Val Controls IHP24-A, IHP24-B, IHP24-AF, IHP24-F, IHP24-BF User Manual

DHP-UM-020

Val Controls A/S • Limfjordsvej 3 • DK-6715 Esbjerg N • Tel. [phone] • Fax [phone]

[e-mail] • www.valcontrols.com

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. [phone] • Fax [phone]

[e-mail] • www.valcontrols.com

Revision: 12

2/38

Table of contents

1 General ......................................................................................................................................... 3

1.1 Safety instructions ................................................................................................................................ 3

2 Application .................................................................................................................................. 4

3 Installation guide ........................................................................................................................ 6

4 User 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

5 Menus ......................................................................................................................................... 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

6 Regulators .................................................................................................................................. 26

6.1 Electronic stepping ............................................................................................................................. 26

6.2 Mechanical stepping ........................................................................................................................... 26

6.3 Proportional ........................................................................................................................................ 26

7 Error 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

8 Software revision list ................................................................................................................ 37

DHP-UM-020

Val Controls A/S • Limfjordsvej 3 • DK-6715 Esbjerg N • Tel. [phone] • Fax [phone]

[e-mail] • www.valcontrols.com

Revision: 12

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1 General

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.

DHP-UM-020

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2 Application

Val Controls intelligent hydraulic positioner controls almost all hydraulic, linear, rotary, single­return (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

DHP-UM-020

Val Controls A/S • Limfjordsvej 3 • DK-6715 Esbjerg N • Tel. [phone] • Fax [phone]

[e-mail] • www.valcontrols.com

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Power supply

Communication

Hydraulic system

Pump

Pressure

ReturnSupply

1 3 4 5 6 7 8 9 1011 122

13 1516171819 202122232414

55%

Valve Position

Calibrate MenuError Status

OK

Val Controls IHP24

Position

Control valve signals

Figure 2: IHP24-B

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3 Installation 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.

DHP-UM-020

Val Controls A/S • Limfjordsvej 3 • DK-6715 Esbjerg N • Tel. [phone] • Fax [phone]

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4 User 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.

DHP-UM-020

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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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5 Menus

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

DHP-UM-020

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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