Val Controls IHP24-A User manual
DHP-UM-020
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. +45 7547 0600 •Fax +45 7547 0611
Revision: 12
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USER MANUAL
Intelligent Hydraulic Positioner
IHP24-A
IHP24-AF
IHP24-B
IHP24-BF
IHP24-F
IHP24-I
DHP-UM-020
Val Controls A/S •Limfjordsvej 3 •DK-6715 Esbjerg N •Tel. +45 7547 0600 •Fax +45 7547 0611
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Table of contents
1General.........................................................................................................................................3
1.1 Safety instructions................................................................................................................................ 3
2Application ..................................................................................................................................4
3Installation guide ........................................................................................................................6
4User interface ..............................................................................................................................7
4.1 Display, indicator and keyboard........................................................................................................... 7
4.2 Display, keyboard, indicator, USB, and status indicators .................................................................... 8
4.3 Display, keyboard, indicator, USB, MT control and status indicators................................................. 8
4.4 Indicator, calibration button and USB.................................................................................................. 9
4.5 Components.......................................................................................................................................... 9
4.5.1 USB connector............................................................................................................................. 9
4.5.2 Display......................................................................................................................................... 9
4.5.3 Keyboard.................................................................................................................................... 10
4.5.4 MT control................................................................................................................................. 10
4.5.5 Status indicators......................................................................................................................... 10
4.5.6 Indicator..................................................................................................................................... 10
4.5.7 Calibration button...................................................................................................................... 10
4.5.8 TTL connector........................................................................................................................... 10
5Menus.........................................................................................................................................11
5.1 Calibrate ............................................................................................................................................. 11
5.1.1 Automatic .................................................................................................................................. 11
5.1.2 Manual....................................................................................................................................... 11
5.2 Error.................................................................................................................................................... 11
5.3 Status.................................................................................................................................................. 12
5.4 Menu................................................................................................................................................... 14
5.4.1 Basic menu................................................................................................................................. 15
5.4.2 Advanced menu ......................................................................................................................... 20
5.4.3 Pump Control menu................................................................................................................... 23
6Regulators..................................................................................................................................26
6.1 Electronic stepping............................................................................................................................. 26
6.2 Mechanical stepping........................................................................................................................... 26
6.3 Proportional........................................................................................................................................ 26
7Error no.....................................................................................................................................29
7.1 Mounting and settings ........................................................................................................................ 29
7.2 Calibration.......................................................................................................................................... 32
7.3 External connections .......................................................................................................................... 33
7.4 Pump unit ........................................................................................................................................... 34
7.5 Communication .................................................................................................................................. 36
7.6 Internal errors ..................................................................................................................................... 36
8Software revision list ................................................................................................................37
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1General
This manual cover software version:
Software ID: DHP-SW-0015 version: 3.17
Software ID: DHP-SW-0016 version: 3.17
1.1 Safety instructions
For a safe installation of a positioner, the following must be observed. The module shall 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.
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2Application
Val Controls intelligent hydraulic positioner controls almost all hydraulic, linear, rotary, single-
return (SR) and double-acting (DA) actuators on the market.
Its compact design, with few moving parts, makes it very reliable. The flexible software calibrates
automatically, it contains intern safety surveillance together with several standard flow curves. A
special flow curve is defined very simple, and the positioner’s set point and deadband can be
adjusted from the user menu.
The positioner works by comparing the control loop signal with the position feedback, it then uses
control valve signals to operate the actuator/valve to the desired position. The control loop and the
transmitter loop signal is a 4-20mA signal with HART communication. The control valve signals
are powered through the 24VDC power supply and can supply valves up to 192W, 48W each. The
position feedback from the actuator/valve can be either a potentiometer or a 4-20mA loop powered
transmitter.
The power unit controller measures the pressure in the hydraulic system and controls a hydraulic
pump unit in order to keep the pressure within a specified range. When the pressure falls below a
user defined value, the positioner will turn on the pump and keep it running until the pressure has
reached the maximum defined value. Two pressure switches can be used instead of a pressure
transmitter.
It is possible to connect temperature and level transmitter/switches to monitor the hydraulic system
and shutdown the pump if a user defined value is reached.
Power Supply
Control loop
Transmitter loop
Hydraulic
system
Position signal
Control valve signals
Pump
Actuator
Valve
Pump signal
Pressure signal
P
E
Level signal
Temperature signal
Figure 1: IHP24-A
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Power supply
Communication
Hydraulic system
Pump
Pressure
ReturnSupply
1 3 4 5 6 7 8 9 1011 122
13 1516 17 1819 2021 22 23 2414
55%
Valve Position
Calibrate MenuError Status
OK
Val Controls IHP24
Position
Control valve signals
Figure 2: IHP24-B
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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 valve function, see 5.4.2 Advanced menu.
b. Configure position feedback, see 5.4.2 Advanced menu.
3. Auto calibrate the unit by pushing CAL button or using ValConnect, see 5.1.1 Automatic.
4. After a successful calibration the green indicator will light, see 4.4.6 Indicator.
5. If the red is light, there was an error during calibration. Press error on the keyboard and see
the error no. on the display or connect ValConnect and see what the error message is and go
to the manual to get an explanation on the error no. and how to solve it, see 7 Error no.
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4User interface
The IHP comes with 4 different user interfaces which are described here.
4.1 Display, indicator and keyboard
To control and monitor the device, it is fitted with a graphical display, four buttons and two
indicators. When the lid is removed a TTL connector is available, for configuration via ValConnect.
A special connector cable is required.
Figure 3: Type B interface
Figure 4: Type B TTL connection. Black marker on cable must face marking 1 and 2
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4.2 Display, keyboard, indicator, USB, and status indicators
This front is only available for type A.
Figure 5: Type A interface
4.3 Display, keyboard, indicator, USB, MT control and status indicators
This front is only available for type BF and AF.
Figure 6: Type BF and AF interface
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4.4 Indicator, calibration button and USB
All configuration and control must be done through ValConnect.
Figure 7: Type A and B interface
Figure 8: Type F interface
4.5 Components
1) USB connector
2) Display
3) Keyboard
4) MT control sensors
5) Status indicators
6) Indicator
7) Calibration button
8) TTL connector
4.5.1 USB connector
The USB connection can be used to connect the IHP to a PC with ValConnect installed.
ValConnect can be used to configure and control the IHP from the PC.
4.5.2 Display
The display is a four lined graphical display with backlight feature and adjustable contrast.
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4.5.3 Keyboard
The keyboard is fitted with four buttons, which have the following functions.
Button
Menu
Menu navigation
Confirmation
←
Calibrate
Back
↑
Error
Up
↓
Status
Down
→
Menu
Forward
OK
4.5.4 MT control
The MT control can be used to operate the IHP through the window lid on the Ex D enclosure.
Position the MT pen above the sensors to emulate a button push. MT control is locked as default
and can be unlocked by touching → and then ←. The auto lock time can be set in the menu.
4.5.5 Status indicators
The functions of the seven indicators are as follows:
•ESD: The ESD input on the IHP is open
•Moving: The valve is opening or closing
•Closed: The valve is closed
•Open: The valve is open
•MT locked: MT control is unlocked
•Local: The IHP is in local mode and can be controlled by external open/close buttons
•Pump: The pump output is active
4.5.6 Indicator
The indicator lights will work as follows:
•Red indicator continuous: Glows when an error has occurred in the positioner
•Red indicator flashing: Calibration in progress
•Green indicator: Glows when there are no errors in the positioner
•Green indicator continuous: Initializing
4.5.7 Calibration button
Push the button for 3 seconds to start an auto calibration. Push it again to abort the auto calibration.
4.5.8 TTL connector
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5Menus
The positioner has four menus. All menus can be directly activated by pressing one of the four
buttons.
•Calibrate ←, enter the calibrate menu
•Error ↑, enter the error menu
•Status ↓, enter the status menu
•Menu →, enter the main menu
5.1 Calibrate
The positioner can be calibrated using two calibration menus.
Calibrate Description
1 Automatic Start the sequence to automatic calibration
2 Manual Start the sequence to manual calibration
5.1.1 Automatic
The automatic calibration is an automated calibration that will find the necessary information to
optimize the performance of the system. The calibration can take from 90 sec. up to 1000 sec.
The automatic calibration is available for the standard and stepping regulator. When the regulator
type is set to proportional the auto calibration is automatic endpoint calibration. Tuning of the
regulator parameters must be done from ValConnect.
If an emergency shutdown occurs while the calibration is in progress, the calibration procedure will
auto abort.
5.1.2 Manual
In manual calibration, it is possible to manually set the travel end points. After manually setting the
end points, the positioner will ask to start auto-tune sequence to optimize system performance.
Auto-tune is recommended.
5.2 Error
The valve positioner will display an error code whenever an error has occurred. The positioner will,
despite the error message, continue to regulate according to the control signal given. For a complete
overview of the various error codes, please take reference to section 6.
Error Description
Error explanation Detalied explanation of the current highest priority
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5.3 Status
If the user wants to get a live status on the control parameters or a general overview of the chosen
configuration parameters, this is accessible by pressing the “↓” button while the positioner is in
regulation mode. The regulation of the valve will not be influenced.
Status
Description
1 Live status Show updated values
SP - Flow % value of the control loop - Flow
PV - Flow % value of the position loop/sensor - Flow
TM - Flow % value of the transmitter loop - Flow
SP - Travel % value of the control loop - Travel
PV - Travel % value of the position loop/sensor - Travel
SP - mA mA value of the control loop from control room
PV - mA mA value of the position loop
TM - mA mA value of the transmitter loop to control room
Cnt DO1 Puls counter for DO1
Cnt DO2 Puls counter for DO2
Cnt DO3 Puls counter for DO3
Cnt DO4 Puls counter for DO4
DO1 Current status of DO1
DO2 Current status of DO2
DO3 Current status of DO3
DO4 Current status of DO4
DO5 Current status of DO5
DO6 Current status of DO6
DI1 Current status of DI1
DI2 Current status of DI2
DI3 Current status of DI3
DI4 Current status of DI4
DI5 Current status of DI5
DI6 Current status of DI6
DI7 Current status of DI7
DI8 Current status of DI8
AI1 - mA mA value of the input
AI2 - mA mA value of the input
AI3 - mA mA value of the input
AI4 - mA mA value of the input
AO1 - mA mA value of the output
AO2 - mA mA value of the output
Control Mode The control mode (ESD/Off/Local/Remote)
2 Identification Values to identify the product
SW-ID Software ID
SW ver. Software version
Serial no. Serial number
Model no. Model number
Regulator Regulator type
Tag no. Tag number
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Status
Description
3 Pump control
Pump State of the pump
Pressure Meassured pressure
Switch Pressure switch state
Level Meassure level
Switch Level switch state
Temperature Temperature
Switch Temperature switch state
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5.4 Menu
The menu consists of three submenus: Basic, Advanced and Pump control. In the basic menu some
basic control parameters can be changed. The positioner is still in service while these changes are
made. In the advanced menu, more advanced parameters can be changed. These parameters will
change how the positioner is working and the positioner will stop regulating while changing settings
in this menu.
Menu changes will not take effect until the user exits the menu and confirms the changes.
Menu Description
1.
Basic Basic control settings
2.
Advanced Advanced control settings
3.
Pump control Pump control settings
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5.4.1 Basic menu
Basic menu structure.
Basic Default Reset Description
1 Deadband 1.0 B A Acceptable deviation from setpoint in percentage
2
Flow curve
Choice of flow curve
1 Linear √B A Linear flow curve
2 Equal pct. 50:1 Equal percentage 50:1 flow curve
3 Custom Custom flow curve
3 Valve action Valve action
1 Direct √B A Valve opens with increasing setpoint value
2 Reverse Valve closes with increasing setpoint value
4 Regulator functions Special function on how the positioner works
1 End settings Settings when the setpoint signal is 0% or 100%
1 Hold at open Function at 100%
1 Status Off B A Timer starts at 100%
2 Time 5 B A Time before positioner goes to stay-put
2 Hold at close Function at 0%
1 Status Off B A Timer starts at 0%
2 Time 5 B A Time before positioner goes to stay-put
5 Transmitter Transmitter settings
1 Transmitter action Transmitter action
1 Direct √B A 0% flow = 4mA
2 Reverse 0% flow = 20mA
2 Transmitter fail position Transmitter fail
1
None
√B A During a failure will the transmitter show the position
2 3.5 mA During failure the transmitter will be 3.5mA
3 21.5 mA During failure the transmitter will be 21.5mA
6 Display Display settings
1 Display light Off B A Controlling the diplay light
2 Contrast 5 B A Controlling the diplay contrast
3. Frontpage Configure the frontpage
1 Valve position B A Selcet who to display the position of the valve
1 Percent √Show valve position in percent
2 Degree Show valve position in degree
2 Configuration Configuration for for the frontpage
1 Action Direct B A Set the direction of the valve position on the frontpage
2 Degree min 0°B A Degree at 0%
3 Degree max 90° B A Degree at 100%
7 Status indicators Status indicators
1 Status On/Off Enable status indicators
8
MT control
Magnetic touch control
1 Status On/Off Enable MT control
2 Auto lock status On/Off Enable auto lock for MT control
3 Auto lock time 1 min Set the auto lock time
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Deadband
The deadband can be manual altered from the user menu. The standard adjustment is 1% but this
value can be changed from 0.1 to 10 %.
Note: The deadband is on the position of the valve - not the flow!
If the deadband is set to e.g. 5% the valve positioner will regulate with a set point accuracy of +/- 5
% and stay there until the position feedback is bigger than 5 %.
Flow curve
The valve characteristic expresses the flow percent through a valve at different opening angles. To
obtain an accurate regulation of the flow media it is important to choose a valve characteristic that
is identical with the one for the valve used.
Linear valve characteristic
The flow through the valve is proportional with the travel of the valve. The linear valve-
characteristic can be chosen from the user menu.
Equal Percentage 50:1
The flow through the valve rises in the last part of the curve. The equal percentage valve
characteristic can be chosen from the user menu.
0
25
50
75
100
025 50 75 100
Flow - %
Travel - %
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Custom curve
The positioner offers the user to define his own valve characteristic from the keyboard. This option
makes it possible to use a wide range of valves and still be able to obtain an accurate regulation.
The positioner needs 11 reference points to linearize an arbitrary valve characteristic. Point 0 and
point 10 cannot be entered as they must be (0%, 0%) and (100%, 100%).
Point
Travel %
Flow %
0
0
0
1
66
0
2
72
16
3
78
33
4
83
50
5
89
66
6
94
83
7
100
100
8
100
100
9
100
100
10
100
100
When the points describing the flow curve are keyed in, the valve positioner will linearize the flow
curve.
0
25
50
75
100
025 50 75 100
Flow - %
Travel - %
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Valve action
Menu to select the Control loop to be Direct or Reverse.
•Direct : Valve opens with increasing set point value
•Reverse : Valve closes with increasing set point value
Regulator
Menu to set whether the regulator should keep opening or closing when within the deadband of 0%
and 100%
End settings
•Hold at Open:
oStatus:
▪Off: Never hold
▪On: Hold after the number of seconds specified in the next menu
oTime: 0-30 sec. Do not have any effect if Status is Off
•Hold at Open:
oStatus:
▪Off: Never hold
0
25
50
75
100
025 50 75 100
Flow - %
Travel - %
0
25
50
75
100
4 8 12 16 20
Flow - %
Control loop - mA
0
25
50
75
100
4 8 12 16 20
Flow - %
Control loop - mA
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▪On: Hold after the number of seconds specified in the next menu
oTime: 0-30 sec. Do not have any effect if Status is Off
Transmitter loop
Menu to select the Transmitter loop to be Direct or Reverse.
•Direct : 0% flow = 4mA
•Reverse : 0% flow = 20mA
The transmitter loop will go into an error position when there is an error in the error log. It is
possible to choose between none and two positions:
•None
•3.5mA +/- 0.2mA
•21.5mA +/- 0.2mA
Display
•In this menu it is possible to turn the display light on, off or set it to automatic. When set on
automatic the display light will turn on when using the keyboard and turn off after 5 min.
not using the keyboard.
•The contrast level of the display can be adjusted.
•The direction of the position shown on the front page can be reversed.
Status indicators
•Enable the extra status indicators on models that have these
MT control
•Status: Enable MT control on models that have that
•Auto lock status: Enable the auto lock function
•Auto lock time: Ste the auto lock time
0
25
50
75
100
4 8 12 16 20
Flow - %
Transmitter loop - mA
0
25
50
75
100
4 8 12 16 20
Flow - %
Transmitter loop - mA
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5.4.2 Advanced menu
Advanced menu Default Reset Description
1
Manual Control
Manual control of positioner.
1
Setpoint
Manual control of set point
2 Actuator Manual control of control valves
3 Actuator pulse Manual control of control valves using pulses only
4 Control valves Manual control of individual control valves
2 Signal Calibration Calibration of signals to control room
1 Control loop Calibration of 4-20 mA control signal
2 Transmitter loop Calibration of 4-20 mA transmitter signal
3 Position loop Calibration of 4-20 mA position loop
4 AI2 Calibration of 4-20 mA analogue input 1
5 AI3 Calibration of 4-20 mA analogue input 2
6 AI4 Calibration of 4-20 mA analogue input 3
7 AI5 Calibration of 4-20 mA analogue input 4
8 AO1 Calibration of 4-20 mA analogue output 1
9 AO2 Calibration of 4-20 mA analogue output 2
3 Configuration Configuration of in- and outputs
1 Valve function Configuration of valve control
1
Open
Not used A Menu to select valve position to open actuator
2 Close Not used A Menu to select valve position to close actuator
3 Stay-put Not used A Menu to select valve position to keep current actuator position
4 Fail position Off A Menu to select valve position at fail position
2 Position feedback Position feedback input
1 Position sensor A Potentiometer input
2 Position loop √4-20mA input
3 End position Configuration of endposition signal
1 Output signal 0% Not used A Select output which is active at 0%
2 Output signal 100% Not used A Select output which is active at 100%
3 Deadband 0.5% A Deadband for endpoint signal
4 Off/Local A Configure off/local signal
1 Off signal Not used A Select off signal input
2 Local signal Not used A Select local signal input
5 Man. valve control Configure the manaul control when in local mode
1Open signal Not used A Select input to open valve
2Close signal Not used A Select input to close valve
6 Emergency shutdown Configure Emergency shutdown
1 Input signal Not used A Select input to ESD signal
7 Error signal Configure error signal
1 Output signal Not used A Select output port for error signal
8 Ok signal Configure ok signal
1 Output signal Not used A Select output port for ok signal
9 Linear correction Calibrate the linearity of the position feedback
1 Status Enable the linear correction
2 Calibrate Perform the linear calibration
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