DVG ITVC Series Service manual

Intelligent Total
Valve Controller
BASIC version
Document Number
Prepared
Approved
Date
Release
IOM-ITVC
AA
GR
05/09/2017
05
INSTALLATION
SET-UP
OPERATING
& SERVICE MANUAL
ITVC Series
ITVC

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
Fully Paid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECT TO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[e-mail]
www.dvgautomation.it SHEET 3 DI 64
DVGITVCSeries–“IntelligentTotalValve
Controller” – Basicversion
1 LEGEND.......................................................................................................................................................7
2 ITVC Intelligent Total Valve Controller .......................................................................................................7
3 Introduction................................................................................................................................................8
4 General information ...................................................................................................................................8
5 Storage........................................................................................................................................................8
6 Applicable regulations................................................................................................................................9
7 Classification and Certification ...................................................................................................................9
8 Warnings...................................................................................................................................................10
9 ITVC-features............................................................................................................................................12
9.1 Block diagram .................................................................................................................................. 12
9.2 Main characteristics ........................................................................................................................ 13
9.3 Input and Output of ITVC ................................................................................................................ 14
9.4 Status signalling............................................................................................................................... 14
9.5 BUS control...................................................................................................................................... 14
9.6 ITVC Terminal blocks ....................................................................................................................... 15
9.7 Operating principle.......................................................................................................................... 16
9.7.1 Actuator control ...................................................................................................................... 16
9.7.2 ESD Emergency Shutdown....................................................................................................... 17
9.7.3 Optional Panic Button ............................................................................................................. 18
9.7.4 Failsafe function ...................................................................................................................... 18
9.7.5 Output signalling relays ........................................................................................................... 18
9.7.6 Configurable Remote controls................................................................................................. 18
9.7.7 Interlock function .................................................................................................................... 19
9.7.8 4-20 mA analogue output........................................................................................................ 19
9.7.9 Configuration parameters protection ..................................................................................... 19
9.7.10 Display control......................................................................................................................... 19
9.7.11 Alarm, MRT Alarm, Warning.................................................................................................... 20

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
Fully Paid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECT TO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[e-mail]
www.dvgautomation.it SHEET 4 DI 64
9.7.12 Instantaneous and Historical data and graphs........................................................................ 20
9.7.13 Test of coils of Solenoid Operated Valves ............................................................................... 21
9.7.14 Measure of closing time .......................................................................................................... 21
9.7.15 Date and time .......................................................................................................................... 21
9.7.16 Digital input repetition ............................................................................................................ 21
9.7.17 CPU’s and Diagnostics ............................................................................................................. 21
9.8 Examples of ITVC applications......................................................................................................... 22
10 ITVC HMI (ITVC Human Machine Interface) .............................................................................................24
10.1 HOME page...................................................................................................................................... 26
10.2 Actuator control mode .................................................................................................................... 27
10.3 Navigation in the MENU.................................................................................................................. 28
10.3.1 MENU chart ............................................................................................................................. 29
10.3.2 Password entry ........................................................................................................................ 30
10.3.3 Visualization of Alarms and Warnings..................................................................................... 30
10.3.4 Visualization of Pressures........................................................................................................ 31
10.3.5 LANGUAGE menu .................................................................................................................... 32
10.3.6 MEASUREMENT menu............................................................................................................. 33
10.3.6.1 Instantaneous measures sub-menu ................................................................................ 34
10.3.6.2 Historical data sub-menu................................................................................................. 36
10.3.7 SETUP menu ............................................................................................................................ 37
10.3.7.1 Set Time and Date ........................................................................................................... 39
10.3.7.2 Display Control................................................................................................................. 39
10.3.7.3 Operator menu................................................................................................................ 40
10.3.7.3.1 Change password ........................................................................................................ 40
10.3.7.3.2 Valve pos set................................................................................................................ 40
10.3.7.3.3 Firmware version......................................................................................................... 41
10.3.7.3.4 ITVC parameter............................................................................................................ 41
10.3.7.4 Administrator menu ........................................................................................................ 41
10.3.7.4.1 Change password ........................................................................................................ 42
10.3.7.4.2 Digital inputs................................................................................................................ 42

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
Fully Paid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECT TO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[e-mail]
www.dvgautomation.it SHEET 5 DI 64
10.3.7.4.3 Output relays............................................................................................................... 43
10.3.7.4.4 Modbus 1 and Modbus 2 ............................................................................................ 43
10.3.7.4.5 Temperature limits...................................................................................................... 45
10.3.7.4.6 Service date ................................................................................................................. 45
10.3.7.4.7 Maximum stroke time ................................................................................................. 45
10.3.7.4.8 ITVC serial number ...................................................................................................... 45
10.3.7.4.9 Valve ............................................................................................................................ 45
10.3.7.4.10 Coil test...................................................................................................................... 45
10.3.7.4.11 Local and remote controls......................................................................................... 45
10.3.7.4.12 ESD shutdown............................................................................................................ 45
10.3.7.4.13 Operator menu.......................................................................................................... 45
10.3.7.4.14 MRT Maximum Repair Time...................................................................................... 45
10.3.7.4.15 Calibration L/S ........................................................................................................... 45
10.3.7.4.16 Stroke time calibration.............................................................................................. 49
10.3.7.4.17 Test coil absorption ................................................................................................... 49
10.3.7.4.18 Pressure eng unit....................................................................................................... 50
10.3.7.4.19 OP after PB action ..................................................................................................... 50
10.3.7.4.20 Panic button mode .................................................................................................... 50
10.3.7.4.21 Reset config ............................................................................................................... 50
10.3.7.4.22 Analog inputs............................................................................................................. 51
10.3.7.4.23 Out analog 1-2 calib................................................................................................... 51
11 Installation................................................................................................................................................52
11.1 Safety Recommendation ................................................................................................................. 52
11.2 Cable size ......................................................................................................................................... 53
11.3 Weights and Measurements ........................................................................................................... 53
11.4 Solenoid Operated Valves fuses ...................................................................................................... 54
11.5 Power supply ................................................................................................................................... 54
11.5.1 Power supply connection ........................................................................................................ 54
11.6 Input/output electrical characteristics............................................................................................ 55
12 Maintenance and cleaning .......................................................................................................................55

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
Fully Paid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECT TO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[e-mail]
www.dvgautomation.it SHEET 6 DI 64
13 Troubleshooting .......................................................................................................................................56
14 Decommissioning .....................................................................................................................................59
15 Start-up procedure ...................................................................................................................................60
15.1 General checks................................................................................................................................. 60
15.2 End of travel setting ........................................................................................................................ 60
15.3 Test of absorption of coil of Solenoid Operated Valves.................................................................. 61
15.4 Test of Stroke time .......................................................................................................................... 61
15.5 Set of coil test option....................................................................................................................... 61
16 Nameplates...............................................................................................................................................61
17 Battery option...........................................................................................................................................62
17.1 Setting options in the ADMINISTRATOR menu ............................................................................... 63
WARRANTY .......................................................................................................................................................64
Trade Marks:.....................................................................................................................................................64

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
Fully Paid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECT TO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[e-mail]
www.dvgautomation.it SHEET 7 DI 64
1 LEGEND
Protective Gloves Required
Work tools Necessary
Protective Shoes Required
Mechanical Operator
Protective Glasses Required
Operator
Prohibited to alter or remove the
nameplate
Advise
2 ITVC Intelligent Total Valve Controller
User terminal block
Actuator
terminal
block
ITVC Intelligent Total Valve Controller
HMI
Human
Machine
Interface
Cable entries
Main voltage terminals
Fuses of
Solenoid
Operated
Valves
Covers
Optional
Panic Button
ITVC
enclosure

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
Fully Paid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECT TO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[e-mail]
www.dvgautomation.it SHEET 8 DI 64
3 Introduction
This document, IOM-ITVC-Basic, is the Installation, Operation and Maintenance manual (IOM) of ITVC,Intelligent
Total Valve Controller for pneumatic and hydraulic actuators. This manual includes only the instructions relevant to
BASIC version of ITVC. The instructions of the ITVC optional functions (PST, Line Break, HPU control module,
Modbus protocol, HIPPS, Battery, etc.) are in the documents Annex A,…,I, of the above IOM.
DVG Automation will activate only the functions requested by the user application and needed to correctly control the
actuator.
This document does not contain the instructions relevant to the actuator controlled by the ITVC. The wiring and
hydraulic diagrams present in the next pages should be considered only as examples of application of ITVC.
Refer to documentation supplied with the actuator to view the specific mechanical, electrical and hydraulic functional
diagram and instructions.
This document is an integral part of the apparatus, which must be carefully read, understood and consulted
before use and must be retained for future reference
WARNING!
Do not install, operate, or maintain an ITVC without first being fully trained and qualified in valve,
actuator and accessory installation, operation and maintenance, and carefully reading and
understanding the contents of this manual, including all safety cautions and warnings. For any
questions regarding these instructions, contact the factory before proceeding.
4 General information
DVG Automation spa products are engineered, manufactured and tested in accordance with the quality control system
complying with the international standard EN ISO 9001.
ITVC (Intelligent Total Valve Controller) is an electronic device designed to control pneumatic and hydraulic
actuators.
DVG Automation will not be responsible for any possible damage or physical injury resulting from use in other than the
designated applications or by lack of care during installation, operation, adjustment and maintenance of the machine.
Such risks lie entirely with the user. Depending on the specific working conditions, additional precautions may be
requested. Considering that DVG Automation has no direct control over particular applications, operation or
maintenance conditions, it is operator’s responsibility to comply with all applicable safety rules. Contact urgently DVG
Automation in case of dangerous situations not considered in the manual. It is total responsibility of the operator to be
according to the local health and safety regulations.
5 Storage
Receipt
On receipt of the ITVC, always check any damage. Never install a damaged unit and report the detected defect to the
forwarding agent.
Packing
Ensure that adequate protections were secured during transport.
Handling and Storage
Ensure that principal holes on enclosure are occluded with a cap.
Storage temperature: -60°C ≤ T ≤ +85°C.

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
Fully Paid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECT TO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[e-mail]
www.dvgautomation.it SHEET 9 DI 64
6 Applicable regulations
94/9/CE: Directive on equipment and protective systems intended for use in potentially explosive atmospheres
(ATEX)
2004/108/CE EMC Directive (EMC)
EN 60079-0 Electrical apparatus for explosive gas atmospheres- Part 0: General requirements
EN 60079-1 Electrical apparatus for explosive gas atmospheres – Part 1: Flameproof enclosures "d"
EN 60079-31 Explosive atmospheres - Part 31: Equipment dust ignition protection by enclosure "t"
EN 61326-3-1 Electrical equipment for measurement, control and laboratory use. EMC requirements. Immunity
requirements for safety-related systems and for equipment intended to perform safety-related
functions (functional safety). General industrial applications
EN 61010-1 Safety requirements for electrical equipment for measurement, control, and laboratory use - Part 1:
General requirements
2006 / 95 / CE Low Voltage Directive (LVD)
EN 60529 Specification for degrees of protection provided by enclosures (IP code)
IEC 60068-2-6 Environmental testing – Part 2: Tests – Test Fc: Vibration (sinusoidal)
IEC 60068-2-27 Environmental testing - Part 2-27: Tests - Test Ea and guidance: Shock
IEC 61508 Functional safety of electrical/electronic/programmable electronic safety-related systems
7 Classification and Certification
EUM1 12 ATEX 0789 – ATEX 94/9/CE
II 2GD Ex db IIB+H2T5 Ex tb IIIC T88°C -60°C ≤ Tamb ≤ +85°C
II 2GD Ex db IIB+H2T5 Ex tb IIIC T88°C -45°C ≤ Tamb ≤ +85°C
II 2GD Ex db IIB+H2T5 Ex tb IIIC T88°C -20°C ≤ Tamb ≤ +85°C
IECEx EUT 14.0008
IP 68 – EN 60529
SIL 3 – IEC 61508
GOST – Certificate No. RU C-IT.ГБ08.B.00033
Resistance to Vibration – Certificate No. 223221TRFENV – IEC 60068-2-6
Seismic test – Certificate No. 223221TRFENV – IEC 60068-2-27

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
Fully Paid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECT TO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[e-mail]
www.dvgautomation.it SHEET 10 DI 64
8 Warnings
WARNING!
Every notice in this manual, marked with the symbol shown to the left, concerns to the explosion risk and
must be enforced by all operators working in potentially explosive areas.
Not abiding by these rules can lead to health dangers for people and damages for things.
WARNING!
Do not open in explosive atmosphere and/or while energized. The area must be cleaned from explosive
mixture since battery and residual capacitor charge could generate electrical spark and cause explosion
WARNING!
The equipment must not be mechanically connected to a separate heat source with temperature higher than
85°C.
WARNING!
Cable glands and/or plugs must be IEC Ex certified.
WARNING!
Installation of equipment must be in accordance with IEC 60079-14 (latest edition) or national standard.
WARNING!
Earthing and protective conductors
Minimum cross-sectional area of protective conductors (IEC 60079-0 Table 10)
(S = cross sectional area of phase conductor [mm2]; SP= Minimum cross-sectional area of the corresponding
protective conductor [mm2])
S≤16; SP=S
WARNING!
External earth connection
Equipment must be securely connected to an earth ground. An earthing connection is provided externally to
the equipment. Connection must be secure so that the electrical conductors cannot be readily loosened or
twisted and contact pressure on electrical connection can be maintained in all conditions. Care must be taken
to protect the connection against corrosion.