7 ND 70 en

Software Revision 3
Issue 2/97

VALVE CONTROLLER
Series ND800

INSTALLATION, MAINTENANCE
AND OPERATING INSTRUCTIONS
2

Table of Contents
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 3 10 DRAWINGS AND PARTS LISTS . . . . . . . 16
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 10.1 Exploded view and parts list . . . . . . . . . . . . . . 16
1.2 Principle of operation . . . . . . . . . . . . . . . . . . . . 3 10.2 Mounting parts for BC/BJ 6-20
1.3 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Technical specifications . . . . . . . . . . . . . . . . . . . 3 10.3 Mounting parts for BC/BJ 25-50,
1.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . 4 BC 502 and BJ322 actuators. . . . . . . . . . . . . . 17
2 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . 5 10.4 Mounting parts for Quadra-Powr
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Mounting on Neles-Jamesbury actuators . . . . 5 11 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Mounting on actuators with 12 TYPE CODING . . . . . . . . . . . . . . . . . . . . . . 19
the new VDI/VDE mounting face . . . . . . . . . . 5
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 travel 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 . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.5 Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . 14
6 ERROR MESSAGES. . . . . . . . . . . . . . . . . . . 14
7 TROUBLE SHOOTING . . . . . . . . . . . . . . . 14
8 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9 ORDERING SPARE PARTS . . . . . . . . . . . . 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 of manufacturer’s representative.
Addresses and phone numbers are printed on the back cover.
SAVE THESE INSTRUCTIONS!

Quadra-Powr is a registered trademark 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 Input signal (voltage range)
cylinder or diaphragm type pneumatic actuators for rotary or linear Input resistance
valves. Enclosure class
Supply pressure range
1.2 Principle of operation Operational temperature
Manufacturing series number
The ND800 is a 4-20 mA loop-powered microcontroller based
CE mark
valve controller. A 3.84 mA input signal will allow energy enough to
start communication via push buttons on the circuit board or HART.
A 275 HART hand-held terminal or a PC with HART modem (Valve
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.
Fig. 2. Identification plate
In control service the microcontroller (µC) reads input signal (mA),
position sensor (α) and pressure sensor (p). A change in input signal Alternative markings on the optional plate, Fig. 3:
will be detected by control algorithm inside the µC. The microcon- Single action ( S)
troller will change the pilot current to one of prestage (PR) coils. Filter-regulator (-K)
Prestage valve lowers the pilot pressure at the end of the spool Operational temperature
valve (SV). The spool moves in direction of low pressure to open Conduit entries (-L, -I or -NJ)
the flow to the top of the actuator cylinder and to open the flow
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

General
SV PR ND800 valve controller is suitable for rotary and sliding stem valves.
Actuator connection In accordance with new VDI/VDE 3845
µC standard or optionally other NE-series
α
C2
P compatibility.
C1 To replace an existing NE/NP positioner,
S
specify existing valve assembly
Action: Double or single acting
HART
Turning angle: 45°- 95°
1 2 3 4

Characteristic: Linear, equal percentage or user

defined with 11 reference points exactly
to application requirements through
4-20 m A + HART
Valve Manager program

Fig. 1. Schematic diagram

4

Environmental influence Electrical connections

Operational temp.: -40 - +85 °C (-40 - +185 °F) Input signal: 4-20 mA, 2-wire.
Influence of temperature on valve position acc. to ANSI/ISA S50.1
< 0.05%/°C
Approvals: Intrinsically safe
Influence of vibration on valve position
Cenelec EEx ia IIC T5/T6,
< 1% under 2g 5-150 Hz and
1g 150-300 Hz Temp. ≤ 75 °C; T5 temp. ≤ 50 °C; T6
0.5g 300-2000 Hz CSA Class 1 Groups A, B, C and D (pending)
Enclosure Position transmitter:
Material: Anodized aluminium alloy Output signal: 4-20 mA (galvanic isolation, 2500 VDC,
Protection class: IP65 passive device)
Mechanical position Supply voltage: 12-36 VDC, 2-wire
indicator: on cover 12-24 VDC, EExi...
Pneumatics ports: 1/4 NPT Power from external supply
Electrical connection: Screw terminals internals for 2.5 mm2 Load resistance: max 0-1200 Ω
and 1 PG 13.5 conduit entry max 0-600 Ω, EExi...
(1/2 NPT, M20x1.5 and R 1/2 as option, Approvals: Intrinsically safe as option
see optional plate)
Weight: 2.1 kg (4.6 lbs) User interfaces

Pneumatics Local: 3 keys + LCD display

HART: Universal 275 HART hand-held terminal
Supply pressure: 2.5-8 bar (36-115 psi) or PC with a HART modem (RS 232 or
Effect of supply PCMCIA interface) together with
pressure: < 0.2 %/10 kPa (0.14%/psi) Valve Manager program.
Air quality: As defined by ISA S7.3 standard Connection points are on the screw
Capacity: Max 30 Nm3/h (18 scfm) terminal strip
at 4 bar (60 psi) supply
Electromagnetic protection
Consumption: 0.3 Nm3/h (0.18 scfm)
at 4 bar (60 psi) supply Protection standards: EN50081-1 and EN50082-2
IEC 801-2 ESD, level 4,
Electronics IEC 801-3 Electro Magnetic Field, level 3
Supply power: Taken from the 4-20 mA input signal. IEC 801-4 Fast Transients, level 4
No external power needed CE marking
Minimum signal: 3.84 mA
Load voltage: max 12.8 VDC / 20 mA Electromagnetic
(corresponding 640 Ω) compatibility: 89/336/EEC
Supply voltage: max 30 VDC
Polarity protection: -30 VDC 1.5 Safety precautions
Overcurrent
protection: active over 25 mA CAUTION:
Performance with moderate constant load actuators Do not exceed the permitted values!
Exceeding the permitted values marked on the valve control-
See 3.2 ler may cause damage to the controller and equipments
Hysteresis + dead band: < 1 % attached to controller and lead to uncontrolled pressure
Linearity error : < ±2% release in the worst case.
Damage to the equipment and personal injury may result.
Local keypad functions
Calibration: Automatic / Manual CAUTION:
Feedback parameters: 0-100 (d and b) Do not remove or dismantle a pressurized controller!
Gain configuration: 0-100 (gain) Removing or dismantling a pressurized prestage, spool valve or
Mode Selection: Auto/Man/Off pressure sensor of ND800 leads to uncontrolled pressure release.
Signal, DIR: - direct (default) Always shut off the supply air and release pressure from the pipelines
- reverse and equipment before removing or dismantling the controller.
Rotation, ROT: - clockwise (default) Otherwise personal injury and damage to equipment may result.
- counterclockwise
Dead angle, A0: acc. to valve (0 % default)
CAUTION:
Cut-off-safety range, SAF:
During the automatic or manual calibration the valve
2 % (default)
is operated to open and closed positions. Make sure
that operation does not danger people or process!
 5

2 MOUNTING

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
mounting pars for the assembly must be ordered at the same time. C2
Example order: (B1C13)-Z-ND826.
S
The controller has the new Neles-Jamesbury mounting face
for connection according to VDI/VDE 3845 and also the old C1
Neles-Jamesbury mounting face (NE).
The mark on the shaft
For mounting parts for Neles-Jamesbury actuators, see Sections should stay in this sector
10.2-10.4.

2.2 Mounting on Neles-Jamesbury actuators Fig. 5. Mounting on Neles-Jamesbury actuator with

Run the actuator until the piston is in the top position (spring the new VDI/VDE mounting face
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 Check that you have all of the parts.
the draught piece e.g. with Loctite and tighten it sufficiently. Insert the stud (3) through the center hole of the actua-
Attach the bracket (1) to the ND800. Note the washers. tor/valve coupling, attach lockwasher (7) and nut (6) to
Attach the bracket (1) to the actuator. The shaft (40) of both sides of the coupling. Before tightening assure that
ND800 must find it’s place to the draught piece (2) shown the stud is perpendicular to the yoke. Thread one of the
in Fig. 4. See also drawings in Sections 10.2 and 10.3. jam nuts (4) down the stud until it is just above the nut
Note the differences in the installation between the BC, BJ actuator (6) slide one of the flat washers (5) down to the nut.
and BJA actuators. Move the stem/driver to midposition.
Attach the accessory mounting bracket (17) to the actua-
tor yoke using the mounting bolts (16), nuts (10), and
washers (9). Snug the fasteners only, bracket may have to
bracket (1) BC, BJ
be adjusted for proper alignment of the ND800.
Loosely attach the ND800 mounting bracket (1) to the
accessory mounting bracket (17) by first sliding the rack
subassembly (2) on to the stud (3) then attaching the
coupling mounting bolts (8), nuts (10), and washers (9).
draught piece (2) Slide the mounting bracket (1) back until the rack subas-
sembly (2) is parallel to the ND800 bracket. Adjust the jam
coupling
nut (4) and flat washer (5) up the stud (3) until it supports
bracket (1)
BJA the rack subassembly in its parallel position. Move the
accessory mounting bracket (17) up or down until the rack

17
6 7
9 10 16

8 9 10

Fig. 4. Mounting on Neles-Jamesbury actuator

3
1
4 5

2.3 Mounting on actuators with the new

VDI/VDE mounting face 11 12

13 14 15
Run the actuator until the piston is in the top position (spring 2

return actuators in the position determined by the spring).

Attach the bracket (1) to the ND800. Note the washers. C2
"OPEN"

Turn the shaft of the ND800 to a position where the mark S "CLOSE"
on the shaft is located acc. to Fig. 5. C1
Guide the shaft to the slot and fasten the bracket to the actuator.
Make sure that the slot in the cover of the actuator is
parallel to the cylinder for spring-to-close actuators (BJ, The mark on the ND800 shaft
QP) and at right angle to the cylinder for spring-to-open to stay within this quadrant.

actuators (BJA, QP). See also Fig. 5.

Fig. 6. Mounting on Neles-Jamesbury linear actuator

6

protrudes equal amounts from top and bottom of the Spring to Close Actuators (Reverse Acting)
ND800 bracket (1). Attach the other flat washer (5) and With the valve plug on the plug seat, adjust the ND800
jam nut (4) from the top of the stud to lock the rack shaft clockwise until the tongue is vertical and the ground
subassembly in its parallel position. Before going to next indicating flat is facing down.
step make sure, using a level or square, that the rack Slide the ND800 towards the valve/actuator stem until
and guide tubes are parallel with the valve stem and the gear (13) engages the rack.
actuator driver. Failure to align the rack and guide may Carefully slide the ND800 in further to load the rack until
result in damage to the linkage. it is slightly bowed.
Tighten mounting bolts (8) and (16). Carefully stroke the unit, Fix the ND800 in place by tightening all of the bolts and screws.
if there is not enough travel on the rack to either fully close Slowly cycle the unit while watching to insure that the
or open the valve immediately stop the valve and return to gear (13) and rack do not bind and are always in contact
the mid-stroke position. Adjust the accessory mounting through out the entire stroke kenght of the valve.
bracket in the appropriate direction. Slowly cycle the unit Connect the ND800 to tubing.
several times. Calibrate the ND800 as required.
Attach the gear (13) to the ND800 using the hex
screw (14) and the flat washer (15).
Loosely attach the ND800 to the mounting bracket (1)
using the four hex cap screws (11) and lockwashers (12).
Table 1. Piping and parameters

Actuator Piping Controller

Plastic/Cu/SS (") Plastic/Cu/SS (mm)
BC Cyl. vol. NPT 1/4 3/8 1/2 6 10 12 Spool Gain Gain d b
dm3 valve <6.0 bar >6.0 bar
6 0.3 1/4 x x 2 4.5 3.0 3 3.5
9 0.6 1/4 x x 2 7 3.6 2 3
11 1.1 3/8 x x 6 4.5 2.3 1 1
13 2.3 3/8 x x 6 7 3.5 0.5 1
17 4.3 1/2 x x 6 9 4.5 0.2 0.5
20 5.4 x x 6 10 6 0.2 0.5
25 10.5 1/2 x (x) x (x) 6 12 7 0.2 0
32 21 3/4 x (x) x (x) 6 15 10 0.2 0
40 43 3/4 (x) x x 6 17 12 0.2 0
50 84 1 (x) x x 6 20 15 0.2 0
502 195 1 x x 6 20 15 0.2 0
BJ Cyl. vol. NPT 1/4 3/8 1/2 6 10 12 Spool Gain d b
BJA dm3 valve spring range+1 bar*
8 0.9 3/8 x x 2 7 0.6 1
10 1.8 x x 6 7 0.6 1
12 3.6 1/2 x x 6 10 0.6 0.5
16 6.7 x x 6 13 0.4 0.5
20 13 3/4 x (x) x (x) 6 15 0.2 0
25 27 x (x) x (x) 6 17 0.2 0
32 53 1 (x) x x 6 20 0.2 0
322 106 x x 6 20 0.2 0
QP Cyl. vol. NPT 1/4 3/8 1/2 6 10 12 Spool Gain d b
dm3 valve spring range+1 bar*
1 0.62 3/8 x x 2 5 0.2 1.5
2 1.08 3/8 x x 2 7 0.2 1
3 2.18 3/8 x x 6 7 0.2 1
4 4.34 3/8 x x 6 10 0.2 0.5
5 8.7 3/8 x x 6 14 0.2 0
6 17.5 3/4 x x 6 16 0.2 0
7 35 3/4 x x 6 20 0.2 0
*) In order to achieve symmetrical operation. Use always filter regulator if above values are exceeded.
Spring ranges: BJ = 4 bar; BJK = 3 bar; BJV = 5 bar.
 7

Spring to Open Actuators (Direct Acting) 2.6 Electrical connections

With the valve plug fully open, adjust the ND 800 shaft
until the tongue is horizontal and the ground indicating flat ND800 is powered by a standard 4 - 20 mA current loop.
HART is carried over the current loop too.
is facing toward the rack.
Slide the ND800 towards the valve/actuator stem until The input signal cable is lead through a PG13,5 cable gland. Connect
the gear (13) engages the rack. the conductors to the terminal strip according to Fig. 7.
Carefully slide the ND800 in further to load the rack until Check the wire polarity before connection. The controller has 30 V
it is slightly bowed. polarity protection. EMC requirements require earthing.
Fix the ND800 in place by tightening all of the bolts and
screws. NOTE:
Slowly cycle the unit while watching to insure that the gear ND800 equals a load of 640 Ω in the current loop.
(13) and rack do not bind and are always in contact
through out the entire stroke lenght of the valve. NOTE:
Connect the ND800 to tubing. Without earthing the valve position may vary in a strong
Calibrate the ND800 as required. magnetic field.

2.5 Piping of supply air Connect the cables for the optional position transmitter acc. to
Fig. 7. The position transmitter needs an external power supply.
Do not exceed the permitted supply pressure ND800 and position transmitter circuits are galvanically isolated,
of ND800! isolation voltage is 2500 VDC.

Table 1 provides the recommended tube sizes in accordance with

the actuator sizes. Tube sizes are minimum values allowed. For

1 2 3 4
supply air choose one size bigger tube. Operating times can be Position signal 4...20 mA

5 6 7
calculated for given load by Valve Manager and Nelprof programs.
Connect air supply to S (1/4 NPT).
Input signal 4...20 mA
Connect C1 and C2 (1/4 NPT) to the actuator.
For pipe threads are liquid sealants, e.g. Loctite, recommended.
HART-connection (ø2,3 mm)
NOTE:
A single action connection alone is permitted for controllers
mounted on the spring actuator. Place a plug in connection
C1. See Fig. 9. Fig. 7. Terminals

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.

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. 8. 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. 9. Operation directions and air connections

 9

3 USER INTERFACE 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
3.1 Keyboard and display gain value shown in the display with + and - keys. Accept a changed
The keyboard and the display of ND800 are shown in Fig. 10. Only value with r key, which returns you automatically back to the setting
the applicable information is shown on the display in each mode. state.
The operations and display are controlled by +, - and r keys. d includes positioner feedback parameters d and b. By pressing
Four setting functions are available: m, g, d or r key you can select one of the above mentioned parameters with
c. Each of these names refer the function to be adjusted or + and - keys. Accept your choice with r key and change values
changed. with + and - keys. Accept the value with r. Default values are
In a or M mode the display indicates 0-100 % as the valve mentioned in Table 1.
travel. In o mode the display shows two horizontal lines (--) The next setting to move on with + key is c. By pressing the
instead of digits. By pressing r key the display shows input signal in r key you can start zero and travel range calibration. More detailed
mA within about 5 seconds. Under other situations the digit display information about c is given in Section 4.1.
indicates the selected adjustable parameter value. You can move within different options with + key forwards and -
key backwards.
In addition, there are four control valve related configuration
MODE: AUTO MAN OFF parameters: di r. rot, A0 and SAF, which are explained in Section 4.3
GAIN You can return from any setting point back to the operation state
DB by pressing simultaneously + and - keys < 1 second, repeat pressing
CALIB 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. 11. 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-
Fig. 10. LCD-display and keyboard nection at the ND800 terminal strip is shown in Fig.7.

3.2 Keyboard functions

See keyboard operations from Fig. 12.
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 DIP1 DIP1
first. a, M or o will start to blink showing that the OFF
ON
ON
ON

changing of the mode is enabled. Choose with + or - key the

desired mode, a, M or o. After the mode has been
1 2 1 2
1 1

selected, press the r key. 1

DIP1

ON

1 2

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 Fig. 11. DIP switch
is not read to the 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.
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. 12. Keyboard operations

 11

4 CONFIGURATION Select g function from the keyboard acc. to Section 3.1.

Now the display should indicate the current parameter
4.1 Zero and travel range value. If you want to change it, press the r key.
Increase the parameter value by pressing the + key or
The ND800 position sensor operational range is factory adjusted decrease the value by pressing the - key. The default
to suit Neles-Jamesbury actuators. In case the ND800 shall be fitted values for g are given in Table 1.
into other manufacturer’s actuator, there may be a need to readjust
Press the r key when a desired value is shown on the
the sensor as explained in Section 5.4.
Connect the air supply and input signal. Make sure that the display.
voltage is max 12.8 VDC with 20 mA, measured from the Press the + and - keys simultaneously to return into the
+ and - terminals. operation state.
Select c function from the keyboard according to 3.1. The recommended d parameters are also given in Table 1
Now you can select from the display a or M and those can be adjusted in the same manner, see Fig. 12.
calibration mode by pressing + or - keys. ND800 stays in the selected operation mode during the
g and d settings.
WARNING:
The automatic calibration drives the valve against 4.3 Control valve related settings
mechanical open and closed travel limits of the The basic factory settings of ND800 assumes raising signal to open
valve-actuator assembly. Make sure that this proce- the valve and clockwise closing direction for the position sensor as
dure can be safely executed. well as sets the signal cutoff safety margin to 2 ± 0.5 % to guarantee
full closure of the valve against mechanical travel stops.
a calibration function:
Increasing input signal closes valve Increasing input signal opens valve
Due to safety precautions the r key needs to be pressed
for 5 seconds to activate a calibration function. POSITION %

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. In case this sequence is terminated by error indica- α0 α0
tion Err on the display, see Chapter 7.
Now the ND800 works with basic settings including 2 ± 0.5 % signal cut-off safety range 2 ± 0.5 % INPUT SIGNAL %

cutoff margins to secure full opening and closing of the valve. Basic setting α0-setting

In case you can not drive the valve fully open position or if there is Fig. 13. Principle of setting
no mechanical limit stop available, act as follows:
To modify the settings proceed as follows:
M calibration function: Select c function from the keyboard according to
After selecting from the display the M calibration Section 3.2.
function press the r key to activate the procedure. Select settings by pressing simultaneously the keys + and
Drive the valve manually from the + or - keys to the r.
closed (0%) position and after this press the r key. You can return back to operation state by pressing + and
In case you cannot drive the valve into open position, then - keys simultaneously once, alternatively press + or -
you may skip this sequence now by pressing + and - keys repeatedly.
simultaneously. Now the ND800 assumes that the maxi-
Now you can modify the four parameters as follows:
mum valve opening is the latest calibrated value, the
factory setting is 90°. Direction of signal
Drive the valve to the desired maximum opening position When letters di r appear on the display you may read the
(100%) with + and - keys and press the r key. signal action direction by first pressing the key r and then
Press simultaneously + and - keys to return into operation selecting between two values OPE or CLO by pressing +
state. and - keys. The value OPE signifies raising signal 4-20 mA
Now the valve controller works with basic settings including to open the valve and CLO means raising signal to close the
2 ± 0.5 % signal cutoff margins. valve.
To conclude press the key r when the desired value is
4.2 Position control shown on the display. See default values from Fig. 9 and
functions from Fig. 12.
g is gain parameter, d and b are actuator specific feedback
parameters. The default values for different actuator sizes are given Valve action
in Table 1. If the step response of a valve is overshooting, the gain The next application specific parameter rot defines relationship be-
must be decreased and correspondingly if the positioning of a valve tween the position sensor rotation and valve action.
is too slow, the gain must be increased.
12

After getting rot displayed press the key r and the current Cut-off safety range
parameter value is shown on the display. Now you may select When SAF appears on the display, press the key r and the
between two values by pressing the + or - keys. The value current default value in percentage (%) from input range
cC means clockwise rotation for closing valve and ccC signifies appears on the display. The standard default value of
counterclockwise to close. Neles-Jamesbury is 2 % (2.0). Now modify this value to
After the desired value is displayed press the key r to the desired number and press the key r to return into
conclude this operation. See default values and tubings setting state. See Fig. 12 for functions.
from Fig. 9 and functions from Fig. 12. After all the control valve related parameters are correctly
set, return to operational state by pressing simultaneously
α0 setting (dead angle)
the + and - keys for a short time.
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 14 and Table 2.
The maintenance requirements of ND800 valve controller depends
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
α0 = dead angle
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
environment. After replacement apply locking glue (like for instance
Fig. 14. Dead angle
Loctite 243) and tighten the screws firmly.

Table 2. Dead angle as percentage 5.1 Prestage

Valve size Valve series NOTE:
DN MBV, D, T5, T25, R, QR The prestage must be handled very carefully. Especially the
QMBV, QD QT5, QT25 moving parts on both ends of prestage should not be touched
Dead angle as % when the prestage is functional and the protective cover is
25 18 21 15 not in place.
40 18 21 12
50 18 21 17 Disassembly
65 16 - 13 Unplug the prestage (3) wire connectors from the circuit
80 14 15 9 board (5). Unscrew the M4 screws (92, 2 pcs.) and
100 14 15 8 remove the prestage module.
125 14 15 8 Reassembly
150 12 14 8 Place the O-rings (91) into the respective grooves and
200 10 11 7 press the prestage into place. Make sure that the nozzles
250 9 11 7 are properly guided on top of the O-rings. The screws
300 9 11 6 guide the prestage body into the correct position.
350 9 11 5 Push the prestage 2-pole wire connectors into sockets on
400 9 11 5 circuit board. Make sure that the wires do not cross each
450 9 11 - other. The wire connectors can be fitted only in correct way.
500-800 8 - - Tighten the screws (92) evenly with a torque of approx.
900-1000 6 - - 0.8 Nm/0.6 ft.lb..
Mount the protective cover (46) carefully in place an
After selecting A0 on the display, press the key r and the tighten the screws (48).
currently selected parameter value in percent (%) appears
on 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 into
setting state. See Fig. 12 for functions.
 13

5.2 Spool valve Take hold of the sides of circuit board and lift it directly
upwards and out. Handle the board carefully, touching
Before removing the spool valve (4) the prestage (3) must be taken
only on the sides.
off, see Section 5.1.
Disassembly Reassembly
Unscrew the M4 screws (99, 4 pcs.) and remove the pilot Remount the circuit board carefully. Don’t let the feed-
valve assembly. back shaft touch the circuit board.
Locate the pins of the pressure sensor on the matching
The spool valve cleaning can be done by following especially clean connections located on the board.
and careful procedures. The seal (106), filter (105), restriction (104) Tighten the M3 screws (111) evenly.
and spring (100) are located at the end pieces of the spool valve (102)
Push the rubber grommet on the slot located on the
and (103). Also the spool (97) can be removed for cleaning.
intermediate wall of the body and connect the wires on
the terminal block as shown in Fig. 16. Plug the prestage
NOTE:
wire connectors into the board making sure that the wires
Each spool valve body has an individual matching spool which
don’t cross each other. Plug the position sensor (6) wire
cannot be replaced with any other spool piece. Never ex-
connector into the board.
change the location of the pilot springs.
Mount the protective cover (46).
Mount the position indicator (65) to the shaft and tighten
Reassembly M8 screw (66) temporary. The final locking of position
Place a new gasket (98) in location determined by the fitting
indicator is made during the installation for actuator.
screw holes. Mount the pilot valve on top of the seal in
corresponding position and tighten the M4 screws (99) evenly.
NOTE:
The O-rings must be mounted first to their grooves located
Changing of new circuit board requires updating of calibration
in the spool valve unit. While mounting the O-rings to their
values of sensors using HART communication. See HART
grooves the O-rings must be compressed because the sealing
instructions from Valve Manager User’s Guide.
is done radially. Make sure that the O-rings are evenly
compressed and that they are fully inside the grooves. The 5 red circuit board
O-rings must be in perfect condition, no defects are allowed. 6 yellow
If a tool is used it must be blunt. 7 blue
8 black
Mount the prestage unit directly on the spool valve unit.
The ends of the nozzles will guide the prestage unit on

1 2 3 4
right location. The prestage unit must fit by pushing gently
with no excessive force. Ensure that the spool valve unit grommet 5 6 7
and the prestage unit have an even surface connection
before tightening the screws.

102 96 103 Fig. 16. Circuit board

5.4 Position sensor
104 Before loosening the position sensor (6) you have to first loosen
the circuit board according to 5.3.
105 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
106 108 109 97 100 101 107 the main shaft.

Shaft alternatives
45°

40 40 40
Fig. 15. Spool valve
5.3 Circuit board mark mark mark
mark
Disassembly 45°
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 114
40
the signal wires from the terminal block (35). mark
119 118 116 117
mark to this
Remove the M3 screws (111, 5 pcs.). 45° position

NOTE:
Ground yourself on the device body before touching the mark
circuit board.
Fig. 17. Position sensor
14

Disassembly 6 ERROR MESSAGES

Loosen M3 screws (116, 2 pieces) and lift the sensor out
from the housing. ND800 stores error messages to its non-volatile memory, which
Loosen the lock ring (119) on the shaft and open the holds 20 latest error codes. The memory can be read out with
M3-screw (118). Mark the top of the spiral before removing. HART communication using Valve Manager program, which shows
Slide the spiral out from the shaft. the corresponding alerts.
Reassembly Table 3 gives the error messages shown on LCD display and their
Mount the new sensor and spiral as a pair. Slide the spiral back explanations. When an error message as E00 is displayed, ND800
to the shaft and instal the lock ring back to the shaft. Turn the enters fail-safe mode and control valve is driven to 4 mA position.
spiral and the shaft to the position shown in the Fig. 17, Error messages as E00 are displayed until the unit is restarted or the
corresponding 45° opening of valve. Tighten the M3 screws. cause of error is eliminated. Error message Err indicates calibration
error and disappears when any key is pressed.
NOTE:
The position sensor and the spiral constitute a pair, and must 7 TROUBLE SHOOTING
not be replaced separately.
Mechanical/electrical defects
Install 0,1 mm thick strip (delivered with the sensor) 1. A change in the input signal does not affect the position of the
between the sensor and the spiral. Press the sensor against actuator
the spiral, not using unnecessary high force, and tighten supply pressure too low
the screws (116) evenly. Remove the strip. pilot valve sticks
Mount the circuit board and the protective cover (46) tubes between controller and actuator are incorrect, see Fig. 9
according to 5.3. actuator and/or valve jammed
signal wires connected incorrectly, no value on display
NOTE: circuit board is defective
Changing of new position sensor requires updating of calibra- calibration is not carried out (a or M)
tion values of sensors using HART communication. See HART ND800 is either in M or o mode
instructions from Valve Manager User’s Guide. incorrect load voltage, maximum is 12.8 VDC / 20 mA
prestage is defective
position sensor is defective
5.5 Pressure sensor
Before loosening the pressure sensor (7) you have to loosen the 2. The actuator goes to the final position with a small change of
circuit board according to 5.3. input signal
tubes between controller and actuator are incorrect, see Fig. 9
Disassembly the parameter settings di r and rot are selected incor-
Loosen M3 screws (126, 2 pcs.) and lift out the pressure
rectly. See Figs. 9 and 12
sensor (7) holding from the both angle parts.
Reassembly 3. Inaccurate positioning
Mount the O-rings (123, 2 pcs.) to their grooves located pilot valve dirty
in the housing. Push the pressure sensor back to its place dirt in the permanent magnet air gap
oriented by the O-rings. The final location is shown in the actuator too small
Fig. 18. Tighten the M3 screws evenly. supply pressure too low
Mount back the circuit board and the protective cover pressure sensor is defective
according to 5.3. d and b parameters in the d mode are not acc. to
recommendations, shown in Table 1
NOTE: g parameter is too small
Changing of new pressure sensor requires updating of calibra- 4. Overshooting or too slow positioning
tion values of sensors using HART communication. See HART g is too high or too low, see Table 1
instructions from Valve Manager User’s Guide. pilot valve dirty
supply air tube too small or supply air filter dirty
valve sticks
5. Err is shown during a calibration
position sensor is out of range, see Section 5.4

Fig. 18. Pressure sensor

 15

Table 3. Error messages shown on LCD display

Error message Reason Action

Input signal measurement failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E21 Change circuit board.
Input signal measurement failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E22 Change circuit board.
Pneumatic prestage control failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E41 Check wire connections and plug or change circuit board.
Pneumatic prestage control failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E44 Check wire connections and plug or change circuit board.
Position feedback failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E51 Check wire connections, plug and position sensor assembly or change
circuit board.
Position feedback failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E52 Check wire connections, plug and position sensor assembly or change
circuit board.
Memory (EEPROM) failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E61 Change circuit board.
Memory (EEPROM) failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E65 Change circuit board.
Memory (RAM) failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E81 Change circuit board.
Memory (ROM) failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E82 Change circuit board.
Processor failure. Check that ND800 is not in safety mode; input signal should not be 4 mA.
E91 Change circuit board.
Err Zero and travel calibration fails. Check range of position sensor or mechanical limits of actuator.

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 serial
number
code of this manual, part number, name of the part and
quantity required
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 BC/BJ 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)

10.3 Mounting parts for BC/BJ 25-50,

BC 502 and BJ322 actuators

Item Qty Description

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

10.4 Mounting parts for Quadra-Powr

actuators

Item Qty Description

1 1 Mounting bracket
2 1 Coupling
3 Screw
4 Washer
5 2 Screw
6 2 Washer

11 DIMENSIONS

25 26 30 5/16 UNC / 13
ND800
C2

31
28
15
PG 13.5

S
117

ø6
C1
23.5

25
4

M6x12 4

23 F05-Ø50
New (VDI/VDE 3845)

47.5 21 1/4 NPT (35.4)

ND800/S
-standard-
23
39.5

C2

(35.4)
33

S
137

33

M6 / 10
C1
(26)

137 -/L = 1/2NPT

-/I = M20x1.5
-/NJ = R1/2
 19

12 TYPE CODING
AUSTRALIA Unit 7, 2-6 Apollo Cour t, Blackburn, Victoria 3130 JAPAN K-1 Building, 6 F, 5-8-7 Kamata, Ohta-ku, Tokyo 144 SPAIN Parc Tecnologic del Valles, C/.Argenters, 08290 Cerdanyola
Tel. int. +61-53-9894 7922, Fax +61-53-9894 7933 Tel. int. +81-3-3737 3311, Fax +81-3-3737 3303 Tel. int. +34-3-582 4454, Fax +34-3-582 4453
AUSTRIA Russbergstrasse 58, A-1210 Vienna KOREA, SOUTH Room 1101, Manhattan Bldg. 36-2, Yoido-Dong SWEDEN Gåsängsv. 1-3, P.O.Box 1068, S-14122 Huddinge
Tel. int. +43-1-292 2604, Fax +43-1-290 1213 Yungdeungpo-Ku, Seoul Tel. int. +46-8-774 0640, Fax +46-8-774 9789
Tel. int. +82-2-786 1507/1508, Fax +82-2-786 1509
BELGIUM Bogemansstraat 155, B-1780 Wemmel THAILAND 1000/58 Sukhumvit 71 Road
Tel. int +32-2-461 0227, Fax +32-2-461 0386 MEXICO Neles-Jamesbury Fabmex S.A. de C.V. 15th Floor, PB Tower, Klongton, Klontoey, Bangkok 10110
BRAZIL Caixa Postal 691, 12 201-970 Sao José dos Campos, SP 1430 Gail Borden Place, Unit B, El Paso, Texas 79935, USA Tel. int. +66-2-713-3301/2, Fax +66-2-713-3303
Tel. int. +55-123-401 000, Fax +55-123-211 400 Tel. int. +915-595-3772, Fax +011-521-422 0955
U.A.E P.O.Box 17175, Jebel Ali Freezone, Dubai
CANADA 2445 Sheffield Road, Ottawa, Ontario K1B 3V6 NETHERLANDS Pampuslaan 15, P.O.Box 417, NL-1380 AK Weesp Tel. int. +971-4-836 974, Fax +971-4-836 836
Tel. int. +1-613-746 7239, Fax +1-613-746 0639 Tel. int. +31-294-418 585, Fax +31-294-419 472
UNITED KINGDOM Rutherford Road,
CHINA 1063 Si Ping Road, Shanghai 200092 NORWAY Soknedalsveien 23, Postuttak, N-3500 Hönefoss Basingstoke, Hampshire RG24 8PD
Tel. int. +86-21-502 1410, Fax +86-21-502 0368 Tel. int. +47-32-125 111, Fax +47-32-126 008 Tel. int. +44-1256-376 200, Fax +44-1256-811 668
DENMARK Vitus Berings Plads 1, P.O.Box 468, DK-8700 Horsens PORTUGAL Av. 5 de Outubro, 12-4 Esq. 1000 Lisbon USA 640 Lincoln Street, Worcester, Mass. 01605
Tel. int. +45-75-601 111, Fax +45-75-612 522 Tel. int. +351-1-315 2249, Fax +351-1-355 7468 Tel. int. +1-508-852 0200, Fax +508-852 8172
FINLAND Levytie 6, P.O.Box 6, FIN-00881 Helsinki SAUDI ARABIA c/o Al-Bustan Village, P.O.Box 88, VENEZUELA Torre Miranda, Nùcleo "A", Piso 6, Oficina A-64,
Tel. int. +358-204-80 150, Fax +358-204-80 151 Dhahran Airport 31932 Avenida Francisco de Miranda, Chacao, Caracas 1060
Tel. int. +966-3-857 1896, Fax +966-3-857 1094 Tel. int. +58-2-267 4364, Fax +58-2-267 0562
FRANCE 6-8 rue du Maine, F-68271 Wittenheim Cedex
Tel. int. +33-389-506 400, Fax +33-389-506 440 SINGAPORE 501 Orchard Road #05-09, Wheelock Place,
Singapore 238880
GERMANY Zur Kaule 2-3, D-51491 Overath Tel. int. +65-735 5200, Fax +65-735 4566
Tel. int. +49-2206-60 040, Fax +49-2206-80 691 SOUTH AFRICA 54 Suni Avenue, Corporate Park, Midrand,
ITALY Via Santa Maria 90, I-20093 Cologno Monzene P.O.Box 6975, Halfway House 1685, Johannesburg NELES-JAMESBURY GROUP
Tel. int. +39-2-254 5137, Fax +39-2-254 8445 Tel. int. +27-11-314-1234, Fax +27-11-314-1826 A MEMBER OF RAUMA CORPORATION