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Val Controls IDC24-A, User Manual

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Val Controls IDC24-A User Manual Download Page 49

 
 

 

DID-UM-002 

Val Controls A/S 

•

 Limfjordsvej 3 

•

 DK-6715 Esbjerg N 

•

 Tel. +45 7547 0600 

[email protected] 

•

 www.valcontrols.com 

Revision: 10 

 

 

49/74 

No. 462 

FST error: Breakaway timeout 

Description 
 

Breakaway is not detected before the Breakaway timeout was exceeded 
 

Trouble shooting 
 

This error may be due to: 

•

 

Blocked output of actuator 

•

 

Solenoid valve is stuck 

This error can be solved by: 

•

 

Clear the output of the actuator 

•

 

Increasing the Breakaway timeout 

 

 

Summary of Contents for IDC24-A

Page 1: ...j 3 DK 6715 Esbjerg N Tel 45 7547 0600 vc valcontrols com 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 ...

Page 2: ...ion ValConnect 11 6 Diagnostic 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 7 Calibration 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 8 Test errors 30 8 1 Par...

Page 3: ... 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 ...

Page 4: ...10 4 74 2 Application 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 ...

Page 5: ...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 ...

Page 6: ...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 ...

Page 7: ...OV 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 ...

Page 8: ...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 Descriptio...

Page 9: ...lay 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 connect...

Page 10: ...n 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...

Page 11: ... 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 ...

Page 12: ...ck 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 p...

Page 13: ...DID UM 002 Val Controls A S Limfjordsvej 3 DK 6715 Esbjerg N Tel 45 7547 0600 vc valcontrols com www valcontrols com Revision 10 13 74 Figure 2 PST time definitions ...

Page 14: ... 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 fl...

Page 15: ...low 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 ...

Page 16: ...tal 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 b...

Page 17: ...DID UM 002 Val Controls A S Limfjordsvej 3 DK 6715 Esbjerg N Tel 45 7547 0600 vc valcontrols com www valcontrols com Revision 10 17 74 Figure 5 Breakaway timeout Figure 6 PST timeout ...

Page 18: ...DID UM 002 Val Controls A S Limfjordsvej 3 DK 6715 Esbjerg N Tel 45 7547 0600 vc valcontrols com www valcontrols com Revision 10 18 74 Figure 7 PST total timeout Figure 8 Minimum breakaway pressure ...

Page 19: ...DID UM 002 Val Controls A S Limfjordsvej 3 DK 6715 Esbjerg N Tel 45 7547 0600 vc valcontrols com www valcontrols com Revision 10 19 74 Figure 9 Minimum allowed pressure ...

Page 20: ... 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 ...

Page 21: ...he deviations from the reference signature are small In cases like this the signatures must be extracted and analysed visually The Figure 11 shows a signature from a valve with increased torque which leads to uneven movement The measured times and pressures for this test does not give an error but in time the performance cab get so bad that it will give errors Figure 11 Rough movement ...

Page 22: ...est The full stroke test will move the valve from 100 0 100 The test can be initiated from the test menu a communication protocol or a digital input depending on the configuration Signatures from typical full strokes shown in Figure 12 and Figure 13 including definitions on the different terms further used in this manual Figure 12 FST time definitions ...

Page 23: ...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 limits it will run until finished and then the warning parameters ...

Page 24: ...T timeout Reference total time Total timeout 2 Reference total time Minimum breakaway pressure Reference pressure at 50 The Start pressure error limits are not set automatically and function is disabled The full stroke warning parameters are set to the following values Low breakaway time Reference breakaway time 50 High breakaway time Reference breakaway time 50 Low breakaway pressure Reference br...

Page 25: ...DID UM 002 Val Controls A S Limfjordsvej 3 DK 6715 Esbjerg N Tel 45 7547 0600 vc valcontrols com www valcontrols com Revision 10 25 74 Figure 15 FST timeout Figure 16 Total timeout ...

Page 26: ...of the solenoid operated valve SOV The test can be initiated from the test menu a communication protocol or a digital input depending on the configuration System without pressure sensor System is detecting movement in the system to verify SOV performance System with pressure sensor System is detecting pressure drop in the system to verify SOV performance Below is a signature from a typical solenoi...

Page 27: ...ditions are as follow Valve must be at the operational position Pressure must be within the Start pressure low and Start pressure high limits This function can be disabled 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 lim...

Page 28: ...nce breakaway time Total timeout Total time 2 The Start pressure error limits is not set automatically and the function is disabled For the solenoid test the error parameters are set to the following values when not using pressure sensor Reaction timeout Reference breakaway time 2 Total timeout Total time 2 6 4 Emergency shutdown test When an Emergency shutdown test has been recorded then it can b...

Page 29: ...lve must not have a travel time larger than 300 seconds The steps in the automatic calibration can be performed individually from the calibration menu 7 2 Endpoint calibration The endpoints calibration set the travel endpoints It can be used if the position signal has been changed 7 3 PST reference Records a partial stroke reference signature and set the partial stroke error and warning parameters...

Page 30: ...erational position Perform an endpoint calibration Increase the partial stroke position deadband No 402 PST start condition Low start pressure Description The measured pressure is below Start pressure low Trouble shooting This error can be solved by Increase the pressure in the hydraulic pneumatic system Decrease Start pressure low No 403 PST start condition High start pressure Description The mea...

Page 31: ...uble shooting This error can be solved by Perform a new PST No 411 PST Error Pressure drop no breakaway Description Breakaway is not detected but the pressure is below the Minimum breakaway pressure Trouble shooting This error may be due to Actuator is stuck Position sensor malfunction This error can be solved by Check the actuator and valve Check the position sensor Decreasing the Minimum breakaw...

Page 32: ...412 PST Error Breakaway timeout Description Breakaway is not detected before the Breakaway timeout was exceeded Trouble shooting This error may be due to Blocked output of actuator Solenoid valve is stuck Valve is stuck This error can be solved by Clear the output of the actuator Increasing the Breakaway timeout Resolve mechanical problem ...

Page 33: ...413 PST error Breakaway no pressure drop Description Breakaway is detected but the pressure has not dropped the Pressure deadband since the test was started Trouble shooting This error is generated when the pressure transmitter is not sensing the pressure drop This error can be solved by Check pressure transmitter Reduce Pressure deadband ...

Page 34: ... 414 PST Error Pressure below minimum allowed Description Breakaway is detected but pressure is below the Minimum allowed pressure during the travel Trouble shooting This error may be due to Increased torque in the actuator or valve Broken spring The error can be solved by Resolve the mechanical problem Decrease Minimum allowed pressure ...

Page 35: ...or Timeout during partial stroke Description The valve did not move the desired PST travel before the PST timeout Trouble shooting This error can occur if The valve gets stuck during the test due to an obstruction in the hydraulic pneumatic system The valve is moving slow It can be solved by Resolve the mechanical problem Increasing the PST timeout ...

Page 36: ...416 PST error Total timeout position Description The operational position was not reached after the partial stroke Trouble shooting This error can be caused by No supply pressure The valve is stuck The valve is moving slow The solenoid valve cannot be activated It can be solved by Resolve the mechanical problem Increase PST total timeout ...

Page 37: ...error At 0 position Description The position measured to be 0 Trouble shooting This error can be caused by Position sensor was disconnected Position sensor is operating in the illegal area Wrong configuration of the position switches The valve moved to 0 It can be solved by Check the position sensor Make sure the position sensor is operating within the legal area Check the function of the position...

Page 38: ...ontrols com Revision 10 38 74 8 2 Partial stroke warnings 431 to 440 No 431 PST warning Breakaway pressure is too low Description The breakaway pressure is lower than Breakaway pressure low Trouble shooting This alarm can be solved by Resolve the mechanical problem Decrease the Breakaway pressure low value ...

Page 39: ...rols com www valcontrols com Revision 10 39 74 No 432 PST warning Breakaway pressure is too high Description The breakaway pressure is higher than Breakaway pressure high Trouble shooting This alarm can be solved by Resolve the mechanical problem Increase the Breakaway pressure high value ...

Page 40: ...vc valcontrols com www valcontrols com Revision 10 40 74 No 433 PST warning Breakaway time is too low Description The breakaway time is lower than Breakaway time low Trouble shooting This alarm can be solved by Resolve the mechanical problem Decrease the Breakaway time low value ...

Page 41: ... valcontrols com www valcontrols com Revision 10 41 74 No 434 PST warning Breakaway time is too high Description The breakaway time is higher than breakaway time high Trouble shooting This alarm can be solved by Resolve the mechanical problem Increase the Breakaway time high value ...

Page 42: ...5 7547 0600 vc valcontrols com www valcontrols com Revision 10 42 74 No 435 PST warning PST time is too low Description The PST time is lower than PST time low Trouble shooting This alarm can be solved by Resolve the mechanical problem Increase the PST time low value ...

Page 43: ...7547 0600 vc valcontrols com www valcontrols com Revision 10 43 74 No 436 PST warning PST time is too high Description The PST time is higher than PST time high Trouble shooting This alarm can be solved by Resolve the mechanical problem Increase the PST time high value ...

Page 44: ...trols com www valcontrols com Revision 10 44 74 No 437 PST warning Travel too large Description During the partial stroke did the actuator move more than Travel high alarm Trouble shooting This alarm can be solved by Perform service on the actuator and valve Increase the Travel high value ...

Page 45: ...600 vc valcontrols com www valcontrols com Revision 10 45 74 No 438 PST warning Total time is too low Description The total time is lower than PST total time low Trouble shooting This alarm can be solved by Resolve the mechanical problem Increase the PST total time low value ...

Page 46: ...c valcontrols com www valcontrols com Revision 10 46 74 No 439 PST warning Total time is too high Description The total time is higher than PST total time high value Trouble shooting This alarm can be solved by Resolve the mechanical problem Increase the PST total time high value ...

Page 47: ...ed pressure is below Start pressure low Trouble shooting This error can be solved by Increase the pressure in the hydraulic pneumatic system Decrease the Start pressure low value No 453 FST start condition High start pressure Description The measured pressure is above Start pressure high Trouble shooting This error can be solved by Increase the pressure in the hydraulic pneumatic system Increase t...

Page 48: ...FST error Pressure drop no breakaway Description Breakaway is not detected but the pressure is below the Minimum breakaway pressure Trouble shooting This error may be due to Actuator is stuck Position sensor malfunction This error can be solved by Check the actuator and valve Check the position sensor Decreasing the Minimum breakaway pressure ...

Page 49: ...Revision 10 49 74 No 462 FST error Breakaway timeout Description Breakaway is not detected before the Breakaway timeout was exceeded Trouble shooting This error may be due to Blocked output of actuator Solenoid valve is stuck This error can be solved by Clear the output of the actuator Increasing the Breakaway timeout ...

Page 50: ...463 FST error Breakaway no pressure drop Description Breakaway is detected but the pressure has not dropped the Pressure deadband since the test was started Trouble shooting This error is generated when the pressure transmitter is not sensing the pressure drop This error can be solved by Check pressure transmitter Reduce Pressure deadband ...

Page 51: ... FST error Timeout during FST Description The valve did not reach the fail position before the FST timeout Trouble shooting This error can occur if The valve gets stuck during the test due to an obstruction in the hydraulic pneumatic system The valve is moving slow It can be solved by Resolve the mechanical problem Increasing the FST timeout ...

Page 52: ...epressurising Description The valve is at the fail position but the pressure does not reach 0 bar Trouble shooting This error can be caused by Blocked exhaust Offset in the calibration of the analogue input Sensor error It can be solved by Resolve the mechanical problem Verify that the measured pressure value is zero when unpressurised Increase Depressurising timeout ...

Page 53: ...T error Total timeout position Description The valve did not reach the operational position within the FST total timeout Trouble shooting This error can be caused by No supply pressure The valve is stuck The valve is moving slow The solenoid valve cannot be activated It can be solved by Resolve the mechanical problem Increase FST total timeout ...

Page 54: ...trols com Revision 10 54 74 No 467 FST error Total timeout pressure Description The pressure did not reach the start pressure after the full stroke Trouble shooting This error can be caused by Low supply pressure It can be solved by Increase pressure Resolve the mechanical problem Increase FST total timeout ...

Page 55: ...ed before the 100 switch was released Trouble shooting This error can be caused by Position sensor was disconnected Position sensor is operating in the illegal area Wrong configuration of the position switches The valve moved from 100 directly to 0 It can be solved by Check the position sensor Make sure the position sensor is operating within the legal area Check the function of the position switc...

Page 56: ...controls com Revision 10 56 74 8 4 Full stroke warnings 481 to 488 No 481 FST warning Breakaway pressure is too low Description The breakaway pressure is lower than Breakaway pressure low Trouble shooting This alarm can be solved by Resolve the mechanical problem Decrease the Breakaway pressure low value ...

Page 57: ...rols com www valcontrols com Revision 10 57 74 No 482 FST warning Breakaway pressure is too high Description The breakaway pressure is higher than Breakaway pressure high Trouble shooting This alarm can be solved by Resolve the mechanical problem Increase the Breakaway pressure high value ...

Page 58: ...vc valcontrols com www valcontrols com Revision 10 58 74 No 483 FST warning Breakaway time is too low Description The breakaway time is lower than Breakaway time low Trouble shooting This error can be solved by Resolve the mechanical problem Decrease the Breakaway time low value ...

Page 59: ...trols com www valcontrols com Revision 10 59 74 No 484 FST warning Breakaway time is too high Description The breakaway time is higher than Breakaway time high Trouble shooting This error can be solved by Resolve the mechanical problem Increase the full stroke breakaway time high warning ...

Page 60: ...5 7547 0600 vc valcontrols com www valcontrols com Revision 10 60 74 No 485 FST warning FST time is too low Description The FST time is lower than FST time low Trouble shooting This error can be solved by Resolve the mechanical problem Decrease the FST time low value ...

Page 61: ...hanical problem Increase the FST time high value No 487 FST warning Total time is too low Description The FST total time is lower than FST total time low Trouble shooting This error can be solved by Resolve the mechanical problem Decrease the FST total time low value No 488 FST warning Total time is too high Description The FST total time is higher than FST total time high Trouble shooting This er...

Page 62: ...t pressure Description The measured pressure is below Start pressure low Trouble shooting This error can be solved by Increase the pressure in the system Decrease the Start pressure low No 503 SOT start condition High start pressure Description The measured pressure is above Start pressure high Trouble shooting This error can be solved by Decrease the pressure in the system Increase Start pressure...

Page 63: ...op Description Breakaway is detected but there is no pressure drop Trouble shooting This error is generated when the pressure transmitter is not sensing the pressure drop This error can be solved by Check pressure transmitter Decrease Pressure deadband No 513 SOT error Total timeout Description Position based SOT The valve did not open within the SOT total timeout Pressure based SOT The pressure d...

Page 64: ...lve is at 0 position Trouble shooting This error can be caused by Position sensor was disconnected Position sensor is operating in the illegal area Wrong configuration of the position switches The valve moved from 100 directly to 0 It can be solved by Check the position sensor Make sure the position sensor is operating within the legal area Check the function of the position switches ...

Page 65: ... been selected as the position signal but there is not connected a potentiometer Trouble shooting Connect sensor to AI1 Select another position signal No 113 Analogue output 1 is not calibrated Description Analogue output 1 calibration data has not been set Trouble shooting Contact Val Controls No 114 Analogue output 2 is not calibrated Description Analogue output 2 calibration data has not been s...

Page 66: ...pressure limit Disable the function No 322 Pressure input 2 is high Description The Prevent open at high pressure function is activated and Pressure input is over the limit Trouble shooting This error can be caused by High pressure It can be solved by Lower the pressure Increase the pressure limit Disable the function No 354 SD card error Description There is a problem with the SD card Trouble sho...

Page 67: ...fill the tank with oil Decrease Level Low limit value No 602 Pump control Temperature Description The measured temperature is above or below the limit values Trouble shooting This error can be caused by Low oil temperature High oil temperature Sensor malfunction It can be solved by Change oil temperature Adjust temperature Low limit Adjust temperature High limit No 610 Pump control Motor safety re...

Page 68: ...unning time Description The motor has been running for too long Trouble shooting This error can be caused by Digital output to the motor has been On longer than the Max running time It can be solved by Investigate what causes the motor to run Is it not able to get the pressure within the limits Increase the Max running time Disable the Max running time feature ...

Page 69: ...or log Argument System error no No 11 ESD line was power off Description The ESD line was power off This event is only applicable for IDCs with external power supply No 12 ESD line was power on Description The ESD line was power on This event is only applicable for IDCs with external power supply No 13 ESD reset Description An ESD reset was issued This event is only applicable for IDCs with extern...

Page 70: ...A reference PST was aborted by the operator No 31 FST start Description A FST was started No 32 FST finished Description A FST finished No 33 Reference FST start Description A reference FST was started No 34 Reference FST finished Description A reference FST finished No 35 FST aborted by operator Description A FST was aborted by the operator No 36 Reference FST aborted by operator Description A re...

Page 71: ... by operator Description A reference SOT was aborted by the operator No 51 Operational Description The IDC was set in operational mode No 52 Fail position remote Description The IDC was set in fail position mode No 57 Set in local mode Description The IDC was set in local mode No 58 Set in remote mode Description The IDC was set in remote mode No 61 Auto calibration was started Description An auto...

Page 72: ...d Description An auto calibration finished 10 1 Argument For the events describing an action the argument denotes what is the responsible for the action No Responsible Description 1 Remote The action was initiated through Remote controlled digital inputs 2 Local The action was initiated through Local controlled digital inputs 3 Menu The action was initiated through the local interface on the devic...

Page 73: ...3 00 Added System Error 113 and 114 AO1 And AO2 not calibrated Added System Error 102 AI10 not connected Added System Error 103 AI1 not connected Added Disable Bluetooth from Digital input Improvements to EST recording Version 1 14 00 Endpoint calibration can be performed from ValConnect Bluetooth and MTcontrol enable functions are combined with Local switch Version 1 14 01 Minor improvements Vers...

Page 74: ...evision 10 74 74 Version 1 17 00 Feature Reverse open close output on HART and Modbus Version 1 18 00 Feature Immune to spikes on ESD line Feature HART TV can retransmit Closed by LCP alarm Version 1 19 00 Feature Virtual DO Feature Add on time to DI to DO function Version 1 20 00 Feature Prevent open at high pressure ...

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