

= input signal (mA)

KEY STROKES

= Escape < 1 s

Ope

rati

onst

ate

Sett

ing

stat

e

Fig. 11. Keyboard operations

10

4 CONFIGURATION

4.1 Zero and rangeThe ND800 position sensor operational range is factory adjustedto suit Neles-Jamesbury actuators. In case the ND800 shall be fittedinto other manufacturer’s actuator, there may be a need to readjustthe sensor as explained in Section 5.4.

Connect the air supply and input signal. Make sure that thevoltage 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 Mcalibration mode by pressing + or - keys.

CAUTION:The automatic calibration drives the valve againstmechanical open and closed travel limits of thevalve-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 pressedfor 5 seconds to activate a calibration function.During calibration the display shows

CAL text. After cali-bration the ND800 returns automatically to its settingfunction.At any instance you may interrupt the calibration se-quences by pressing simultaneously the + and - keys.After the a calibration sequence is concluded presssimultaneously the + and - keys to get back to operationstate. 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 % signalcutoff margins to secure full closing of the valve.

In case you can not drive the valve fully open position or if there isno mechanical limit stop available, act as follows:

M calibration function:After selecting from the display the M calibrationfunction press the r key to activate the procedure.Drive the valve manually from the + or - keys to theclosed (0 %) position and after this press the r key.In case you cannot drive the valve into open position, thenyou may skip this sequence now by pressing + and - keyssimultaneously. Now the ND800 assumes that the maxi-mum valve opening is the latest calibrated value, thefactory 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 operationstate.

Now the valve controller works with basic settings including2 ± 0.5 % signal cutoff margins.

4.2 Position controlg is gain parameter,

d is actuator pressure feedback parameterand

b is valve velocity feedback parameter. The default values fordifferent actuator sizes are given in Table 1. Values are defined at amoderate load in the actuator. However, because of the large rangein pressure drop and temperature at the different processes, variety

in supply air pressure and large variety of valve constructions,actuator load may differ considerably from the default value. Forthat reason g,

d and

b may have to be adjusted to meetoptimum control performance. Use the following guideline to adjustg,

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 theconstant 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 overshootingand then increase

b to dampen it.If deviation between input signal and actual valve positionis 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 parametervalue. If you want to change it, press the r key.Increase the parameter value by pressing the + key ordecrease the value by pressing the - key.Press the r key when a desired value is shown on thedisplay.Press the + and - keys simultaneously to return into theoperation 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 gand d settings.

4.3 Control valve related settingsThe basic factory settings of ND800 assumes raising signal to openthe valve and clockwise closing direction for the position sensor aswell as sets the signal cutoff safety margin to 2 ± 0.5 % to guaranteefull closing of the valve against mechanical travel stops.

To modify the settings proceed as follows:Select c function from the keyboard according toSection 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.

Increasing input signal opens valveIncreasing input signal closes valve

α0

cut-off safety range 2 ± 0.5 %

α0

α0-settingBasic setting

INPUT SIGNAL %

POSITION %

Fig. 12. Principle of setting

11

Now you can modify the four parameters as follows:

Direction of signalWhen letters

di r appear on the display you may read thesignal action direction by first pressing the key r and thenselecting between two values

OPE or

CLO by pressing + and- keys. The value

OPE signifies raising signal 4-20 mA to openthe valve and

CLO means raising signal to close the valve.To conclude press the key r when the desired value isshown on the display. See default values from Fig. 8 andfunctions from Fig. 11.

Valve action

The next application specific parameter

rot defines relationship be-tween the position sensor rotation and valve action.

After getting

rot displayed press the key r and the currentparameter value is shown on the display. Now you may selectbetween two values by pressing the + or - keys. The value

cC means clockwise rotation for closing valve and

ccC signifiescounterclockwise to close. After the desired value is displayed press the key r toconclude this operation. See default values and tubingsfrom Fig. 8 and functions from Fig. 11.

α0 setting (dead angle)

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.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 valvesnot mentioned in the Table 2.

After selecting

A0 on the display, press the key r and thecurrently selected parameter value in percent (%) appearson the display.Modify the parameter value by pressing sequentially + or- keys until the desired value appears on the display.Press the r key to finalize the selection and return intosetting state. See Fig. 11 for functions.

Cut-off safety rangeWhen

SAF appears on the display, press the key r and thecurrent default value in percentage (%) from input rangeappears on the display. The standard default value ofNeles-Jamesbury is 2 % (

2.0). Now modify this value tothe desired number and press the key r to return intosetting state. See Fig. 11 for functions.After all the control valve related parameters are correctlyset, return to operational state by pressing simultaneouslythe + and - keys for a short time.

5 MAINTENANCE

The maintenance requirements of ND800 valve controller dependson the service conditions like for instance the quality of instrumentair. 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 partnumbers of assembly drawing in Chapter 10, unless otherwise stated.

The ND800 valve controller includes the following interchangeablemodules: prestage (3), spool valve (4), circuit board (5), positionsensor (6), and differential pressure sensor (7).

The modules are located underneath protective cover (46) whichis attached with M3-screws (48, 4 pcs.). If a module fails it must bechanged. The module retrofit must be made in clean and dryenvironment. After replacement apply locking glue (like for instanceLoctite 243) and tighten the screws firmly.

5.1 Prestage

NOTE:The prestage must be handled very carefully. Especially the movingparts on both ends of prestage should not be touched when theprestage is functional and the protective cover is not in place.

DisassemblyUnplug the prestage (3) wire connectors from the circuitboard (5). Unscrew the M4 screws (92, 2 pcs.) andremove the prestage module.

ReassemblyPlace the O-rings (91) into the respective grooves andpress the prestage into place. Make sure that the nozzlesare properly guided on top of the O-rings. The screwsguide the prestage body into the correct position.Push the prestage 2-pole wire connectors into sockets oncircuit board. Make sure that the wires do not cross eachother. The wire connectors can be fitted only in correct way.

Valve sizeValve series

MBV, D,QMBV,

QD

T5, T25,QT5,QT25

R, QR

mm in Dead angle as %2540506580100125150200250300350400450

500-800 900-1000

11 1⁄2 2

2 1⁄2345681012141618

20-3236-40

1818181614141412109999986

212121-

15151514111111111111--

15121713988877655---

Table 2. Dead angle as percentage

α0 = dead angle

Fig. 13. Dead angle

12

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 andtighten the screws (48).

Prestage trimming

Changing of prestage module requires updating of prestage trim-ming values by using HART communication. Automatic prestagetrimming requires connecting the supply pressure and pluggingpressure connections C1 and C2. Automatic trimming can beactivated via HART and it lasts approx. 5-10 minutes. See detailedinstructions from the user’s manual of ND800 HART mastersoftware, 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 fromthat of trimming location, the trimming should be adjustedmanually via HART in order to get optimal control perform-ance. See detailed instructions from the user’s manual ofND800 HART master software, e.g., Valve Manager (v. 2.0 orlater) or ND800 DD for HART handheld (rev. 4 or later).

5.2 Spool valveBefore removing the spool valve (4) the prestage (3) must be takenoff, see Section 5.1.

DisassemblyUnscrew the M4 screws (99, 4 pcs.) and remove the spoolvalve assembly.

The spool valve cleaning can be done by following especially cleanand 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 whichcannot be replaced with any other spool piece. Never ex-change the location of the spool springs.

ReassemblyPlace a new gasket (98) in location determined by the fittingscrew holes. Mount the spool valve on top of the seal incorresponding position and tighten the M4 screws (99) evenly.The O-rings must be mounted first to their grooves locatedin the spool valve unit. While mounting the O-rings to theirgrooves the O-rings must be compressed because the sealingis done radially. Make sure that the O-rings are evenlycompressed and that they are fully inside the grooves. The

O-rings must be in perfect condition, no defects areallowed. 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 onright location. The prestage unit must fit by pushing gentlywith no excessive force. Ensure that the spool valve unitand the prestage unit have an even surface connectionbefore tightening the screws.

5.3 Circuit boardDisassembly

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) andthe signal wires from the terminal block (35).Remove the M3 screws (111, 5 pcs.).

NOTE:Ground yourself on the device body before touching thecircuit board.

Take hold of the sides of circuit board and lift it directlyupwards and out. Handle the board carefully, touchingonly on the sides.

ReassemblyRemount the circuit board carefully. Don’t let the feed-back shaft touch the circuit board.Locate the pins of the pressure sensor on the matchingconnections located on the board.Tighten the M3 screws (111) evenly.Push the rubber grommet on the slot located on theintermediate wall of the body and connect the wires onthe terminal block as shown in Fig. 15. Plug the prestagewire connectors into the board making sure that the wiresdon’t cross each other. Plug the position sensor (6) wireconnector into the board.Mount the protective cover (46).Mount the position indicator (65) to the shaft and tightenM8 screw (66) temporary. The final locking of positionindicator is made during the installation for actuator.

NOTE:Changing of new circuit board requires updating of moduleparameters by using HART communication. See instructionsfrom 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).

100

102 103

104

105

106 97

96

107101108 109

Fig. 14. Spool valve

87

65 1

23

4

5 red6 yellow7 blue8 black

circuit board

grommet

Fig. 15. Circuit board

13

5.4 Position sensorBefore loosening the position sensor (6) you have to first loosenthe 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 tothe main shaft.

DisassemblyLoosen M3 screws (116, 2 pcs.) and lift the sensor outfrom the housing.Loosen the lock ring (119) on the shaft and open the hexagon socket screw (118, 2 pcs.). Mark the top of the spiralbefore removing. Slide the spiral out from the shaft.

ReassemblyMount the new sensor and spiral as a pair. Slide the spiral backto the shaft and instal the lock ring back to the shaft. Turn thespiral and the shaft to the position shown in the Fig. 16,corresponding 45° opening of valve. Tighten the M3 screws.

NOTE:The position sensor and the spiral constitute a pair, and mustnot be replaced separately.

Install 0,1 mm thick strip (delivered with the sensor)between the sensor and the spiral. Press the sensor againstthe spiral, not using unnecessary high force, and tightenthe screws (116) evenly. Remove the strip.Mount the circuit board and the protective cover (46)according to 5.3.

NOTE:Changing of new position sensor requires updating of calibrationvalues of sensor using HART communication. See instructionsfrom the user’s manual of ND800 HART master software (e.g.Valve Manager (v. 2.0 or later) or ND800 DD (= DeviceDescription) for HART handheld (rev. 4 or later).

5.5 Pressure sensorBefore loosening the pressure sensor (7) you have to loosen thecircuit board according to 5.3.

DisassemblyLoosen M3 screws (126, 2 pcs.) and lift out the pressuresensor (7) holding from the both angle parts.

ReassemblyMount the O-rings (123, 2 pcs.) to their grooves locatedin the housing. Push the pressure sensor back to its placeoriented by the O-rings. The final location is shown in theFig. 17. Tighten the M3 screws evenly.Mount back the circuit board and the protective coveraccording to 5.3.

NOTE:Changing of new pressure sensor requires updating of calibrationvalues of sensor using HART communication. See instructionsfrom the user’s manual of ND800 HART master software (e.g.Valve Manager, ND800 DD for HART handheld).

6 ERROR MESSAGES

When ND800 detects serious device failure (analogue inputs,analogue outputs or electronics) it enters fail-safe mode which drivescontrol valve into 4 mA position. Fail-safe mode is indicated by LCDas message

Exx, where xx is a number between 1-99 or by HARTmaster software (e.g. Valve Manager). Error message is displayeduntil the cause of error is eliminated and the ND800 unit iscold-started, i.e. input signal disconnected momentarily.

When ND800 detects error during travel calibration, en errormessage

Err is displayed. It disappears when any key is pressed.

ND800 stores error messages to its non-volatile memory, whichholds 20 latest error codes. The memory can be read out withHART communication by using Valve Manager.

Table 3 gives the error messages shown on LCD display and theirexplanations.

7 TROUBLE SHOOTING

Mechanical/electrical defects

1. A change in the input signal does not affect the position of theactuator

supply pressure too lowspool valve stickstubes between controller and actuator are incorrect, see Fig. 8actuator and/or valve jammedsignal wires connected incorrectly, no value on displaycircuit board is defectivecalibration is not carried out (a or M)ND800 is either in M or o modeincorrect load voltage, maximum is 12.8 VDC / 20 mAprestage is defectiveposition sensor is defective

119

118 117116114

40

40 40

45°

45°

mark to thisposition

mark

mark

mark

Shaft alternatives

mark = yellow dot

yellow

yellow

Fig. 16. Position sensor

Fig. 17. Pressure sensor

14

2. The actuator goes to the final position with a small change ofinput signal

tubes between controller and actuator are incorrect, see Fig. 8the parameter settings

di r and

rot are selected incor-rectly. See Figs. 8 and 11

3. Inaccurate positioningspool valve dirtydirt in the permanent magnet air gapactuator too smallsupply pressure too lowpressure sensor is defective

d and

b parameters in the d mode are not acc. torecommendations, shown in Table 1g parameter is too small

4. Overshooting or too slow positioningg is too high or too low, see Table 1spool valve dirtysupply air tube too small or supply air filter dirtyvalve sticks

5.

Err is shown during calibrationposition sensor is out of range, see Section 5.4mechanical actuator travel exceeds position sensor lineartravel, i.e. 110°. If it fails in fully closed position, turn thespiral (117) in 5° steps counterclockwise. If it fails in fullyopen 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. 8the actuator did not move or was stuck during calibration

input signal is less than 4 mAND800/actuator mounting is incorrect, see Figs. 4, 5, 16 andSection 10.5

HART trouble shooting is explained in the user’s guide of HARTmaster software (e.g. Valve Manager).

8 TOOLS

No special tools needed.

9 ORDERING SPARE PARTS

When ordering spare parts, always include the following information:controller type designation (from the id plate) and serialnumbercode of this manual, part number, name of the part andquantity requiredserial number of the position sensor when ordering thecircuit board

Error message Reason Action

E21Input signal measurement ADC low limitfailure.

If error message occurs after cold-start within the input signal range of4-20 mA, change circuit board.

E22Input signal measurement ADC high limitfailure.

If error message occurs after cold-start within the input signal range of4-20 mA, change circuit board.

E41Pneumatic prestage valve 1 (VA1) controlfailure.

Check wires and connectors or change circuit board.Resistance of the coil is approx. 100 Ω, measured from the prestage connectors.

E44Pneumatic prestage valve 2 (VA2) controlfailure.

Check wires and connectors or change circuit board.Resistance of the coil is approx. 100 Ω, measured from the prestage connectors.

E51

Position feedback ADC low limit failure. Check wires, connector and position sensor rotation range or change circuit board.Rotate the position feedback shaft counterclockwise and cold-start the device.

E52

Position feedback ADC high limit failure. Check wires, connector and position sensor rotation range or 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.

E81Memory (RAM) failure. Change circuit board.

E82Memory (ROM) failure. Change circuit board.

E91 Processor failure. Change circuit board.

ErrZero and travel calibration fails. Check range of position sensor or mechanical limits of actuator.

Check wires and connectors.

ADC = analog/digital converter

Table 3. Error messages shown on LCD display

15

10 DRAWINGS AND PARTS LISTS

10.1 Exploded view and parts list

66

48

111

65

46

5

119

116

118

6

126

7

123

107

103, 104, 105

100

98 102, 104, 105

106

109

91

99

392

3132

44

40

54

5251

2

351

96

64

974

101

108

Item Qty Description Recommended spare

1 1 Housing2 1 Cover3 1 Prestage unit *4 1 Spool valve assembly * x5 1 Circuit board6 1 Position sensor *7 1 Differential pressure sensor *31 1 Exhaus cover32 2 Screw35 4 Terminal block40 1 Shaft assembly44 1 Washer46 1 Protective cover48 4 Screw51 1 Ear52 1 Screw54 1 Couplings jacket64 4 Screw65 1 Pointer66 1 Screw91 2 O-ring x92 2 Screw

Item Qty Description Recommended spare

96 1 Spool valve body **97 1 Spool **98 1 Gasket x99 4 Screw100 2 Spring **101 1 Back stop **102 1 End piece I **103 1 End piece II **104 2 Restriction **105 2 Filter **106 2 Gasket **107 4 Screw **108 1 Adjustable back stop **109 1 O-ring **111 5 Screw116 2 Screw118 2 Screw119 1 Lock ring123 2 O-ring126 2 Screw

*) delivered as a module**) part of the spool valve assembly

16

10.2 Mounting parts for B1C/B1J 6-20actuators

10.3 Mounting parts for B1C/B1J 25-50,B1C 502 and B1J322 actuators

Item Qty Description

1 1 Mounting bracket2 1 Draught piece3 4 Washer4 4 Screw27 4 Washer28 4 Screw

Item Qty Description

1 1 Mounting bracket2 1 Draught piece3 4 Washer4 4 Screw13 2 Stud (BC6)14 2 Hexagon nut (BC)28 4 Screw29 1 Screw36 1 Coupling jacket

17

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

10.5 Mounting parts for D/R linear actuators

STROKE IN INCHES

70°

60°

2-1/4

3-1/2

STROKE IN INCHES

28.6 [1-1/8]

57.2 [2-1/4]

38.1 [1-1/2]

25.4 [1.0]

88.9 [3-1/2]

19.1 [0.75]

18.1[0.71]

20.4[0.80]

27.2[1.07]

40.8[1.61]

63.5[2.50]

2

1

7 8

5 6 3

4

16.5[0.65]

9

10

11

12

ACTUATOR PIN

LEVERARM IN HORIZONTALPOSITION (MID-STROKE).

MAKE SURE THIS MARK ON THELEVER ARM IS IN THE SAMEQUADRANT AS THE MARK ONTHE FLAT OF THE SHAFT.

MARK ON SHAFT SHOULDSTAY IN THIS QUADRANT

FOR 3/4" STROKEVALVES

DISTANCE FROM FEEDBACK ARM CENTERTO ACTUATOR PIN CENTER.

STROKE

Item Qty Description

1 1 Mounting bracket2 1 Feedback leverarm3 1 Clamp4 1 Leverarm spring5 1 M5 hex screw6 1 Lockwasher7 4 M6 hex screw8 4 Flatwasher9 2 5/16 hex screw10 4 Flatwasher11 2 Lockwasher12 2 Hex nut

Item Qty Description

1 1 Mounting bracket2 1 Ear4 4 Screw28 4 Screw29 1 Screw30 4 Screw35 1 Adapter plug

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

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

Item Qty Description

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

18

11 DIMENSIONS

C1

SC

2

ND800/S2

5/16UNC/13

15

¯6

28

25

26

31

30

-/NJ=R1/2-/I=M20x1.5-/L=1/2NPT

137

137

39.5

(26)

47.5

5.39

1.02

1.870.98

¯0.23

1.02 1.18

5.39

1.55

1.22

1.10

0.59

C1

SC

2

PG13

.5

M6/

10

1/4NPT

ND800/S1

M6x12

3333

23

23

4 (3)

23.5

21

2511

7

(35.

4)

(35.4)

F05-¯50(VDI/VDE3845)

(1.3

9)

0.98

4.60

1.30

1.30

0.90

(0.1

2)

0.90

0.93

(1.39)

0.16

0.83

19

12 TYPE CODING

Unit 7, 2-6 Apollo Court, Blackburn, Victoria 3130AUSTRALIATel. int. +61-53-9894 7922, Fax +61-53-9894 7933

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NELES-JAMESBURY GROUPA MEMBER OF RAUMA CORPORATION

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20