Val Controls IDC24-A User manual

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
1/74
USER MANUAL
Intelligent Diagnostic Controller
IDC24-A
IDC24-AF
IDC24-AFL
IDC24-F
IDP24-A*
IDP24-AF*
IDP24-AFL*
IDP24-F*
*) Require software ID: DID-SW-001

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
2/74
Table of contents
1General.........................................................................................................................................3
1.1 Safety instructions................................................................................................................................ 3
2Application ..................................................................................................................................4
3Installation guide ........................................................................................................................5
4Interface.......................................................................................................................................6
4.1 LEDs..................................................................................................................................................... 6
4.2 MTControl............................................................................................................................................ 6
4.3 Buttons - menus.................................................................................................................................... 7
4.3.1 Test menu..................................................................................................................................... 7
4.3.2 Diagnostic menu.......................................................................................................................... 7
4.3.3 Control menu............................................................................................................................... 8
4.3.4 Setup menu .................................................................................................................................. 9
4.4 Bluetooth.............................................................................................................................................. 9
4.5 Internal memory ................................................................................................................................... 9
4.5.1 Standard....................................................................................................................................... 9
4.5.2 local storage on microSD card................................................................................................... 10
4.6 Local/Remote ..................................................................................................................................... 10
5Configuration - ValConnect.....................................................................................................11
6Diagnostic ..................................................................................................................................12
6.1 Partial stroke test ................................................................................................................................ 12
6.1.1 PST error and warning parameters ............................................................................................ 16
6.2 Full stroke test .................................................................................................................................... 22
6.2.1 FST error and warning parameters ............................................................................................ 24
6.3 Solenoid test ....................................................................................................................................... 26
6.3.1 SOT error parameters................................................................................................................. 28
6.4 Emergency shutdown test................................................................................................................... 28
7Calibration.................................................................................................................................29
7.1 Automatic........................................................................................................................................... 29
7.2 Endpoint calibration ........................................................................................................................... 29
7.3 PST reference..................................................................................................................................... 29
7.4 FST reference..................................................................................................................................... 29
7.5 SOT reference..................................................................................................................................... 29
8Test errors .................................................................................................................................30
8.1 Partial stroke errors (401 to 419)........................................................................................................ 30
8.2 Partial stroke warnings (431 to 440)................................................................................................... 38
8.3 Full stroke errors (451 to 468)............................................................................................................ 47
8.4 Full stroke warnings (481 to 488) ...................................................................................................... 56
8.5 Solenoid valve test errors (501 to 514)............................................................................................... 62
9System errors ............................................................................................................................65
9.1 Pump unit errors................................................................................................................................. 67
10 Event log................................................................................................................................69
10.1 Argument ....................................................................................................................................... 72
11 Software revision list............................................................................................................73

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
3/74
1General
This manual cover software version:
Software ID: DID-SW-001
Software Version: 1.14
1.1 Safety instructions
For a safe installation of an IDC, the following must be observed. The module must only be
installed by qualified personnel who are familiar with the national and international laws, directives
and standards that apply to this product as well as all instructions in this manual.
The information in this user manual is subject to changes without notice.

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
4/74
2Application
The IDC from Val Controls is an Intelligent Diagnostic Controller. To be used for valve testing and
operation. It has an integrated microprocessor with very flexible software, which makes the IDC fits
almost any hydraulic and pneumatic, rotary and linear, double acting and spring return actuator on
the market.

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
5/74
3Installation guide
1. Connect all wires and make sure that all is connected correctly according to the hardware
manual/installation drawings.
2. Configure the unit using ValConnect or the display and keyboard
a. Configure the position feedback, through ValConnect
b. Configure the pressure feedback, through ValConnect
3. Auto calibrate the unit by pushing CAL button or using ValConnect.

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
6/74
4Interface
4.1 LEDs
LED
Colour
ON
OFF
Blinking
System: Red
Red
System error
-
Calibrating
System: Green
Green
System OK
-
Initializing
ESD
Red
ESD trip
ESD normal
-
Local
Yellow
Local mode
Remote mode
-
Closed 1
Red
Valve is closed
-
Moving towards close
Open 1
Green
Valve is open
-
Moving towards open
Pump
Green
Pump is running
-
-
MT
Red
MTControl is locked
-
-
TIP
Yellow
Test in progress
-
-
Fail
Red
Last test failed
-
-
Pass
Green
Last test passed
-
-
1) Open/close can be switched in the Interface section in ValConnect
System: Red and System: Green are the only LEDs available on the F model.
If both System: Red and System: Green is ON, the device is in bootloader mode. Power cycle the
device to return to normal operation.
4.2 MTControl
MTControl can be used to operate the AF models without opening the Ex d enclosure. It requires a
magnetic pen to “press” the buttons. The magnet must be aimed just beneath the buttons, see Figure
1. To unlock MTControl activate →and then , the red MT LED will turn off if MTControl is
unlocked.
Figure 1: MTControl sensitive area

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
7/74
4.3 Buttons - menus
Four menus can be accessed from the main screen by pressing each of the buttons or using
MTControl.
The F model only has one button. Pressing it for 3 seconds will initiate the auto calibration. The
tests and auto calibration can be aborted by pressing the button for one second.
4.3.1 Test menu
Test Menu
Description
1
Start PST
Start a partial stroke test
2
Start FST
Start a full stroke test
3
Start SOT
Start a solenoid test
4.3.2 Diagnostic menu
Diagnostic Menu
Description
1
PST
View the reference and latest partial stroke test values and limits
Date
Date the test was performed
Time
Time the test was performed
Last test result
Result of the latest test
Start pressure
Start pressure
React
SOV reaction time
Breakaway time
Breakaway time
Breakaway pressure
Breakaway pressure
PST time
PST time
Press
PST pressure
PrsTi
PST pressurising time
RetTi
PST return time
FilTi
Actuator fill time
Total time
PST total time
Max. travel
PST maximum travel
Min. pressure
PST minimum pressure
Enable errors
Enable errors
Enable warnings
Enable warnings
2
FST
View the reference and latest full stroke test values and limits
Date
Date the test was performed
Time
Time the test was performed
Last test result
Result of the latest test
Start pressure
Start pressure
React
SOV reaction time
Breakaway time
Breakaway time
Breakaway pressure
Breakaway pressure
Breakaway pos.
limit
Breakaway position error limit
FST time
FST time
DePrs
FST depressurising time
PrsTi
FST pressurising time
RetTi
FST return time
FilTi
Actuator fill time
Total time
FST total time
Enable errors
Enable errors
Enable warnings
Enable warnings
3
SOT
View the reference and latest solenoid valve test values and limits
Date
Date the test was performed
Time
Time the test was performed

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
8/74
Last test result
Result of the latest test
Start pressure
Start pressure
Reaction time
SOV reaction time
Breakaway time
Breakaway time
Total time
SOT total time
Enable errors
Enable errors
4
EST
View the latest Emergency shutdown test
Date
Date the test was performed
Time
Time the test was performed
StaPr
Start pressure
React
SOV reaction time
BrkTi
Breakaway time
BrkPr
Breakaway pressure
FSTTi
FST time
DePrs
FST depressurising time
TotTi
EST total time
4.3.3 Control menu
Control Menu
Description
1
Manual
Manual operate the valve

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
9/74
4.3.4 Setup menu
Setup Menu
Description
1
Calibration
1
Auto calibration
Start the auto calibration
2
End point cal.
Start endpoint calibration
3
Start PST ref
Start the partial stroke reference
4
Start FST ref
Start the full stroke reference
5
Start SOT ref
Start the solenoid valve test reference
2
Identification
Software ID, Software version, serial no. and tag no.
3
Live
Current state of digital and analogue signals
4
Event log
The last 10 events
5
Scheduler
Configure the scheduler
6
HART
Configure HART communication
7
Modbus
Configure Modbus configuration
8
Display
Adjust the contrast and backlight
4.4 Bluetooth
Bluetooth can be used to control the valve system though the IDC or to download signatures to a
mobile device.
Range:
IDC24-AF with external antenna: 20 meters
IDC24-F with external antenna: 20 meters
IDC24-A with internal antenna: 2 meters
IDC24-AF with internal antenna and glass lid: 2 meters
When connecting to a IDC with internal antenna, the connecting devices must be right in front of
the IDC.
After the Tag no. is changed the device must be power cycled to update the Bluetooth name.
4.5 Internal memory
The device is available in two models, standard or with local storage on microSD card.
A signature contains all test data and a curve of the test.
4.5.1 Standard
The last 10 events are stored in memory.
The IDC will store test data from the last performed test of each type
•one PST
•one PST reference
•one FST
•one FST reference
•one SOT
•one SOT reference

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
10/74
•one EST.
When a new test is performed, previously stored data will be overwritten in the device. To avoid
data loss the operator shall download test data between the tests.
The IDC will store one test curve in memory until the unit is either powered off or a new
test/reference test is performed. To avoid overwriting a test curve, the curve shall be downloaded
between tests.
No test curves are generated during auto calibration. The recommended procedure to get reference
tests with data and curves is as follows:
1) Perform an auto calibration
2) Perform a PST reference
3) Download PST reference signature
4) Perform a FST reference
5) Download FST reference signature
6) Download SOT reference signature (The SOT reference never contains a curve)
4.5.2 local storage on microSD card
All events and signatures are stored on the SD card. Up till 50.000 event logs and signatures can be
stored on the SD card.
Note: In case of a full SD card no further data will be saved.
4.6 Local/Remote
The IDC has the option to use a Local/Remote selector. The table below shows when the interfaces
are available. The communication protocols are always allowed to read parameters, but sending
commands like “Start PST” will not work when the selector is in Local.
Selector: Local
Selector: Remote
No selector
Local interface
√
√
√
USB
√
√
√
MTcontrol
√
√
Bluetooth
√
√
Local control panel
√
√
Digital input from DCS
√
√
HART
√
√
Modbus
√
√
Fieldbus
√
√

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
11/74
5Configuration - ValConnect
All configuration of the IDC must be done through a USB connection to a computer with
ValConnect installed. ValConnect can be downloaded at www.valcontrols.com.
Disable PST, FST or SOT
PST, FST and SOT can be disabled, so that reference tests are not run during the autocalibration.
This can be archived by setting all DO to “Not used” in valve configuration under each
corresponding section in ValConnect.

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
12/74
6Diagnostic
The IDC can perform tree different test types.
•Partial stroke test, PST
•Full stroke test, FST
•Solenoid test, SOT
Furthermore, the IDC can record signatures and record test data in case of emergency shutdowns.
•Emergency shutdown test, EST
6.1 Partial stroke test
The PST moves the system to a predefined position and back. The test can be initiated from the test
menu, a communication protocol or a digital input depending on the configuration.
The system will move the distance specified by “PST travel”. If PST travel is 20%, the actuator will
move from 100% to 80%.
To avoid overshoot, a function called “PST overshoot prevention” is enabled as default. During the
reference stroke, two partial strokes will be performed. The first partial stroke is used to measure
the overshoot which is then avoided in the second stroke. In all further PST will use this function.
Below are signatures from typical partial strokes shown, including definitions on the different terms
further used in this manual.

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
13/74
Figure 2: PST time definitions

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
14/74
Figure 3: PST position and pressure definitions
The IDC must be calibrated before it can perform a test.
When a test is started the position and pressure is evaluated. A test will not be started if the start
conditions are not correct. The start conditions are as follow:
•Valve must be at the operational position
•Pressure must be within the Start pressure low and Start pressure high limits.
An error will indicate what the problem is.
The IDC monitors the position and pressure during the test. The IDC aborts the test and report an
error if the limits in the error parameters are reached.
If a test does not reach the error limits it will run until finished and then the warning parameters are
evaluated. See Figure 4 for flow diagram describing the general functional description of a PST.
If the system does not have a pressure sensor, all pressure related parameters, warnings and errors
will be ignored.
The errors or warnings can only be removed by performing a successful test.

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
15/74
Figure 4: Flow diagram for a partial stroke
Start test
Check start
conditions
Set DO to PST
valve configuration
Check error
conditions
Set DO to
Operationel valve
configuration
Check error
conditions
Stroke is finished
Check warnings
Test finished
sucessfull
Test finished with
error
Test finished with
error
Test finished with
error
Test finished with
error

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
16/74
6.1.1 PST error and warning parameters
The error and warning parameters are automatically set during auto calibration and Partial stroke
reference tests but can be manually adjusted through ValConnect, the display or remote
communication.
PST errors
For the partial stroke the error parameters are set to the following values:
•Breakaway timeout = Reference breakaway time + reference PST time
•PST timeout = Reference total time
•Total timeout = 2 * Reference total time
•Minimum breakaway pressure = Reference pressure at SP
•Minimum allowed pressure = Reference minimum pressure –10% of Reference start
pressure
The Start pressure low and high error limits are not set automatically and the function is disabled as
default.
PST warnings
The partial stroke warning parameters are set to the following values after a successful calibration:
•Low breakaway time = Reference breakaway time –50%
•High breakaway time = Reference breakaway time + 50%
•Low breakaway pressure = Reference breakaway pressure –50%
•High breakaway pressure = Reference breakaway pressure + 50%
•Low partial stroke time = Reference partial stroke time –50%
•High partial stroke time = Reference partial stroke time + 50%
•Maximum travel = Move at reference stroke + 5 %

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
17/74
Figure 5: Breakaway timeout
Figure 6: PST timeout

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
18/74
Figure 7: PST total timeout
Figure 8: Minimum breakaway pressure

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
19/74
Figure 9: Minimum allowed pressure

DID-UM-002
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. [phone]
[email protected] •www.valcontrols.com
Revision: 10
20/74
Start pressure
Varying start pressures has impact on the PST, this is shown in Figure 10. The breakaway time is
increasing a lot along with the start pressure in the actuator. The PST return time also have a high
dependence on the start pressure.
Figure 10: Four PSTs with varying start pressures