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DVG ITVC Series Installation, Set-Up, Operating & Service Manual

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

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Summary of Contents for DVG ITVC Series

  • Page 1 ITVC Series Intelligent Total Valve Controller BASIC version INSTALLATION SET-UP OPERATING ITVC & SERVICE MANUAL Document Number Prepared Approved Date Release IOM-ITVC 05/09/2017...

  • Page 3: Table Of Contents

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 DVG ITVC Series – “Intelligent Total Valve Controller” – Basic version LEGEND ...............................7 ITVC Intelligent Total Valve Controller .......................7 Introduction..............................8 General information ...........................8 Storage................................8 Applicable regulations ..........................9 Classification and Certification ........................9 Warnings..............................10 ITVC-features ............................12 Block diagram ..........................12 Main characteristics ........................13 Input and Output of ITVC ........................
  • Page 4 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 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 ......................
  • Page 5 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 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 ..........................
  • Page 6 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 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...

  • Page 7: Legend

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 1 LEGEND Work tools Necessary Protective Gloves Required Mechanical Operator Protective Shoes Required Operator Protective Glasses Required Advise Prohibited to alter or remove the nameplate 2 ITVC Intelligent Total Valve Controller ITVC...

  • Page 8: Introduction

    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.

  • Page 9: Applicable Regulations

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 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 –...

  • Page 10: Warnings

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 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.
  • Page 11 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 WARNING! Internal earth connection Earth conductor of cables must be electrically connected to ground. An earthing connection is provided internally 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.

  • Page 12: Itvc-Features

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 9 ITVC-features 9.1 Block diagram The main features of the ITVC electronic unit are:  To acquire the commands from control room To acquire the feedback from sensors of the actuator (position pressure, etc.) and ITVC hardware (temperature, ...

  • Page 13: Main Characteristics

    Operating temperature and enclosure suitable for application in field, according to limits reported in the  Classification/Certification paragraph  Separated mounting option Here below are listed the most important functions available and activated by DVG Automation according to the user request PST function (Partial Stroke Test) (see Annex A: PST function) ...

  • Page 14: Input And Output Of Itvc

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 9.3 Input and Output of ITVC This paragraph lists the inputs and outputs available in the ITVC electronics. These I/O’s are collected in two terminal blocks, one terminal block is available to user, for connection of signals with the control room, the other one is available for connection of the actuator signals (Solenoid operated Valves, transmitters, etc.).

  • Page 15: Itvc Terminal Blocks

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 9.6 ITVC Terminal blocks Actuator terminal block User terminal block ITVC Intelligent Total Valve Controller Electrical main power supply DVG AUTOMATION S.p.A. Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2 Tel.

  • Page 16: Operating Principle

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 9.7 Operating principle 9.7.1 Actuator control H/PCU: Hydraulic Pneumatic Control Unit: made of Solenoid Operated Valves, hydraulic and pneumatic valves, filter, directional valves, etc. to drive the Actuator in open and close direction.

  • Page 17: Esd Emergency Shutdown

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 Remote control type  Digital input: the hardwired digital signals control the actuator Bus: the commands by Modbus control the actuator Digital input and Bus: digital inputs and bus can control the actuator. The Bus commands have the priority over the digital inputs.

  • Page 18: Optional Panic Button

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 9.7.3 Optional Panic Button On demand, the ITVC can be equipped with an emergency Panic Button (PB) (push or pull operation can be set and the procedure is described in the paragraph Administrator menu, SETUP chapter). When engaged, ITVC drives the valve- actuator to its predetermined safe position.

  • Page 19: Interlock Function

    Unauthorised changes of parameters is prevented by 2 alphanumeric passwords, OPERATOR and ADMINISTRATOR. One further password is reserved to DVG Automation, for factory configuration of ITVC. By the password OPERATOR, the user can view all parameters, but can change few of them. By the password ADMINISTRATOR, the user can view all parameters and can modify a lot of them.

  • Page 20: Alarm, Mrt Alarm, Warning

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 9.7.11 Alarm, MRT Alarm, Warning The ITVC is provided with a powerful diagnostic program that monitors the hardware and the software execution and generates Alarms, MRT alarm Warning in case of malfunction. The table of the Alarms,...

  • Page 21: Test Of Coils Of Solenoid Operated Valves

    9.7.14 Measure of closing time At the end of every valve closure, the closing time is compared with the reference “closing time” set by DVG Automation. If the comparison fails the ITVC raises an Alarm. The user can measure the closing time by the procedure described in the paragraph “Stroking time test”, SETUP menu (it can be useful in the start-up phase to calibrate the...

  • Page 22: Examples Of Itvc Applications

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 9.8 Examples of ITVC applications Example 1: Hydraulic actuator, single acting spring return, analogue position and pressure transmitters Single acting spring return actuator H/PCU ITVC Hydraulic Intelligent Control Total Valve Unit Controller DVG AUTOMATION S.p.A.
  • Page 23 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 Example 2: Gas-over Oil actuator, double acting, remote electrical ESD DVG AUTOMATION S.p.A. Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2 Tel. (+39) 0523 255811; Fax (+39) 0523 255890;...

  • Page 24: Itvc Hmi (Itvc Human Machine Interface)

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10 ITVC HMI (ITVC Human Machine Interface) The ITVC is provided with a powerful Human Machine Interface (HMI). It allows the following operations: to set the actuator control mode in  LOCAL:...
  • Page 25 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 The below figure shows some icons of the display. When an icon flashes, the cursor is positioned on it. The following paragraphs shows the procedure to navigate in the ITVC menu. = Position:open...

  • Page 26: Home Page

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.1 HOME page In the normal operation the HMI display shows the HOME page. Depending on the ITVC configuration, three different HOME pages are available. The presence of the optional battery is shown by the icon , on the high, left corner of the display.

  • Page 27: Actuator Control Mode

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 The actuator works according to the configured actuator control mode, LOCAL, REMOTE, OFF: in LOCAL and in HOME page, the pushbuttons are available for menu operations  In LOCAL and in Local Command page, the pushbuttons ...

  • Page 28: Navigation In The Menu

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 The next figure shows the procedure to switch from HOME page to Local Command page without changing the actuator control mode. No password is required. This procedure enables the local actuator commands if the control mode is LOCAL.

  • Page 29: Menu Chart

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.1 MENU chart The following figure shows the flow chart of the ITVC menu. This IOM shows only the MENU chart with HOME MENU type”. In case of HPU and HIPPS type, the...

  • Page 30: Password Entry

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.2 Password entry The ITVC working parameters are protected against unauthorized changes by passwords. Two password levels are available, Operator ( ) and Administrator ( ). The default value of the Operator password is “1000”.

  • Page 31: Visualization Of Pressures

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 The above procedure allows viewing only the current Alarms, MRT alarms and Warnings. When an Alarm/Warning ceases, the list is automatically updated. In case of contemporary presence of Alarms and Warnings, only the Alarms can be viewed.

  • Page 32: Language Menu

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.5 LANGUAGE menu The following procedure allows setting the menu language. No password is required to change the menu language move the cursor on the icon a ß ṅ to switch to Setup/Language/Measurement page. By...

  • Page 33: Measurement Menu

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.6 MEASUREMENT menu This menu allows viewing the instantaneous and historical values and graphs of the variables managed by the ITVC. move the cursor on the icon switch to Setup/Language/Measurement page. By...

  • Page 34: Instantaneous Measures Sub-Menu

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.6.1 Instantaneous measures sub-menu  Pressure measure and MRT (Maximum Repair Time) sub-menu Pressure measure: the values are visible only if the relevant sensor are connected to ITVC If the pressure sensor is configured “absent”, the message of display is “NOT AVAILABLE”...
  • Page 35 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 Position-Temperature- Voltage-Oil turbidity-Motor current-Oil level-Accu strok, Micro 2 alarms  If the measure is not done (since the sensor is not present or the ITVC does not manage the data) the ...

  • Page 36: Historical Data Sub-Menu

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.6.2 Historical data sub-menu 24 hours records: L1, L2, S3, S4 pressure history, Position history.  The records are available only if the acquisition of data was previously enabled in the SETUP operation.

  • Page 37: Setup Menu

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 Event History:  The records are available only if the acquisition of data was previously enabled in the SETUP operation. This is shown by (enabled) and (disabled) in the MEASUREMENT page The following events are recorded: External ESD ...
  • Page 38 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 SETUP flow chart In the HOME page, by move the cursor on the icon then press , to view the SETUP/Language/Measurement page. By position the cursor on the icon , then press...

  • Page 39: Set Time And Date

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.7.1 Set Time and Date The function sets the current date and time of the ITVC. No password is required to set it. In the SETUP page, by select the icon 21-12-2012...

  • Page 40: Operator Menu

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.7.3 Operator menu Four options are available: Change password, Valve position led set, Firmware version, ITVC parameters. 10.3.7.3.1 Change password The default Operator password is “1000”. By the option “Change password” the Operator can enter its password.

  • Page 41: Firmware Version

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.7.3.3 Firmware version Logic board: Ver 5.1.0 May 2014 10.3.7.3.4 ITVC parameter Power board: Ver 4.0.0 June 2014 List of significant ITVC parameters: stroke duration, stroke delay, next service date, ITVC serial number, Modbus address, analogue channels, etc.

  • Page 42: Change Password

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.7.4.1 Change password The default Administrator password is “00001”. By the option “Change password” the Administrator can enter its password. As the new password is entered the old one is no longer valid. Enter one character at a time, enter 5 10.3.7.4.2 Digital inputs...

  • Page 43: Output Relays

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.7.4.3 Output relays The ITVC has 4 latching SPST output relay R1, R2, R3, R4 (see paragraph Output Signalling Relays). For each relay can be configured: Action of contact when the “condition to trip” occurs: make (close the contact) or break (open the...
  • Page 44 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 The below figure shows the procedure to configure one relay and the Modbus 1 and 2 parameters. DVG AUTOMATION S.p.A. Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2 Tel.

  • Page 45: Temperature Limits

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.7.4.5 Temperature limits When warning limits are exceeded (75°C) the ITVC raises a warning. When alarm limits are exceeded (maximum and minimum) the ITVC raises an alarm and drive the actuator according to the configured option (inhibit all or go to safe 10.3.7.4.6 Service date...
  • Page 46 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 The below figure shows the procedure to configure the Temperature limits, the Service date, the Valve tag, the valve maker and to view the ITVC serial number and Max stroke time. The following figure shows the procedures Coil test, Local/Remote controls and L/S calibration Calibration L/S: Set the Local Selector in “LOCAL”...
  • Page 47 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 Coil test, Local/Remote control, Calibration L/S DVG AUTOMATION S.p.A. Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2 Tel. (+39) 0523 255811; Fax (+39) 0523 255890; 9001, ISO 14001, OHSAS 18001 Fully Paid In Capital: Euro 1.000.000,00=...
  • Page 48 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 The following figure shows the procedure to set ESD shutdown, MRT and Operator menu DVG AUTOMATION S.p.A. Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2 Tel. (+39) 0523 255811; Fax (+39) 0523 255890;...

  • Page 49: Stroke Time Calibration

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.7.4.16 Stroke time calibration The sub-menu starts the procedure that records the closing stroke time, by moving the valve. If the valve is open the ITVC closes the valve. If the valve is closed the ITVC open the valve and then closes it. The function is available only if the actuator control mode is “LOCAL”...

  • Page 50: Pressure Eng Unit

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.7.4.18 Pressure eng unit The sub-menu allows setting the engineering unit of the pressure. The available options are: MPag, psig, barg and kg/cm2 10.3.7.4.19 OP after PB action The sub-menu allows setting the reset mode of panic Button action if the Panic Button mode is latched (automaintained).

  • Page 51: Analog Inputs

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 10.3.7.4.22 Analog inputs The sub-menu allows setting the variable connected to the analogue input channels. The set of type of variable and hardware channel must be previously done by the ITVC manufacturer. This sub-menu allows setting the availability...

  • Page 52: Installation

    ITVC 24 VDC M.C.C. type: 25 A curve D (unless already included in M.C.C. by DVG)  DVG reserves the right to advise different sizes of circuit breakers based on the configuration of the systems to be controlled. This information will be recorded on the wiring diagrams supplied with the apparatus.

  • Page 53: Cable Size

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 11.2 Cable size ITVC Power cables: max. 10mm² Signal cables: max. 2,5mm² (Use of shielded cables is recommended, especially for analogue signals) Earthing and protective conductors: Minimum cross-sectional area of protective conductors (IEC 60079-0 Table 10) (S = cross sectional area of phase conductor [mm ];...

  • Page 54: Solenoid Operated Valves Fuses

    Fuses for 8 Solenoid Operated Valves are located under the upper right cover. DO NOT OPEN the covers in hazardous area (i.e. in presence of explosive atmosphere). FUSES MUST BE REPLACED IN A SAFE AREA AND USING ONLY DVG ORIGINAL PARTS.

  • Page 55: Input/Output Electrical Characteristics

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 11.6 Input/output electrical characteristics This paragraph describes the characteristics of the input and output channels available in the ITVC electronics in the customer and actuator terminal blocks. Customer terminal block: Digital inputs: ...

  • Page 56: Troubleshooting

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 13 Troubleshooting ITVC has a powerful diagnostic program to monitor the operation of system “ITVC-Actuator-Pneumatic/Hydraulic” control unit. In case of ITVC malfunction and depending on the type of malfunction the ITVC raises an Alarm, a MRT alarm, a Warning.
  • Page 57 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 Alarm displayed Potential cause Action NO 5VAP ITVC failure Reset alarm. If alarm persists, replace ITVC OVER TEMPERATURE Internal ITVC max temp. exceeded Solve cause of overheating and restore ITVC CRC ERROR ITVC failure Reset alarm.
  • Page 58 ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 Alarm displayed Potential cause Action CTO-CTO ELV n (n= 1÷8) Short circuit of SOV No. n Check SOVs, coils and connections MICRO 2 ALARM ITVC failure Reset alarm. If alarm persists, replace ITVC...

  • Page 59: Decommissioning

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 14 Decommissioning Disposal and recycling At the end of the life the ITVC must be disassembled. WARNING! Do not dump non-biodegradable products, lubricants and non-ferrous (rubber, resins, PVC, etc.) into the environment. Dispose of all such materials as indicated in the below table...

  • Page 60: Start-Up Procedure

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 15 Start-up procedure 15.1 General checks Before powering the ITVC the following check should be done:  Temperature: it should be correct for the installation and according to the value indicated in the label on the...

  • Page 61: Test Of Absorption Of Coil Of Solenoid Operated Valves

    The above test is not necessary if the ITVC is supplied together with the actuator and pneumatic / hydraulic control unit assembled in DVG Automation facility. In this case the test is done in factory, in the test operations. 15.4 Test of Stroke time The test measures the closing time by moving the valve.

  • Page 62: Battery Option

    MINIMUM BATTERY OPERATING TIME IN MONITORING MODE (ITVC disconnected from power supply; No. 3 sensors + No. 1 position sensors connected) STANDARD BATTERY: 12 hours (battery capacity 53Wh) - DVG P/N: CBAEOZZ0001 EXTENDED BATTERY: 36 hours (battery capacity 160Wh) - DVG P/N: CBAEOZZ0002 In case of power supply failure, battery recharge cycle will start automatically when power supply is restored.

  • Page 63: Setting Options In The Administrator Menu

    ITVC Series – Intelligent Total Valve Controller IOM-ITVC-Basic-05 Local signalling: If the battery is enabled the HOME page of the ITVC HMI shows the icon . The icon shows also the charge level of battery. If the battery is discharged or unconnected the ITVC raises an alarm and the icon is The LED of pushbutton lights-up, red colour, the Open and Close actuator commands are available and work.

  • Page 64: Warranty

    WARRANTY DVG Automation S.p.a. products are warranted to be free from defects in materials and workmanship for a period of eighteen months from the date of delivery (unless otherwise agreed when ordering) if they are used according to DVG Automation S.p.a. recommended usages. DVG Automation S.p.a.’s liability is limited to the repair, purchase price refund, or replacement in kind, at DVG Automation S.p.a.’s sole option, of any products proved...

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