VRG Controls RCVC 3000 User manual

VRG CONTROLS LLC. 1 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
VRG Controls LLC. 1 of 35 JANUARY 2019
Applicable Models:
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VPC “SN” SERIES VALVE PILOT CONTROLLER
INSTRUCTION MANUAL
PATENT NO.:
US 9,400,060 B2
VPC PED ATEX Tag - Proof 3
Extreme-Tough
3.05” x 1.84”
OCTOBER 25, 2019
PATENT NO.:
US 9,400,060 B2
US 10,234,047 B2
RCVC 3000
INSTRUCTION MANUAL
Applicable Models:
This Instruction Manual applies to the following VRG - RCVC 3000. To conrm suitability for
additional models and/or componenents, please contact VRG Controls or view us online at
www.vrgcontrols.com
RCVC 3000
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual

VRG CONTROLS LLC. 2 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
DESCRIPTION PAGE
Scope of Manual 3
Technical Assistance 3
Features 3
Warnings 3
RCVC Specications 4
Navigation Wheel Tasks 5-9
USB Cable Setup Tasks 10-18
Figure 1: Wiring Diagram RCVC Analog Potentiometer Transmitter 19
Figure 2: Wiring Diagram RCVC Digital Potentiometer Transmitter 20
Figure 3: Wiring Diagram RCVC with Ballu󰀨 Model BTL5 Linear Sensor 21
Figure 4: Wiring Diagram Remote RCVC Analog
Potentiometer Transmitter
22
Figure 5: Wiring Diagram Remote RCVC with Ballu󰀨 Model BTL 7
Linear Sensor
23
Figure 6: Wiring Diagram Remote RCVC with Ballu󰀨 Model BTL 5
Linear Sensor
24
Ballu󰀨 Calibration 25-29
Figure 7: Spring to Open Ball Control Valve with RCVC, VMO &
Ballu󰀨 TRM: XA-6015-AP01
30
Figure 8: Spring to Open Ball Control Valve with RCVC, VMO &
Ballu󰀨 TRM: XA-6018-AP01
31
Figure 9: Spring to Open Ball Control Valve with RCVC, VMO &
Ballu󰀨 TRM - Fail Closed
32
Figure 10: Spring to Open Glove Control Valve with RCVC, VMO &
Ballu󰀨 TRM
33
Figure 11: Spring to Close Globe Control Valve with RCVC &
Ballu󰀨 TRM
34
Figure 12: Spring to Close Glove Control Valve with RCVC, VMO &
Ballu󰀨 TRM
35
Figure 13: Double Acting Ball Control Valve with RCVC, VMO &
Ballu󰀨 TRM
36
Figure 14: Double Acting Ball Control Valve with RCVC, VMO &
Ballu󰀨 TRM. Up to 250psig
37
Figure 15:Spring to Open Ball Control Valve with RCVC, VMO &
Ballu󰀨 TRM, and Pressure Override
38
Table of Contents

VRG CONTROLS LLC. 3 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
Scope of Manual
This Insturction Manual provides instructions for
operation, maintenance, adjustment and troubleshooting of
VRG Controls RCVC - Red Circle Valve Controller.
Conguration Methods
1. Navigation Wheel
2. Setup Application vis USB Setup Cable
Features
• Reverse Valve Action: Can easily switch between Direct
Acting and Reverse Acting.
• Three states of Edit Fail Modes: Lock Last, Fail Open
and Fail Close
• Three modes of Lockup Mode: Lock up Open, Lock up
Close or both.
• Split Range Conguration: Can set to any Range
• Dead Band Calibration for Open and Close: can be inde-
pendently set.
• Pulse Control: can adjust the Range when the Pulse is
activated
• Pulse Zone Timers: Adjust the length and duration of
pulse
• Fixed Command: Output for Pilot Override Applications
• Enable Anti-Surge Control: Set the Range for when the
Surge will Activate.
• Various Alarm Functions dependent on Failure State.
• Zero Out Solenoid Count: Can reset for new Solenoids
both Open and Close Count.
• Remote Command and Remote Override using 24VDC.
Technical Assistance
Should you have any questions, you may
contact your local VRG Controls sales representative or
VRG Controls technical assistance at:
VRG Controls
Attn: 1199 Flex Court
Lake Zurich, IL 60047
Toll-Free: 844-FLOW-VRG (844-356-9874)
Tel: + 1 847-778-6740
e-mail: [email protected]
websight: www.vrgcontrols.com
To facilitate requests for technical assistance, please have
the following information immediately available:
• Job number or serial number
• Fail states or messages
• Command signal Conguration
4ma to open or 20ma to open
• Interaction method
(navigation wheel or computer software)
Warning
Do NOT use a multimeter to check the feedback readings.
Do NOT use a multimeter to check feedback Retransmission
Signal. By connecting the negative lead to the feedback
(AI1) and the positive lead to 24 VDC, you will short out the
board. This will require a replacement board to x the issue.
Warning
The new RCVC app is not compatible with the old setup
les. To use the new RCVC you will need to load a new
setup le into the RCVC. The new setup les are compati-
ble with the old VRG Programming Application. Any RCVC
purchased after 3/1/2021 will have the new setup le already
installed in the RCVC.
Navigation Wheel USB Setup Cable

VRG CONTROLS LLC. 4 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
Table 1.0 RCVC Specications
Power Supply
Power Supply 19-30 VDC
RCVC Module Current 50mA max
RCVC Total Assembly Rating 2A max
Onboard Fuse Limitron: FNQ-R-2 600VAC IR 200kA
Digital Outputs
Congurable Solenoids 3 Max
Voltage 24 VDC
Load Current (max) 1.0 Amps
Digital Inputs
No. Digital Inputs 2 (Congurable)
Voltage 24 VDC
Input Current 5.0 mAmps
Digital Outputs
No. Digital Outputs 3 (Open Sol, Close Sol, Auxiliary)
Voltage 24 VDC
Load Current (max) 250 mAmp
Analogue Inputs
No. Analogue Inputs 2 (Feedback, Command)
Input Type Current / Voltage
Voltage Input Range 1 - 5.0 VDC
Voltage Input Impedance 100 kOhms
Current Input Range 4 - 20 mA
Current Input Impedance 300 Ohms
Resolution 1 in 3600
Analogue Outputs
Output Type Current / Voltage
Voltage Output Range 4.0 - 20.0 ma / 0 - 3.0 VDC
Resolution 1 in 3600
Solenoid Ohms
AAA 58 - 65 Ohms
Asco 43 - 54 Ohms

VRG CONTROLS LLC. 5 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
Navigation Wheel Common Tasks
1. Local Manual Operation
2. Command Signal Calibration
3. Feedback Signal Calibration
4. Retransmission Signal Calibration
5. Reverse Valve Action
6. Edit Fail Modes
7. Edit Lockup Mode
8. Split Range Conguration
9. Determine RCVC Version
10. Zero Out Solenoid Count
#1 Local Manual Operation
1. Apply 24 VDC Power Supply to RCVC
2. SHORT PUSH Navigation Wheel on RCVC Head
to enter MANUAL mode.
3. Rotate Navigation Wheel AWAY (CW) to increase
valve position percentage (%).
4. Rotate Navigation Wheel to NEUTRAL (center)
position to hold position.
5. Rotate Navigation Wheel Toward (CCW) to
decrease valve position percentage (%).
6. Rotate Navigation Wheel to NEUTRAL (center)
position to hold position.
7. Return Navigation Wheel to Neutral (Center)
Rotation Position. SHORT PUSH Navigation
Wheel on RCVC Head to exit Manual mode.
RCVC display Header should read AUTOMATIC.
#2 Command Signal Calibration
1. Apply 24 VDC Power Supply to RCVC
2. SHORT PUSH Navigation Wheel on RCVC Head
to enter MANUAL mode.
3. LONG PUSH Navigation Wheel on RCVC Head to
enter MENU mode.
4. Select “Application” and SHORT PUSH to enter.
5. Select “Physcial I/O” and SHORT PUSH to enter.
Navigation Wheel

VRG CONTROLS LLC. 6 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
6. Select “Analogue Inputs” and SHORT PUSH to
enter.
7. Select “Command Signal” and SHORT PUSH to
enter.
8. Select “Calibration” and SHORT PUSH to enter.
9. Select “New Calibration” and SHORT PUSH to
enter.
10. Select “Minimum” and SHORT PUSH to enter.
11. Apply 4.0 mA Command Signal (MIN) and
SHORT PUSH to enter.
12. Select “Maximum” and SHORT PUSH to Enter.
13. Apply 20 mA Command Signal (MAX) and
SHORT PUSH to Enter.
14. Rotate Navigation Wheel to ESC Position to
reselect NEW CALIBRATION.
15. Rotate Navigation Wheel Toward (CCW) to
select SAVE CALIBRATION and SHORT PUSH
to enter.
16. Rotate Navigation Wheel to HOLD ESC Position
until menu stops at MANUAL on DISPLAY
HEADER.
17. Return Navigation Wheel to Neutral (Center)
Rotation Position. SHORT PUSH Navigation
Wheel on RCVC Head to exit MANUAL mode.
RCVC display Header should read AUTOMATIC.
#3 Feedback Signal Calibration
1. Apply 24 VDC Power Supply to RCVC
2. SHORT PUSH Navigation Wheel on RCVC Head
to enter Manual mode.
3. LONG PUSH Navigation Wheel on RCVC Head to
enter MENU mode.
4. Select “Application” and SHORT PUSH to enter.
5. Select “Physical I/O” and SHORT PUSH to enter.
6. Select “Analogue Inputs” and SHORT PUSH to
enter.
7. Select “Feedback” and SHORT PUSH to enter.
8. Select “Calibration” and SHORT PUSH to enter.
9. Select “New Calibration” and SHORT PUSH to
enter.
10. Select “Minimum” and SHORT PUSH to enter.
11. Use VMO or other method Stroke control valve
to VALVE OPEN (MIN) position and SHORT

VRG CONTROLS LLC. 7 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
PUSH to enter.
12. Select “Maximum” and SHORT PUSH to enter.
13. Use VMO or other method Stroke control valve
to VALVE CLOSED (MAX) position and SHORT
PUSH to enter.
14. Rotate Navigation Wheel to ESC Position to
reselect NEW CALIBRATION.
15. Rotate Navigation Wheel Toward (CCW) to
select SAVE CALIBRATION and SHORT PUSH
to enter.
16. Rotate Navigation Wheel to HOLD ESC Position
until menu stops at MANUAL on DISPLAY
HEADER.
17. Return Navigation Wheel to Neutral (Center)
Rotation Position. SHORT PUSH Navigation
Wheel on RCVC Head to exit MANUAL mode.
RCVC display Header should read AUTOMATIC.
#4 Retransmission Signal Calibration
1. Apply 24 VDC Power Supply to RCVC
2. SHORT PUSH Navigation Wheel on RCVC Head
to enter Manual mode.
3. LONG PUSH Navigation Wheel on RCVC Head to
enter MENU mode.
4. Select “Application” and SHORT PUSH to enter.
5. Select “Physical I/O” and SHORT PUSH to enter.
6. Select “Analogue Outputs” and SHORT PUSH to
enter.
7. Select “Feedback” and SHORT PUSH to enter.
8. Select “Calibration” and SHORT PUSH to enter.
9. Select “New Calibration” and SHORT PUSH to
enter.
10. Select “Minimum” and SHORT PUSH to enter.
11. Use Navigation Wheel to set the Value so the
Output is equal to 4 ma, then SHORT PUSH to
save value.
12. Select “Maximum” and SHORT PUSH to enter.
13. Use Navigation Wheel to set the Value so the
Output is equal to 20 ma, then SHORT PUSH to
save value.
14. Rotate Navigation Wheel to ESC Position to
reselect NEW CALIBRATION.
15. Rotate Navigation Wheel Toward (CCW) to
select SAVE CALIBRATION and SHORT PUSH
to enter.
16. Rotate Navigation Wheel to HOLD ESC Position
until menu stops at MANUAL on DISPLAY
HEADER.
17. Return Navigation Wheel to Neutral (Center)
Rotation Position. SHORT PUSH Navigation
Wheel on RCVC Head to exit MANUAL mode.
RCVC display Header should read AUTOMATIC.
#5 Reverse Valve Action
1. Apply 24 VDC Power Supply to RCVC
2. Apply Command Signal to RCVC
3. SHORT PUSH Navigation Wheel on RCVC Head
to enter MANUAL mode.
4. LONG PUSH Navigation Wheel on RCVC Head to
enter MENU mode.
5. Select “Application” and SHORT PUSH to enter.
6. Select “Physical I/O” and SHORT PUSH to enter.
7. Select “Analogue Inputs” and SHORT PUSH to
enter.
8. Select “Command Signal” and SHORT PUSH to
enter.
9. Select “Sensor Range” and SHORT PUSH to
enter.
10. Select “Minimum” and SHORT PUSH to enter.
11. Use Navigation Wheel TOWARD (CCW) to ad
just value to 100% on Minimum. SHORT PUSH
to enter.
12. Select “Maximum” and SHORT PUSH to enter.
13. Use Navigation Wheel AWAY (CW) to adjust
value to 0.0% on Minimum. SHORT PUSH to
enter.
14. Rotate Navigation Wheel to HOLD ESC Position
until menu stops at MANUAL on DISPLAY
HEADER.
15. Return Navigation Wheel to Neutral (Center)
Rotation Position. SHORT PUSH Navigation
Wheel on RCVC Head to exit MANUAL mode.
RCVC display Header should read AUTOMATIC.

VRG CONTROLS LLC. 8 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
#6 Edit Fail Modes
1. Apply 24 VDC Power Supply to RCVC
2. Apply Command Signal to RCVC
3. SHORT PUSH Navigation Wheel on RCVC Head
to enter MANUAL mode.
4. LONG PUSH Navigation Wheel on RCVC Head to
enter Menu mode.
5. Select “Application” and SHORT PUSH to enter.
6. Select “System Data” and SHORT PUSH to enter.
7. Select “System Inputs” and SHORT PUSH to
enter.
8. For FAIL OPEN Mode:
A. Select Line 8 - “Fault Open” and Click
Radio Button Current Status = “ACTIVE”
B. Select Line 9 - “Fault Close” and Click
Radio Button Current Status = “OFF”
9. For FAIL CLOSED Mode:
A. Select Line 8 - “Fault Open” and Click
Radio Button Current Status = “OFF”
B. Select Line 9 - “Fault Close” and Click
Radio Button Current Status = “ACTIVE”
10. For FAIL LAST Mode:
A. Select Line 8 - “Fault Open” and Click
Radio Button Current Status = “OFF”
B. Select Line 9 - “Fault Close” and Click
Radio Button Current Status = “OFF”
#7 Edit Lockup Mode
1. Apply 24 VDC Power Supply to RCVC
2. Apply Command Signal to RCVC
3. SHORT PUSH Navigation Wheel on RCVC Head
to enter MANUAL mode.
4. LONG PUSH Navigation Wheel on RCVC Head to
enter Menu mode.
5. Select “Application” and SHORT PUSH to enter.
6. Select “System Data” and SHORT PUSH to enter.
7. Select “System Inputs” and SHORT PUSH to
enter.
8. For LOCKUP OPEN Mode:
A. Select Line 11 - “Lockup Open” and Click
Radio Button Current Status = “ACTIVE”
B. Select Line 12 - “Lockup Close” and Click
Radio Button Current Status = “OFF”
9. For LOCKUP CLOSED Mode:
A. Select Line 11 - “Lockup Open” and Click
Radio Button Current Status = “OFF”
B. Select Line 12 - “Lockup Close” and Click
Radio Button Current Status = “ACTIVE”
1. Apply 24 VDC Power Supply to RCVC
2. Apply Command Signal to RCVC
3. SHORT PUSH Navigation Wheel on RCVC Head
to enter MANUAL mode.
4. LONG PUSH Navigation Wheel on RCVC Head to
enter MENU mode.
5. Select “Application” and SHORT PUSH to enter.
6. Select “System Data” and SHORT PUSH to enter.
7. Select “System Values” and SHORT PUSH to
enter.
8. Select Value 4 Open Limit and SHORT PUSH to
enter.
A. Set Open Limit to desired value when
Lockup needs to engage.
9. Select Value 5 Close Limit and SHORT PUSH to
enter.
A. Set Close Limit to desired value when
Lockup needs to engage.
Mode Line 8 -
Fault Open
Line 9 -
Fault Close
Fail OPEN
Loss 4-20 mA
ACTIVE OFF
Fail CLOSED
Loss 4-20 mA
OFF ACTIVE
LOCK LAST
Loss 4-20 mA
OFF OFF
Mode Line 11 -
LOCKUP OPEN
Line 12 -
LOCKUP CLOSED
LOCKUP OPEN ACTIVE OFF
LOCKUP CLOSED OFF ACTIVE

VRG CONTROLS LLC. 9 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
#8 Split Range Conguration
1. Apply 24 VDC Power Supply to RCVC
2. Apply Command Signal to RCVC
3. SHORT PUSH Navigation Wheel on RCVC Head
to enter Manual mode.
4. LONG PUSH Navigation Wheel on RCVC Head to
enter MENU mode.
5. Select “Application” and SHORT PUSH to enter.
6. Select “Physical I/O” and SHORT PUSH to enter.
7. Select “Analogue Inputs” and SHORT PUSH to
enter.
8. Select “Command Signal” and SHORT PUSH to
enter.
9. Select “Calibration” and SHORT PUSH to enter.
10. Select “New Calibration” and SHORT PUSH to
enter.
11. Select “Minimum” and SHORT PUSH to enter.
12. Apply desired Command Signal value (## mA
Custom Value Here) for VALVE CLOSED
position (MIN) and SHORT PUSH to enter.
13. Select “Maximum” and SHORT PUSH to enter.
14. Apply desired Command Signal value (## mA
Custom Value Here) for VALVE OPEN position
(MAX) and SHORT PUSH to enter.
15. Rotate Navigation Wheel to ESC Position to
reselect NEW CALIBRATION.
16. Rotate Navigation Wheel Toward (CCW) to
select SAVE CALIBRATION and SHORT PUSH
to enter.
17. Rotate Navigation Wheel to HOLD ESC Position
until menu stops at MANUAL on DISPLAY
HEADER.
18. Return Navigation Wheel to Neutral (Center)
Rotation Position. SHORT PUSH Navigation
Wheel on RCVC Head to exit MANUAL mode.
RCVC display Header should read AUTOMATIC.
#9 Determine RCVC Version
1. Apply 24 VDC Power Supply to RCVC
2. SHORT PUSH Navigation Wheel on RCVC Head
to enter MANUAL mode.
3. LONG PUSH Navigation Wheel on RCVC Head to
enter MENU mode.
4. Scroll to SETTINGS and SHORT PUSH to select.
5. Scroll to ABOUT and SHORT PUSH to select.
6. SOFTWARE VERSION will read
A. “V3.13.3” for RCVC 1000
B. “V4.10.2” for RCVC 2000
C. “V4.24.6” for RCVC 3000
#10 Zero Out Solenoid Count
1. Apply 24 VDC Power Supply to RCVC
2. SHORT PUSH Navigation Wheel on RCVC Head
to enter MANUAL mode.
3. LONG PUSH Navigation Wheel on RCVC Head to
enter MENU mode.
4. Select “Application” and SHORT PUSH to enter.
5. Select “System Data” and SHORT PUSH to enter.
6. Scroll to “Open Sol. Count” and SHORT PUSH to
enter.
7. Select “Value” and SHORT PUSH to enter.
8. Use the Wheel to decrease the value to Zero and
SHORT PUSH to save.
9. Rotate Navigation Wheel to ESC position to exit
OPEN SOL COUNT.
10. Select “Close Sol Count” and SHORT PUSH to
enter.
11. Select “Value” and SHORT PUSH to enter.
12. Use the wheel to decrease the value to Zero and
SHORT PUSH to save.
13. Rotate Navigation Wheel to HOLD ESC Position
until menu stops at MANUAL on DISPLAY
HEADER.
14. Return Navigation Wheel to Neutral (Center)
Rotation Position. SHORT PUSH Navigation
Wheel on RCVC Head to exit MANUAL mode.
RCVC display Header should read AUTOMATIC.

VRG CONTROLS LLC. 10 of 39 MAY 2021
RCVC 3000 - Red Circle Valve Controller
Installation, Operation, Maintenance Manual
1 RCVC PROGRAMMING OVERVIEW
RCVC Programming Application is a windows based stand-
alone piece of software which is used to communicate with a
RCVC using a wired Modbus communication
protocol.
2 INSTALLATION
2.1 System Requirements
To ensure proper functionality of the RCVC programming ap-
plication a standard PC is required with at least the following
system resources:
• 1 gigahertz (GHz) or faster 32-bit (x86) or 64-bit (x64)
processor
• 1 gigabyte (GB) RAM (32-bit) or 2 GB RAM (64-bit)
• Screen resolution at least 1024 x 768 pixels
2.2 Operating Systems
The RCVC programming application will run on the following
operating systems:
• Windows 7 SPI (32 and 64 bit)
• Windows 8.1 (32 and 64 bit)
• Windows 10 (32 and 64 bit)
2.3 Hard Disk Space
The RCVC programming application requires approximately
20MB of hard disk space.
2.4 Installation
Extract the installation package to the local disk. Follow the
instructions on the setup wizard to complete the installation.
3 CONNECTION DETAILS
3.1 Modbus Modern
The USB-RS485 modbus modern recommended to be used
to communicate between RCVC programming application
and a RCVC is:
• DSD Tech SH-U10 USB to RS485 Converter with
CP2102 chip compatible with Windows 7, 8 and 10
3.2 Modbus Connection to a RCVC
To connect from a Modbus modem to a RCVC the positive
terminal of the modem must be connected to MOD+ of the
RCVC terminal, and the negative terminal of the modem
must be connected to MOD- of the RCVC terminal.
It must be noted that the specied baud rate and Modbus
address in the RCVC must match the set baud rate and
address in RCVC programming application in order for the
communication to be successful.
4 RCVC PROGRAMMING APPLICATION USER
GUIDE
4.1 Loading Page
When rst loading RCVC Programming Application the
following screen will be shown:
• File Structure - this area contains a list of all controllers
that have been connected to and can be loaded by dou-
ble clicking on a le. They are split into three sections:
• Online - the project and application of the controller
currently connect to
• O󰀪ine - a list of all projects and applications
(read-only)
• Standards - a list of saved standard applications
which can be re-used on projects to ensure similar
setups
• Application Details - detail;s of the application currently
loaded into the RCVC Programming Application
• RCVC Status - Indicates whether a controller is
connected and “Online” or not connected and “O󰀪ine”
• Current File - the program name of the application
loaded
• Main Interactive Area - the area where the application
is shown and can be interacted with. An application is
loaded when a le is double-clicked in the le structure
or when a RCVC is connected to