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VALVE-TRONIC Plus - United Process Controls

1. Example 2 If you would like to set the High Flow Alarm Setpoint which is MODBUS Address 40025 and 40026 and has a data type of UINT32 and you want to send a setpoint of 500 5 you would multiply the value by 10 500 5 x10 5005 So you would send a value of 5005 to register 40025 and 0 to register 40026 Status Monitor 1 The Status Monitor 1 is a 16 bit word located at MODBUS address 30001 and it is a bit field so when a bit is set to logic 1 it indicates that error condition exists Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 44 Example 3 If you look at the table below you will see the value contained in the register is 000010000010000 which shows bit 4 and 11 are active so the Valve Tronic is reporting an error of Home Switch Failure and Control Signal Loss if the register contained all zero s that would indicate that no error conditions exist Value 0 0 0 0 0 0 0 o o Bit 15 14 13 12 11 10 9 8 NIO oO al S w N o N A N A Overheat Comm Time Out Home Switch Failure Home Cal OK Closed Valve Motor Failure Flow Feedback Signal Over Range Control Signal Loss Pressure Feedback Loss Flow Feedback Signal Loss Control Signal Over Range Press Feedback Over Range Temp Feedback Over Range Te
2. Rev 3 Page 11 4 4 Wiring Guidelines Your company may have guidelines for wiring installation If so you should check those before you begin the installation Here are some general things to consider e Use the shortest wiring route whenever possible e Use shielded wiring for all signal wiring and ground the shield at the Field Device end DO NOT ground the shield at both the Valve Tronic Plus and Field Device e Do nat run the signal wiring next to large motors high current switches or transformers This may cause noise problems e Route the wiring through an approved cable housing to minimize the risk of accidental damage Check local and national codes to choose the correct method for your application e Be sure to leave enough slack in the cables to allow easy removal of the Valve Tronic Plus from the Flo Meter for maintenance If seal tight or similar conduit is used be sure to provide an adequate loop of conduit for maintenance access CAUTION To reduce the risk of electrical shock and also to prevent damage to the Flo Tronic Valve Tronic Plus and the Field Device It is advised to turn off the supply power to the Flo Tronic Va ve Tronic Plus and Field Device before connecting or disconnecting any wires WARNING Any electrical or mechanical modification to this equipment without prior written consent of United Process Controls will void all warranties may result in a safety hazard and may void the CE listing WARNING W
3. MU a Bus AL 11 12 13 1415 All rights to copy reproduce and transmit are reserved Pin w cof D wr cw ro Pin WY Col MU SY Ww reo rR Page 12 Digital 1 0 Wiring 9 Pin D sub Plug ir Description ve Color Input D11 Red Yellow Orange White Brown Blue Violet Black Out 1N 0 DO1 Out 2 N 0 DO2 Out 3 N O DO3 Input Com DCM Out 1 Com DO1C Out 2 Com DO2C Out 3 Com DO3C 6 7 8 9 00006 bara 11 2 345 Sensor Wiring 15 Pin D sub Plug Flow Sensor Signal Flow Sensor Signal N C N C N C Flow Sensor Com N C N C Flow Sensor Power N C Pressure Sensor Signal Pres Temp Sensor Com Temp N C Pres Temp Sensor PWR Description wire Color Sensor Signal 54 3210 109 8 7 6 15 14 13 12 11 Valve Tronic Plus Rev 3 Page 13 4 6 Power Wiring Diagram 1Amp DC COMMON BLK DC COMMON WHT EARTH GND GRN Power 24VDC 4 Pin Circular Power Connector Supply 4 7 Control Wiring Diagram Analog Inputs Outputs 9 Pin D Sub Receptacle Valve Tronic Plus Control Valve Digital Inputs Outputs 9 Pin D Sub plug Process Controller ouput a Gee Output AI1C BLK ORG DO2 24VDC 0 5A O Unos oe AO1 GRN BLU DO1C n ine AO1C WHT VIL DO2C GND BLK DO3C RED DI1 BRN DCM 12 24VDC
4. Valve Position 10 0 When Control Type P1 09 is set to 00 Flow the Main Page 01 will display Actual Flow and page 04 will display Valve Position When set to 01 Position the two display pages will swap so Valve Position will become the Main Page 01 Copyright O 2013 United Process Controls Inc Main Page This is the main page that shows either the actual flow rate in engineering units or valve position depending on configuration It also displays alarm messages and mode Totalized Flow Displays the total flow that has flowed through the Flo Meter Note it is possible to reset the totalized flow by pressing and holding the y key for 5 seconds Actual Flow Displays the feedback signal from the Flo Tronic flow sensor in of flow Set point Displays the set point Note it is possible to change the set point with the A and W keys when the set point value is displayed on the keypad and unit is set to Local L setpoint mode To change from Remote R to Local L press the Auto Man mode key Valve Position Actual Flow Depending on the configuration this page will display either the position of the control valve or actual flow rate in engineering units Pressure Feedback Displays actual supply pressure in engineering units to the inlet of Flo Meter Note the pressure temperature sensor is an optional sensor if unit is not equipped with this sensor this status displ
5. A CAUTION Do not over tighten as damage to the threads may occur 7 Install the Valve Tronic Plus onto the valve body assembly Carefully align the valve stem coupling to the valve stem A CAUTION Do not force the Va ve 7ronic Plus onto the valve stem 8 Tighten the union nut by hand until there is little or no play between the valve body assembly and Valve Tronic Plus 9 Tighten the valve stem coupling lower hex head set screws 10 Replace the access window cover plate and Four 4 access window cover plate screws 4 3 Optional Flow Compensating Pressure Temperature Sensor Installation The Pressure Temperature sensor provides the Valve Tronic Plus with feedback of the actual conditions at the inlet of the Flo Meter With this information the Valve Tronic Plus can compensate the flow rate when the pressure or temperature deviates from what the Flo Meter is calibrated for which provides extremely accurate measurement of the flow rate and emulates mass flow type flow measurements Installation of the sensor requires a Tee at the inlet of the Flo Meter The run of the Tee must be large enough to allow the maximum flow through the Flo Meter which will require reducing the branch of the Tee for the sensor to Y NPT For best results the sensor must be installed as close to the inlet of the Flo Meters as possible Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus
6. This information could prevent injury loss of property or even death in extreme cases Any warning in this manual should be regarded as critical information that should be read in its entirety The word WARNING or CAUTION in boldface will mark the beginning of the text HHH When you see the notepad icon in the left hand margin the paragraph to its immediate right will be a special note Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 7 2 CONTROL VALVE INTRODUCTION Purpose of Control Valve Control valves are used to vary the flow of fluid through a Flo Meter The Control Valve is microprocessor based and compares a flow control signal 4 20 mA represents zero to full scale flow to the actual flow signal produced by the Flo Tronic Flow Sensor on the Flo Meter If there is no difference between the control signal and the actual flow signal the system is satisfied and the motor does not drive If the flow signal is different from the control signal the system will tell the valve to drive open or closed until the flow signal matches the control signal The Valve Tronic Plus is programmed to automatically ramp to a set point smoothly to limit under and over shoot The unit is factory tuned to each flow specification to provide smooth control action The unit s response and control is limited by the response of the customer supplied cont
7. Travel Weather Ent Suggested Stes Z FreeHomal E Get More Add ons F VALVE TRONIC Pus m B r X 8 screen shot of curent window P a member of ba Waukee Engineering Co Jn I te d PROCESS CONTROLS Language T English Espa ol Deutsch PX Q D 13 ame Pages Safety Too gt Pr ee u Welcome to the management and configuration web interface Sub pages eee ee Name VALVE TRONIC Plus Serial Number VTP220000 Firmware Revision 1299 37 Ethernet MAC Address 00 04 f3 02 77 fe Ipv4 Addresses 192 168 5 23 Up Time 3 minutes 46 seconds le Done O meras ar Amy gt EHH Language Select desired language i Sub pages Click on the text to goto the desired sub page Sub pages Readings Factory Settings and Flow Calibration are only accessible by factory personnel Name Shows the Product Name Serial Number Shows Serial Number of Unit Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 36 Firmware Revision Shows the current firmware version MAC Address Shows the MAC address of the Unit IPv4 Address Shows the IP Address of the Unit gt VALVE TRONIC Plus Windows Internet Explorer DER Status Page Evu vemonc Pus e D e Pages Safety Tos gt a member of ha Waukee Engineering Co J n i te d PROCESS CONTROLS English Espa ol Deutsch Status urrent Errors
8. 1 Solenoid Valve Sizing and Location When selecting a solenoid valve make sure it is capable of supplying the flow required at the operating pressure Waukee Flo Meters require a constant inlet supply pressure and if the solenoid valve does not have a large enough orifice or CV factor it may have an effect on the supply pressure at the inlet of the Flo Meter which may affect its accuracy For this reason among others United Process Controls Inc recommends installation of the solenoid valve at the outlet of the Flo Meter 6 2 Controlling the Solenoid Valve There are many combinations of wiring and controlling the solenoid valve When closing the solenoid valve you want to ensure that the Valve Tronic Plus Control Valve drives closed This can be achieved many ways some of which are 1 Configure the process controller that is controlling both the Valve Tronic Plus and solenoid valve so that when the solenoid valve is closed that it sends a control signal of 4 5mA or less to the Analog inputs Al1 Al1C This will tell the Valve Tronic Plus to drive the valve closed regardless of feedback signal from the flow sensor 2 Configure the Valve Tronic s Digital Input DI1 DCM via the programming parameter P3 00 01 Closed Valve N O Then wire these contacts to a dry N O contact on the process controller Setup the process controller to close these contacts when the solenoid valve is closed When the process controller closes these c
9. CONTROL SIGNAL LOSS Mode Automatic Valve Position 16 0 Setpoint 277 0 2mA Total Flow 91327 gal Actual Flow 0 83GPH 41 6 Done O temer ar Aos Current Errors Shows a list of current errors Mode Shows the current mode of operation Auto or Manual Valve Position Shows current valve position in open Setpoint Shows the set point in as well as mA if unit is configured to receive its setpoint signal from Al Analog Input Total Flow Shows the totalized flow Actual Flow Show the current actual flow rate in Engineering units as well as of Scale Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 E VALVE TRONIC Plus Windows Internet Explorer Event Log QO ieman Page ae We Favorites ly Second Chance by Shnedo Favorites Toos Help Bax 5AL4 HIFI Stereo FMT E Degrees Mnutes Seconds E Dmensions Surface Fish E nens Travel Weather Ent E Suggested Stes jFreeHomat E Get More Add ons M VALVETRONIC Pus a a 3 a Poges Safety Toos a member of Waukee Engineering Co J n l te d PROCESS CONTROLS E ES eutsch PX Home Sats Time 2010 09 23 19 31 55 Program Message 2010 09 23 19 31 24 Detected Fault CONTROL SIGNAL LOSS 2010 09 23 19 31 27 Cleared Fault CONTROL SIGNAL LOSS Clear Event Log eadinas Licenses Time Download C
10. Internet Explorer 6 0 or higher 10 2 Establish Communication Link to PC Setup the Communication Link Step 1 Get IP Address of Unit Step 2 Open Connection Manager on PC Connect Tronic Valve Plus Cross Over Cable P N TVP EX015 to Communication Port of Valve Tronic Plus and network interface card NIC on the PC On the Valve Tronic Plus go to PROGRAM gt COMMS GROUP gt IP ADDRESS to get IP Address and go to the next parameter GATEWAY to get the gateway On the PC go to START gt CONTROL PANEL gt NETWORK CONNECTIONS to bring up the connection manager S Network Connections File Edit View Favorites Tools Advanced Help Qe BD Osea Es Folders E Address Network Connections e Connection Manager wecl LAN or High Speed Internet See Also Wireless Network Connection 1394 Connection 4 Network Troubleshooter O omen L_ p Inte s Local Area Connection Bluetooth Network Other Places letwork cable unplugged Disabled ES Broadcom NetXtreme Gigabit E Bluetooth LAN Access Server gt Control Panel gt My Network Places Virtual Private Network 2 Waukee Engineering eee System Folder Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 34 Step 3 Open Network Properties Step 4 Open Internet Protocol TCP IP Properties Step 5 Open Internet Explore Double click on the connectio
11. Pros pio ate oos oooo9 Holding Register uintis 10 P1 05 Dead Band 40011 0x000B Holding Register UINT16 10 P1 06 piDDelay 40012 oxo00c HoldimgRegister uiNT16 10 P1 09 Control Type S 40053 oxo03s Holding Register_ UINT16 Display Parameters pzz temperature Units 0018 oxo010 Holding Register untie 2 03 pressureunis soos ooo Holding Register untie Digital I O Parameters esoo Multifunction input Terminal 013 40021 oxoois Holding Register UINTI6 P3 02 Multi function Output Terminal DO2 40023 0X0017 Holding Register UINT16 P3 03 Multi function Output Terminal DO3 40024 0X0018 Holding Register UINT16 paoa High Flow Alarm Setpoint 40025 40026 0x0019 ox001A Holding Register InT32 P3 05 Low Flow Alarm Setpoint 40027 40028 0x0018 0x001C Holding Register INT32 p306 Totalizer Alarm Setpoint 40029 40030 0X0010 0X001D Holding Register int32 Digital Output Logic Analog I O Parameters 12 1 Parameter Memory Addresses HHHH h The parameters in the following list must not be written to on a continuous basis as to do l so will damage the EEPROM greatly reducing its useful life Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 42 12 2 Status Addresses Status Addresses MODBUS Hexadecimal MODBUS Data Type Decimal Data Type Actual Flow R
12. is set to 00 keypad parameter will default to 00 Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 24 9 DETAILED PARAMETER LISTINGS Parameter Parameter Number Name P0 00 Totalizer Decimal Point Default Setting 0 Settings 0 0 0 0 00 This parameter sets the resolution of the totalizer Parameter Description Parameter Setting Range Totalizer Parameters P0 00 Totalizer Decimal Point Default Setting 0 Settings 0 0 0 0 00 This parameter sets the resolution of the totalizer P0 01 Totalizer Scale Factor Default Setting 1 000 Range 0 001 to 65 000 For most applications the totalizer reflects the same decimal point location and engineering units as the Input Display In these cases the Totalizer Scale Factor is 1 000 The Totalizer Scale Factor can be used to scale the Totalizer to a different value than the input display Common possibilities are 1 Changing decimal point location 2 Average over a controlled time frame P0 02 Totalizer Low Cut Value Default Setting 0 Range 10 to 100 This parameter sets a low cut value that disables the totalizer when the input display value falls below this programmed value Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 25 P0 03 P0 04 Totalizer Power Up Reset Default Setting 00 Do No
13. last number in the address is 10 but this could be any number other than 23 For the Subnet mask uses the same as noted in step 1 in this example it is 255 255 255 0 Leave all other fields blank and click on OK Type the address of the Valve Tronic plus as noted in step 1 into the address bar of Internet Explore and press Enter Google Windows Internet Explorer SB 192 168 5 23_ 9 gt lx File Edit View Favorites Tools Help Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 35 Step 6 Enter User name of vtadmin Enter credentials Connect to 192 168 5 23 Enter Password of vtapw FPA Then Click on OK The server 192 168 5 23 at ValveTronic Realm requires a username and password Warning This server is requesting that your username and password be sent in an insecure manner basic authentication without a secure connection User name E v Password C Remember my password l OK Cancel 10 3 Exploring the Interface Now that your PC and Valve Tronic Plus are linked together you will be able to perform any tasks via the web interface The Web interface works just like any website which makes it very easy to navigate Home Page aaa iy Favorites gly E Second Chance by Shnedo A 5A1404 HIFI Stereo FMT E Degrees Mnutes Seconds E Dimensions Surface Frish J nens
14. result in undesirable operation P4 04 Flo Tronic Flow Sensor Bias Default Setting Factory Calibrated Range 999 thru 9999 This parameter is used to calibrate the flow feedback signal from the sensor If the unit does not display the proper flow reading when compared to the Flo Meter this value can be adjusted to make the unit read correctly E Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 32 Communications Parameters P5 00 IP Address Default Setting 0 0 0 0 Range 0 0 0 0 to 254 254 254 254 If the Control Valve is controlled by communications the IP address must be set via this parameter Every component connected to the same network must have a unique IP address Normally a network administrator will assign an IP address to each device on the network WARNING It is extremely important not to have duplicate IP Addresses on your network If you are using the IP Address to link the Control Valve to any network devices PCs or PLCs the Control valve must have a unique number P5 01 Subnet Mask Default Setting 0 0 0 0 Range 0 0 0 0 to 255 255 255 255 If the Control Valve is controlled by communications the Subnet Mask must be set to the correct network class If you do not know your Subnet Mask ask your network administrator B gt P5 02 Gateway Default Setting 0 0 0 0 Range 0 0 0 0 to 254 254 254 254 If the Contr
15. the Valve Tronic Plus Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 17 7 3 Function Keys AUTO MAN Key Pressing the AUTO MAN key will change the mode of operation DISP ENT Key Pressing the DISP ENT key on the keypad repeatedly will cycle through the status messages of the Control Valve It is also used in the programming mode to select and view parameters as well as store parameter settings UP DN Key When the control valve is in the manual mode the UP key will drive the valve open and the DN key will drive the valve closed The UP DN keys are also used to scroll through the parameter groups the various parameters in each group and also changes the parameter settings in single unit increments To quickly run through the range of settings press and hold the UP or DN key 1000000 h After a one 1 minute key inactivity the keypad LCD display will automatically revert to the f main display Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 18 7 4 Displaying the status of the Valve Tronic Plus Press the DISP ENT key on the keypad repeatedly to cycle though the status messages on the control valve The diagram below shows the order of the status messages as you cycle through them and shows the definition of the status messages Actual Flow 20 0
16. you for purchasing a Valve Tronic Plus flow control valve This manual shows you how to install wire and maintain Waukee s Valve Tronic It also helps you understand how to interface it to other devices in a control system This manual contains important information and should be read and understood by all individuals who install use or service this equipment Supplemental Manuals The Installation and Operation of Waukee Flo Meters Manual contain technical information as well as precautions about Waukee Flo Meters Technical Support We strive to make our manuals the best in the industry We rely on your feedback to let us know if we are reaching our goal If you cannot find the solution to your particular application or if for any reason you need technical assistance please call us at 1 414 462 8200 Toll free North America 1 800 438 3347 Our technical support group will work with you to answer your questions They are available Monday through Friday from 8 00 A M to 4 30 P M Central Standard Time We also encourage you to visit our web site where you can find technical and non technical information about our products and company http www group upc com If you have a comment question or suggestion about any of our products services or manuals please e mail or contact us by phone Conventions Used When you see the exclamation point icon in the left hand margin the paragraph to its A immediate right will be a warning
17. 305419896 Float32 Check 30103 30104 0x0067 0x0068 Input Register 123 321 INT16 Check Ox006A Input Register 0X1234 4660 Discrete and Word Locations As you examine the different memory types you ll notice two types of memory in the Valve Tronic Plus discrete and word memory Discrete memory is one bit that can be either a 1 ora 0 Word memory is referred to as V memory variable and is a 16 bit location normally used to manipulate data numbers store data numbers etc Word Memory The word memory area is for data The Valve Tronic Plus utilizes a couple of different data types Some types of words are shown with a multiplier the value has been multiplied before put into its register To interpret the value correctly the value that is read from the register must be divided by this same amount See Example 1 below Example 1 If you would like to know the Actual Flow Rate which is MODBUS Address 30017 and has a data type of UINT16 10 So if this register contains the value 523 the actual flow would be 52 3 523 10 For a higher degree of accuracy some values are stored in more than one register to provide 32 bits or 2 words The least significant word is stored in the register with the lower number little endian word order but the bytes within the word are stored with the most significant byte first big endian byte order Both words must be written at the same time See Example 2 on how to write a value with two words
18. Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 14 5 CONNECTING TO A LEGACY WAUKEE TRONIC The Valve Tronic Plus has the capability of interfacing with our Legacy Waukee Tronic flow sensors A Waukee Tronic conversion cable P N TVP WT005 is required to convert the signal from the Waukee Tronic to a signal that is understood by the Valve Tronic Plus Sensor input Wiring of the Waukee Tronic to a Valve Tronic Plus utilizing this cable is shown below Legacy Waukee Tronic SHIELD 24VDC RED DC COMMON BLK 4 20mA WHT 4 20mA GRN SHIELD Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 15 6 POSITIVE SHUT OFF The control valve provided with the Valve Tronic Plus is a needle valve designed specifically to precisely control the rate of flow This valve is not intended to be used as a means of positive shut off Even when the valve is fully closed a small amount of leakage may be noted WARNING The control valve on the Valve Tronic Plus is not designed as Ah a positive shut off valve a ball valve or similar type valve should be installed up stream of the Flo Meter before servicing equipment that the Flo Meter is servicing If the process is sensitive to this leakage flow or if positive shut off is desired a solenoid valve may be added 6
19. EMBLY FLOAT STOP La BODY O RING sight GLASS TUBE O RING a T FLo TRONIC UNION NUT E OREO DE OO he EA a EE En OS XP A ar Far de FLO TRONIC SENSOR All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 10 4 2 Valve Tronic Plus Control Valve Installation The following instructions are for installing a Valve Tronic Control Valve onto an existing Waukee Flo Meter 1 First remove the valve assembly from the Valve Tronic Plus as follows i Remove the Four 4 access window cover plate screws and the access window cover plate ii Loosen the valve stem coupling lower hex head set screw iii Loosen the valve body union nut iv Carefully separate the valve body assembly from the adapter block v Set the Valve Tronic and valve body assembly aside 2 Remove the cap or manual valve from the existing Flo Meter using the valve tool provided 3 Inspect the top of the Flo Meter and remove any of the following if present Valve orifice orifice gasket or valve spring 4 Insert the O Ring into the top of the Waukee Flo Meter Ensure that the O Ring is seated flat against the shelf of the Flo Meter 5 Insert the orifice on top of the O Ring and ensure that the O Ring is still seated properly 6 Screw the valve body assembly into top of the Flo Meter using the valve tool Tighten until the flat gasket is seated in the Flo Meter body
20. ImputDiscretes Discretes NS Read Multiple Registers Write Multiple Registers Determining the MODBUD Address There are typically two ways that most MODBUS addressing conventions allow you to specify a memory location These are e By specifying the MODBUS data type and address e By specifying a MODBUS address only If your Server Requires the Data Type and Address Many MODBUS TCP clients allow you to specify the MODBUS data type and the MODBUS address that corresponds to the unit s memory location This is the easiest method but not all packages allow you to do it this way From the tables on the following pages you would use the Hexadecimal and MODBUS Data Type If your Server Requires an Address ONLY Some MODBUS TCP clients do not allow you to specify the MODBUS data type and address Instead you specify an address only From the tables on the following pages you would use the MODBUS Decimal Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 41 12 CONTROL VALVE MEMORY ADDRESSES Parameter Memory Addresses MODBUS Hexadecimal MODBUS Parameter Description Decimal Data Type Totalizer Parameters 0 02 rotalizer tow Curvalue gt ao00 oxooo4 Holding Register uINTi6 Control Parameters p10 setpointsource 40006 oooos Holding Register UINTIG proz pio mese zoos oooos Holding Register _ UINTI6 100
21. WAUKEE WWW GROUP UPC COM ENGINEERING company ince VALVE TRONIC Plus User Manual Revision 03 ALN WAUKEE ENGINEER Erry it company ine Jn ited AFFILIATED MEMBERS PROCESS CONTROLS Furnace Control Corp Marathon Monitors Inc Process Electronic Waukee Engineering Co Valve Tronic Plus Rev 3 Page 2 Manual 010 Rev No 03 Date 29 March 2013 COPYRIGHT No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means electronic mechanical magnetic optical chemical manual or otherwise without prior written permission of United Process Controls Inc DISCLAIMER The Valve Tronic Plus is to be used by the industrial operator under his her direction United Process Controls Inc is not responsible or liable for any product process damage or injury incurred while using the Valve Tronic Plus United Process Controls Inc makes no representations or warranties with respect to the contents hereof and specifically disclaim any implied warranties or merchantability or fitness for any particular purpose For assistance please contact United Process Controls Inc TEL 1 414 462 8200 gt FAX 1 414 462 7022 Toll free North America 1 800 438 3347 waukee support group upc com www group upc com Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit
22. are reserved Valve Tronic Plus Rev 3 Page 3 WARNING Thank you for purchasing control equipment from United Process Controls Inc We want your new control equipment to operate safely Anyone who uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regulate the installation and operation of your equipment These codes vary from area to area and usually change with time It is your responsibility to determine which codes should be followed and to verify that the equipment installation and operation are in compliance with the latest version of these codes At a minimum you should follow all applicable sections of the National Fire Code National Electrical Code and codes of the National Electrical Manufacture s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious injury to personnel can result from failure to follow all applicable codes and standards We do not guarantee the products described in this publication are suitable for your particular application nor do we assume any responsibility for you product design installation or operation If you have any questions concerning the installation o
23. ate additional corrective action When tuning begin with a large Reset value and reduce the value until the system goes unstable erratic When instability is reached increase the Reset value slightly until the system becomes stable and the desired set point value is reached Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 26 P1 03 PID Rate Default Setting 0 Range 0 00 to 10 00 min Using only the proportional control the corrective action may not increase fast enough or the set point may never be reached because of system losses The Integral control Reset is used to generate additional corrective action When tuning begin with a large Reset value and reduce the value until the system goes unstable erratic When instability is reached increase the Reset value slightly until the system becomes stable and the desired set point value is reached For most applications a value of 0 min will be used P1 04 PID Filter Default Setting 1 0 Range 0 00 to 10 0 sec To avoid amplification of measured noise in the control output a filter is inserted This filter helps smooth oscillations Larger values provide more smoothing Parameters P1 01 Thru P1 04 are not visible when P1 09 Control Type is set to 00 Position P1 05 Dead Band Default Setting 1 0 Range 0 5 to 5 00 To avoid continual correction of flow a deadband
24. ay will not be visible Temperature Feedback Displays actual supply fluid temperature in engineering units to the inlet of the Flo Meter Note the pressure temperature sensor is an optional sensor if unit is not equipped with this sensor this status display will not be visible Access Level Displays the current level of accessibility to the Va ve Tronic Plus Visible only when the default access level P2 07 is set to 01 User See Access Levels of the Va ve Tronic Plus on page 19 Program Mode Used to program parameters within the unit For programming see Programming the Va ve Tronic Plus on page 20 All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 19 7 5 Alarm Status of the Valve Tronic Plus When Alarms are programmed to trigger P3 01 and P3 03 set to 01 thru 06 the status screen will cycle through the alarms triggered and the main screen The diagram below shows the order of the alarm status messages The display will continue to cycle until all alarms are cleared Alarm Message Displays how the alarm is programmed Refer to Digital I O Parameters P3 01 thru P3 03 for 1000 cFH alarm programming Alarm messages are as follow Alarm 1 Valve Full Closed Fault High Flow Alarm Alarm 2 Low Flow Alarm Alarm Message Totalizer Alarm Alarm 3 Alarm Message 7 6 Access Levels of the Valve Tronic Plus The Valve Tronic Plus has the capabi
25. cess Controls brings together leading brands to the heat treating industry including Waukee Engineering Furnace Control Marathon Monitors and Process Electronic We provide prime control solutions through our worldwide sales and services network with easy to access local support UNITED PROCESS CONTROLS INC WAUKEE PRODUCTS PLANT 5600 West Florist Avenue Milwaukee WI 53218 U S A Phone 1 414 462 8200 Fax 1 414 462 7022 E mail waukee salesOgroup upc com Copyright O 2013 United Process Controls Inc Page 48 E United PROCESS CONTROLS gt e gt PROCESS ELECTRONIC All rights to copy reproduce and transmit are reserved
26. coseesscensesdicess secbessesdsvedsccedtssccdisecesssiaeadestacebieseibesisatacedsasesbesscvisssioneiee 6 2 CONTROL VALVE INTRODUCTION fisssicsesseccessscccssosstensscaconsisoceesseccssesdecesscacosesseccoessecassecssastseccasssseccsesdeccsesscanessescoseseeccsessscsssoetes 7 3 SPECIFICATIONS A O 8 4 INSTALLATION AND WIRING v2 cccsccccscccecesscsdectsescscnssscscessscanssct costscesonsssetosevdsceooesescbsssetondisoccedsccnsessscossssesonsdsetoserssceosssccesssvasonsses 9 AT Flo Meterinstallation renne aee A a a Rade guls da td ai 9 4 2 Valve Tronic Plus Control Valve Installation comoooccconncnnnnoncccnnnannnnnnnanonnnnnnnonnnn nn nrnnnn nr rra nn nr nana nr rr nan n ran nn nr nr naar ara rnnnn nn nnan anno 10 4 3 Optional Flow Compensating Pressure Temperature Sensor Installation cccccscecessseessecessseessecessseensecessseessecssseessecsssseesseensees 10 ALA WIUPING GUIA CINE A A Mba dae taba bah A ine Nase 11 BS Wino Terminal a iaa 12 4 6 Power Witing DIGGIN iin imnari inen dilatada barda aa td ade eii tad e a a did daa thinss 13 As Re CONTIOLWVILIN ODIA Miisioioiicniotadodano capado cs Gos ve 8 IR EEEE EE ET E Sade iia dao caries 13 5 CONNECTING TO A LEGACY WAUKEE TRONIC ooccccccccccncccnncnccccnononcnnnnoncnnononononnoncnnononcnnononccnononcrnnnoncnnononcnnnnoncnnononcncnnoncnnonanss 14 6 AA AA A O A NT 15 6 1 Solenoid Valve Sizing ANA LOCAION cccccccccecessensscesecscessesseeesececeseessaasseseceseesseseeeseces
27. dance 2500 R 3 relay 1A 030VDC user programmable Output Disabled Valve Full Open Valve Closed Fault High Flow Low Flow Totalized Flow Terminals 1 user programmable 4 20ma Flow Totalizer Operator Device 4 key graphics LCD display Parameter values for setup and review fault codes Flow PID Feedback PID Setpoint Valve position Temperature Pressure Totalized Flow Key Function Display Enter UP DN S SF M1 7 90PSI 6 2Bar M8 11 L1 3 75PSI 5 2Bar L4 6 30PSI 2 1Bar L7 10PSI 0 7Bar L8 9 5PSI 0 3Bar MET PO Status Display Working Pressure Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 4 INSTALLATION AND WIRING 4 1 Flo Meter Installation The Installation and Operation of Waukee Flo Meters manual contains instructions on the proper installation of the Flo Meter Read all CAUTIONS and WARNINGS before proceeding The Valve Tronic Plus Flo Meter is shipped as a complete unit Before installing the Flo Meter carefully remove the Flo Tronic Sensor to achieve this lay the unit on its side on a work bench or table Hold the Flo Tronic unit with one hand while unscrewing the union nut counterclockwise with the other hand to loosen it CAUTION Once the Flo Tronic is loose from the A Flo Meter make sure to pull the Flo Tronic Transducer from the Flo Meter straight back off the float rod assembly Moving the Fl
28. duce and transmit are reserved Valve Tronic Plus Rev 3 Page 30 P3 03 Multi function Output Terminal DO3 Default Setting 00 None Settings for P3 01 thru P3 03 00 None 01 Valve Full Open 02 Valve Closed 03 Fault 04 High Flow Alarm 05 Low Flow Alarm 06 Totalizer Alarm Setting 00 No action Setting 01 Valve full open The terminals will be activated when the valve is fully open Setting 02 Valve Closed The terminals will be activated when the valve is fully closed Setting 03 Fault The terminals will be activated when the Control Valve has a error or Problem Setting 04 High Flow Alarm The terminals will be activated when the flow is above High Flow Alarm Setpoint set in P3 04 Se tting 02 Low Flow Alarm The terminals will be activated when the flow is below Low Flow Alarm Setpoint set in P3 05 Setting 03 Totalizer Alarm The terminals will be activated when the totalized flow is Above Totalizer Alarm Setpoint set in P3 06 P3 04 High Flow Alarm Setpoint Default Setting 99999 9 Range 0 0 to 99999 9 High Flow Alarm Setpoint P3 05 Low Flow Alarm Setpoint Default Setting 0 0 Range 0 0 to 99999 9 Low Flow Alarm Setpoint P3 06 Totalizer Alarm Setpoint Default Setting 99999 9 Range 0 0 to 99999 9 Totalized Flow Alarm Setpoint Units are same as set in P2 0 P3 07 Output Logic Default Setting 01 N C Settings 00 N O 01 N C This parameter selects the Logic of the output contacts Sett
29. ead Only mean A E Total Flow Read Only 12 3 Status Monitor 1 Error Codes Description Status Monitor 1 Error Codes 30001 Error Bit Number Temperature Feedback Loss o Temperature Feedback Over Range Pressure Feedback Over Range N Control Signal Loss Control Signal Over Range Flow Feedback Signal Loss Flow Feedback Signal Over Range Motor Failure OIOINIDOJU AJW Closed Valve Home Cal OK Home Switch Failure Comm Time Out Overheat 12 4 Memory Location and Data Types Generally you have many different types of information to process This includes input device status output device status etc It is important to understand how the system represents and stores the various types of data For example you need to know how the system identifies input points output Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 43 points and data words The following paragraphs discuss the various memory types used in Valve Tronic Plus s Data Type Check If you are unsure of the format of a data type you can read the registers as shown in the below table and they should report the values as shown Data Type Check Registers MODB MODB Description O j us Hexadecimal ODBUS Register Value Decimal Data Type INT32 Check 30100 30101 0x0064 0x0065 Input Register 0x12345678
30. eeseaseeeseceseeseaseaesesssussessaasseseceesuaaaaeseseeseenes 15 6 2 Controlling th Solenoid Valve enintaan anea ia chested dea in AA Aa ba Aaa eea ChVebads Riebeabebintbal AEA AEAEE a GEES aaa 15 7 KEYPAD OPERATION AND DISPLAY OVERVIEW ssssssssessssesssssossssessssesssssossseosssccsssscossssosssecsssscssssesssssosessossssesssseossseosessessssesse 16 VAA ROY OGG EAEE E RS NR A A 16 FZ E S BH DI PLY ss AS A E A A SA Ga A E A A ads Bide ad 16 LIZ FUNCUON KEYS A A DAA TA A DA iii 17 7 4 Displaying the status of the Valve Tronic PIUS ccccceesessscesccssessessecssecscesnessaaeseseeeseessaseseseceseessssesesecseeessaseassecscesseasaassesseseeenaaaess 18 7 5 Alarm Status of the Valve Tronic PIUS ccccccssssscesccssncnesecesecseessesseeesecsceseessaeeseseceseessaaeseseesseessasesesecseeeseasasesecseseseasaassessesenenaaaess 18 7 6 Access levels of th VMAlVe TrONICPlUS iii A A Di dea debt ade E ae aa A baii et 19 7 7 Programming the Valve Tronic PIUS enn a a a a a a a a a aas 20 8 CONTROL VALVE PARAMETERS iieccissscccscsiscsscsctensscdecncssocoses ssccoseveseassevecndssevesessseeesessseseseascuessedoned seeds suvescnssessesestecosedssesesessteseess 21 9 DETAILED PARAMETER LISTINGS icici csiscccssscecesscccentssedcsessescssesseensstacosssseccoessasensesdeecdesaseeedssddbusisedosesstendsed ensesccdossdeateesssecodessconse 24 10 WEB INTERFACE MANAGEMENT CONFIGURATION cccccsssssseecccccccssssseeecccccccsssseeecccccccnssse
31. hen making cable assemblies with the included plugs ensure none of the connections are shorted to each other before plugging into the unit Failure to verify the cable assembly may result in damage to the unit and may void the warranty rr gt Waukee has cable assemblies in a variety of lengths available Contact your El If you are not experienced in soldering and would prefer a cable assembly local sales representative or Waukee for information on cable assemblies ii Use 18 22AWG shielded wire for the control signal wiring It is recommended to run all signal wires in a separate steel conduit The shield wire should only be connected at the Field Device Do not connect shield wire on both ends Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 45 Wiring Terminals Digital I O Comm Port Analog l O Power Sensor Port Power Wiring 4 Pin Circular Receptacle Pin Description E 24VDC DC Common Copyright O 2013 United Process Controls Inc Pin Ww ol MIT MD OT Ww re re Pin N e Analog In 1 A11 Analog In 1 AI1C NIC NIC NIC NIC Analog Out 1 A01 Analog Out 1 A01C NIC Analog 1 0 Wiring 9 Pin D sub Receptacle Description Comm Wiring 15 Pin D sub Receptacle Description Bus RTS Wire Color Red Black Green White Wire Color WO Co
32. ic Plus The Valve Tronic Plus Control Valve parameters are organized into six 6 different groups according to their functions The illustration below shows you how to navigate through the parameter groups and parameter settings For a complete list of parameters see Pgs 19 thru 23 o Press the DISP ENT to cycle through the status display until it reads Program then use the UP DN keys to cycle through the parameter groups HER Press the DISP ENT key to display the various parameters for the selected group and use the UP DN keys to view each one o When the desired parameter is shown press the DISP ENT key to select Use the UP DN keys to cycle through the available settings 6 Press the DISP ENT key to select the setting The phrase Value Accepted will be displayed for a moment to show 1003 that the parameter value has been changed 73 Alter the parameter value Yias been set the LCD O North a essplay will cycle to the next parameter in the selected group o Select Parameter Group ENT PROGRAM TOTALIZER GROUP P0 00 P0 04 CONTROL GROUP P1 00 P1 10 P0 00 DECIMAL POINT Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 21 8 CONTROL VALVE PARAMETERS Parameter Summary Parameter Description Range Default User Setting Setting Totalizer Parameters i aa 00 Do Not Re
33. ing 00 N O Contact closure when alarm condition exists Setting 01 N C Contact opens when alarm condition exists Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 31 Analog I O Parameters P4 00 Loss of Control Signal Al1 Default Setting 00 Cont oper By last command Settings 00 Continue operation by last command 01 Drive valve closed 02 Maintain current valve position Action control valve should take in the event that the control signal is lost P4 01 Loss of Flo Tronic Sensor Signal Default Setting 00 Maint Current Pos Settings 00 Maintain current valve position 01 Drive valve closed Action control valve should take in the event that the Flo Tronic Flow Sensor signal is lost P4 02 Analog Output Signal AO1 Default Setting 00 Actual flow rate Settings 00 Actual flow rate 01 Totalizer display value This parameter selects either Actual flow rate or totalizer display value to be retransmitted on AO1 output terminals P4 03 Flo Tronic Flow Sensor Null Default Setting Factory Calibrated This parameter is used to calibrate the zero 0 flow feedback from the Flo Tronic sensor If the unit does not display zero 0 when the Flo Meter is reading zero 0 flow then press the ENT DISP key to accept the new zero HHH h Before setting the Null ensure that the Flo Meter is reading zero flow Failure to do so will
34. is added This deadband is a percentage of set point flow When control valve is within deadband no correction will be made until PV is out of the deadband Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 27 P1 07 P1 08 P1 09 P1 10 he b Control Mode Default Setting 00 Direct Settings 00 Direct 01 Reverse This parameter selects the action of the control valve in relation to the Control Signal Setting 00 Direct Acting Mode a 4mA control signal corresponds to Zero 0 flow and a 20mA control signal corresponds to full flow Setting 01 Reverse Acting Mode a 20mA control signal corresponds to Zero 0 flow or closed valve and a 4mA control signal corresponds to 100 flow or full flow Control Range Default Setting 00 4 20mA Settings 00 4 20mA 01 4 12mA 02 12 20mA This parameter selects the control signal range that the valve responds to Ex When the parameter is set to 01 4mA will correspond to Zero 0 flow and 12mA will correspond to full flow Control Type Default Setting 00 Flow Settings 00 Flow 01 Position This parameter selects the control Type where 00 Flow Control is based on flow rate The Main page will display actual flow rate in engineering units 01 Position Control is based on Valve Position The Main page will display Valve Position 100 Valve Posi
35. lity to lock out parameter settings and data entry screens requiring a pass code to change values By Default the Valve Tronic Plus is setup with an Access Level of Admin which provides the operator full access to all parameter settings and data entry If desired the default Access Level can be changed to User The User Access Level can view but not change any parameter settings Read Only and data entry screens have the option to be Ready Only or Read Write For information regarding setting up Access Levels refer to the programming section of the manual Entering Pass Code 11 Press the amp or W key to change the pass code in increments or decrements of 1 a Once the correct pass code is entered press the 0 A Y DISP ENT Key al If the pass code is correct the display will show Pass 001 Code Accepted otherwise it will show Pass Code Oo Denied and then show the current Access Level Access Level Pass Code Accepted access to that level of access until 5 minutes of keypad inactivity After 5 minutes of keypad inactivity the access level reverts back to the default Access Level If the default Access level is ADMIN then there is no need to enter a pass code El Once the correct pass code is entered you will have Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 20 7 7 Programming the Valve Tron
36. mit are reserved Valve Tronic Plus Rev 3 Page 29 P2 08 Totalizer Reset Access Default Setting 00 Disabled Settings 00 Disabled 01 Enable Enable this setting to allow the User Access Level to reset the totalizer P2 09 Restore To Defaults Settings Yes No Restarts all parameters to factory defaults HHHH k P2 08 thru P2 10 are only Visible when P2 07 is set to 01 User Digital I O Parameters P3 00 Multi function Input Terminal DI1 Default Setting 00 None Settings 00 None 01 Closed Valve N O 02 Closed Valve N C 03 Reset Totalizer N O 04 Enable Totalizer N O Setting 00 No action Setting 01 and 02 When a signal is received the control valve will drive closed and the words Closed Valve will display on the LCD display and inhibit operation To resume normal operation these contacts must be cleared Setting 03 When a signal is received the control valve will reset the totalized flow to 0 Setting 04 When a signal is received the control valve will enable totalization of flow When signal is not received flow totalizer will stop totalizing N O Control Valve receives signal when N O contact closes N C Control Valve receives signal when N C contact opens P3 01 Multi function Output Terminal DO1 Default Setting 00 None P3 02 Multi function Output Terminal DO2 Default Setting 00 None Copyright 2013 United Process Controls Inc All rights to copy repro
37. mperature Feedback Loss Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 45 13 TROUBLESHOOTING 13 1 Error Messages The Control Valve has a comprehensive diagnostic system that includes several different error messages The error messages are displayed on the digital keypad LCD display Error Messages Error Name Description Corrective Actions 1 Check all connections to Temp Pressure Sensor TEMP FBACK LOSS dl Replace Temp Pressure Sensor Temperature Feedback Signal Loss Check all connections to Temp Pressure Sensor TEMP FBACK OVER Pf Replace Temp Pressure Sensor Temperature Feedback Signal Over Range 1 Check all connections to Temp Pressure Sensor PRES FBACK LOSS al 2 Replace Temp Pressure Sensor Pressure Feedback Signal Loss PRES FBACK OVER Check all connections to Temp Pressure Sensor Replace Temp Pressure Sensor Pressure Feedback Signal Over Range CONT SIGNAL LOSS Loss of Control Signal CONT SIGNAL OVER 1 Check all connections to Controller 2 Check if control signal is within 4 20mA range Check all connections to Controller Check if control signal is within 4 20mA range Control Signal above 21mA FLOW FBACK LOSS 1 Check and verify all connections to the Flo Tronic Sensor Flow Sensor Feedback Loss FLOW FBACK OVER 1 Check and verify all connections to the Fl
38. n that the Valve Tronic Plus is connected General Advanced to This will bring up the Connect using Network Properties for HD Broadcom NetXtreme Gigabit Etheme that connection 4 Local Area Connection Properties This connection uses the following items Client for Microsoft Networks r File and Printer Sharing for Microsoft Networks aos Packet Scheduler F Intemet Protocol TCP IP instal Uninstall Description Allows your computer to access resources on a Microsoft network vi Y C Show icon in notification area when connected Notify me when this connection has limited or no connectivity Double click on Internet Protocol TCP IP to bring up the Internet Protocol TCP IP Properties Change Radio button to Use the following You can get IP settings assigned automatically if your network supports P a d d ress this capability Otherwise you need to ask your network administrator for the appropriate IP settings Internet Protocol TCP IP Properties General For the IP address use the first three e numbers that you noted from Step 1 the last number of the address can be anything AAN 22o between 0 and 255 as long as it is not the E pin same as the Valve Tronic Plus For example if the IP address of the Valve a Tronic Plus is 192 168 5 23 you would Prefered DNS server _ type in the address as shown to the right Ae ST i Notice the
39. o Tronic Sensor Flow Sensor Feedback signal out of range Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 46 Error Messages Continued Error Name Description Corrective Actions MOTOR FAILURE 1 Try to free up motor using Manual override valve located on top of unit Internal Stepper Motor Failure 2 Contact Waukee Engineering for assistance CLOSED VALVE ms If cee Input DI1 is not being used set P3 0 to 00 None Closed Valve contacts open 2 Check and verify all connections to controller HOME CAL OK 1 Press DISP ENTER key to OK calibration Unit needs to drive the valve closed to set zero valve position 1 Home Switch out of adjustment contact Waukee HOME SW FAILURE ee a Engineering for assistance Home Switch Failure 1 Verify and check all communications wirin COMM TIME OUT ey apes i 2 Verify that communication settings for Controller Communications Time Out and Control valve are the same 1 Shield Unit from any Heat Sources OVER HEAT Unit is too Hot Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 47 14 APPENDIX A DRAWINGS On demand Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Reach us at www group upc com United Pro
40. o Tronic Transducer to one side or another during removal may result in damage to the float rod assembly Remove the Float Rod Assembly and store it in a safe location until Flo Meter body is installed and mounted Once the Flo Meter is installed remove the red tape from the float rod and insert the float rod assembly into the Flo Meter body Fill the Sight Glass Tube with Waukee Flo Meter Oil so that the level of oil is approximately one 1 inch from the top Then carefully install the Waukee Tronic on to the Flo Meter Do not put oil in the sight glass tube of meters used for oxygen or methanol service Oxygen Flo HHHH Meters should be run dry or with distilled water h Flo Meters for Methanol service will automatically i fill the sight glass tube with Methanol when in service H WARNING Do not fill the sight glass tube with Flo Meter oil on meters used for oxygen service Use of oil may cause fire or explosion Serious personal injury may result from fire or explosion If the Valve Tronic Plus is shipped separately to be installed onto an existing Flo Meter please refer to the following page Copyright 2013 United Process Controls Inc Page 9 MANUAL VALVE 7 OVERIDE w AV WAUKEE VALVE TRONIC A VALVE UNION NUT VALVE ASSEMBLY lt VALVE BODY FLAT GASKET VALVE ORIFICE O RING Lo re is lt FLO METER BODY OAM PIMPS AL FLOAT ROD ASS
41. ol Valve is controlled by communications the Gateway must be set to the IP address of the Router If you do not know your Gateway address ask you network administrator P5 03 MAC Address Default Setting Set at Factory A unique Ethernet MAC Address is assigned to each module at the factory and will not change The Ethernet MAC Address is a twelve digit number with no deliberate relationship to your network or functional areas of your plant It does not usually serve as a convenient and easily remembered identifier P5 04 Module ID Default Setting 1 Range 1 to 64 If the Control Valve is controlled by communications the Module ID must be set The Module IDs must be unique for each Control Valve but they do not have to be in sequence P5 05 Comm Time Out Default Setting 10 Range 0 to 600 Seconds Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 33 10 WEB INTERFACE MANAGEMENT amp CONFIGURATION All Valve Tronic Plus Control Valves include a build in web interface Besides being easy to use the Web Interface includes the following features e Easy viewing and setup of parameter settings e Viewing and exporting of Event Log e Firmware upgrade capability e Backing up and restoring of configuration e Remotely view status of unit 10 1 System Requirements e PC with Network Interface Card NIC e Windows operating system with
42. ontacts the Valve will drive closed regardless of what the control or feedback signal is These are just two examples of how to properly use a solenoid valve with a Valve Tronic Plus Flo Meter The main objective is that the control valve must drive closed whenever the solenoid valve is closed CAUTION Failure to configure and wire a solenoid valve as mentioned above may result in over gassing of equipment or may cause damage to the float rod assembly within the Flo Meter due to a sudden in rush of flow spiking the Flo Meter WARNING When using a solenoid valve be sure to select the proper solenoid configuration for fail safety N O or N C Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 16 7 KEYPAD OPERATION AND DISPLAY OVERVIEW 7 1 Keypad The digital keypad includes a graphics LCD display and 4 function keys Gene ENGINEERING Waukee a member of United PA PROCESS CONTROLS Not a shut off valve 7 2 LCD Display The LCD Display shows the operation values parameters and faults Status Mode Displays the mode of operation as follow A Automatic Mode M Manual Mode Mode Drive Indicator Drive Indicator Indicates direction of valve travel and relative speed related to how fast the indicator is flashing Status Displays status of unit for a complete list of status screens refer to pg 18 Displaying the status of
43. ove power from the Valve Tronic Plus or PC during firmware update Failure to maintain power during update may result in the unit becoming inoperable and require sending it back to the factory for repair VALVE TRONIC Plus Windows Internet Explorer Reboot Page Ge vE 192 168 524 Fle Edt Wew Favores Tools Hep Se Favorites a E Second Chance by Shinedo AY BA1404 HIFI Stereo FMT E Degrees Minutes Seconds 2 Dimensions Surface Finish E News Travel Weather Ent E Suggested Sites Free Hotmail E Get More Add ons VALERO Pes gt GS Pager Safety Too fr a member of s Waukee Engineering Co In ited PROCESS CONTROLS Reboot Click Reboot to reboot this device Copyright 2010 Waukee Engineering Co All rights reserved Some parameter changes my require a reboot to take effect but clicking on Reboot it will force the unit to reboot Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 40 11 MODBUS COMMUNICATIONS 11 1 MODBUS TCP MODBUS TCP is used for TCP IP communications between client and server devices on an Ethernet network The TCP version of MODBUS follows the OSI Network Reference Model For more information on MODBUS communication visit www modbus org Supported MODBUS Function Codes The following MODBUS function codes are supported by the Valve Tronic Plus MODBUS Function A Read Read
44. r operation of this equipment or if you need additional information please call us at 414 462 8200 Toll free North America 1 800 438 3347 WARNING Read this manual thoroughly before using Control Valve WARNING This unit contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures refer to an applicable ESD protection handbook WARNING The Valve on this unit is not designed for positive shut off Valves may leak gas into equipment and cause asphyxiation or poisoning to personnel within confined space If positive shut off is desired install a mechanical valve prior to the Flo Meter and verify that it is shut off prior to servicing equipment attached to the unit WARNING Flo Meter must be earth grounded Ungrounded Flo Meters may become a source of Ignition Pr gt gt Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 4 TABLE OF CONTENTS WARNING 65 cicsiscscccsescucincscccnsevescncescecnsescncosedsnnnsesosenessssonsessseossesucsoesesenesssncnsessnesssessensessssnssesecnsesseconeesosesssesassercecnsesssconedseceesveocsessssessesss 3 1 MANUAL OVERVIEW iii ecscesecesei ess ces ecic nies ae chiscaceotsdoccoesis
45. rminal DI1 Close Valve N C Reset Totalizer Enable Totalizer Multi function Output Terminal DO1 Output Disabled Valve Full Open Valve Closed Multi function Output Terminal DO2 Fault High Flow Alarm Low Flow Alarm Multi function Output Terminal DO3 Totalizer Alarm High Flow Alarm Setpoint 1 99999 Low Flow Alarm Setpoint 0 99999 Totalizer Alarm Setpoint 0 99999 P3 07 Output L ele j did 01 N C Parameter Only Functions when a Multi Function Terminal is set to trigger the alarm Parameter only visible when P2 07 01 User Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 23 Parameter Summary continued Parameter Description Range Default User Setting Setting Analog I O Parameters 00 Continue Operation by last command Loss of Control Signal Al1 01 Drive valve closed 02 Maintain current valve position 00 Maintain current valve Loss of Flo Tronic Sensor Signal position 01 Drive valve closed 00 Actual Flow Rat Analog Output Signal AO1 j ua on ae 01 Totalizer Display Value 00 Disabled Pres Temp Sensor Input Pres rempsensor impar OS Enabled Fact P4 04 Flo Tronic Flow Sensor Null Press DISP ENT to Calibrate as Piy Calibrated Flo Tronic Flow Sensor Bias 999 to 9999 Factory Calibrated Communications Parameters mac address seara O O O If P1 0 PID control signal source
46. roller inlet pressure flow range gas type and downstream restrictions If necessary the Valve Tronic Plus may be field tuned for a variety of applications The Valve Tronic Plus control valve offers the following features Control and Flo Tronic Feedback diagnostic Indicators P 1 D Control Error codes to aid in troubleshooting Shut off contacts to close the valve by opening a remote switch or contact Three Alarm contacts that can be programmed for various alarm types Built in set point generator which allows the unit to function from an internal set point Model Explanation VTP 1M1 Series Name Internal Use Sizing Code Nameplate Information VALVE TRONIC Plus MODEL VTP 1M1 SERIAL VTP21875 Model Serial Number gt Input Specifications gt Operating Temperature gt INPUT 24VDC 10 50mA TEMP 32F 0C 150F 65C Group upc com Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 8 3 SPECIFICATIONS General Specifications Operation Specification Operating Le 24VDC 10 PaT Keypad Setting by lt UP gt or lt DN gt keys Flow Setting External 4 20mA Input Impedance 2500 Signal Ethernet Modbus TCP 1 user programmable Input Disabled Close Valve N O Close Valve N C Digital Reset Totalizer Enable Totalizer 1 4 20mA Input Impe
47. seeececccusssssesecesscaasssseeesesesansees 33 10 1 S ste Requirements aiii dida ide dina dias ii aaia a aa did dei italia dia tan 33 10 2 Establish COMMUNICATION LINK OPE A AAA 33 10 3 Exploring the INCCLL ACC bac ii Lada A Ad AAA SARA A A idas 35 11 MODBUS COMMUNICATIONS aveesicccccsscassecsseccsecseccssesessesvecsonesvevosesssesescsstenevescseussecosessscossecesossvevensssseeoses vesesesstasesescsesssecosessnes 40 11 1 MODBUSTER A a ia 40 Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 5 12 CONTROL VALVE MEMORY ADDRESSES wi lt cccscccvtscsicecescazscctsesacecescascevtcesacedeccedcccecesacedescaacevesesaeedeecedscvedesagedecteasevecesadeceeseaceeased 41 12 1 Parameter Memory Addresses A dabstvasa vealeoeiecs abadasieteeesagsd vaucadsdendsadvaxiesnasdeacdeseate 41 12 2 Status AUTE ES A A A A a A a AA ii bd 42 12 3 Status Monitor 1 Error Code iii a A A dd AA add is 42 12 4 Memory location ANA Data Ty PES A E aa tasa 42 E MS A O TN 45 13 1 LPO MOSS AGES dais 45 14 APPENDIX AY DRAWINGS 5 ssciciscciecisseties Giccssccasetsedsssac eccasecdsadasacieciasedieaiabacdecdaseddecdasacdsadabedisaiabacdscdasedieadasacieasasedieasasadieasiaees 47 Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 6 1 MANUAL OVERVIEW The Purpose of this Manual Thank
48. set Power UP Reset 01 Reset P0 04 Max Value for AO 0 to 99999 99999 Control Parameters 01 Analog Input P1 00 Setpoint Source i 01 02 Communication P1 01 PID Gain 0 to 100 Factory Cal P1 02 PID Reset 0 00 to 50 00 min Factory Cal P P1 03 PID Rate 0 0 to 10 0 min Factory Cal fF P1 04 PID Filter 0 0 to 10 0 sec 10 71 05 bead band 0 5 t0 5 0 aio a P1 06 PID Delay 0 0 to 60 0 sec Factory Cal P 00 Direct Rev 00 4 20mA P1 08 Control Range 01 4 12mA 02 12 20mA 00 Flow P1 09 Control Type 01 Position p1 10 100 Valve Position Press DISP ENT to Calibrate om Display Parameters e e pe P2 01 Flo Meter Scale 1 0 99999 9 100 0 EA T arein 00 F emperature Units 01 C When Control Type P1 09 00 Position Parameter not visible When Control Type P1 09 01 Flow Parameter not visible Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 22 Parameter Summary continued Parameter Description Range Default User Setting Setting Display Parameters continued 00 English 01 Spanish Language 02 German 03 Chinese ati id 00 Admin efault Access Leve died 00 Enable P2 07 Set point Access 01 Disabled 00 Enable P2 08 Totalizer Reset Access 01 Disabled MON AE dd dl mw oo a Digital I O Parameters Input Disabled Close Valve N O Multi function Input Te
49. t Reset Setting 00 Do Not Reset 01 Reset This parameter determines if the totalizer resets after powering up the unit or maintain current count Totalizer Max Value for AO Default Setting 99999 Range 0 to 99999 This parameter determines the value of the Totalizer that will result in a 20mA output Control Parameters P1 00 P1 01 P1 02 Set point Source Default Setting 01 Analog Setting 01 Analog Input 02 Communications This parameter sets the source of command signal PID Gain Default Setting Range 0 to 100 The First parameter of PID control is Proportional Control Gain For a given process if the Gain value is set too low the control action will be too sluggish If the Gain value is too high the control action will be unstable erratic Set the Integral Reset and Derivative Rate to 0 Begin tuning the process with a low Gain value and increase the Gain value until the system goes unstable erratic when instability is reached reduce the Gain value slightly until the system becomes stable Stability can be tested by moving between two wide spread set point values The Default setting for this parameter varies depending on application PID Reset Default Setting Varies Range 0 00 to 50 00 min Using only the proportional control the corrective action may not increase fast enough or the set point may never be reached because of system losses The Integral control Reset is used to gener
50. tion Default Setting N A This parameter is used to set the 100 valve position for Automatic Mode when control type P1 09 is set to 01 Position Parameters P1 10 is visible when P1 09 Control Type is set to 01 Position Copyright O 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 28 Display Parameters P2 00 Flow Units Default Setting 00 CFH Settings 00 CFH 01 M3H 02 L H 03 GPH Flow units to display on LCD display Also determines units for P2 01 P2 01 Flo Meter Scale Default Setting 100 0 Range 1 0 to 99999 9 Scale of Flo Meter Control Valve is being used on P2 02 Temperature Units Default Setting 00 F Settings 00 F 01 C Temperature units to display on LCD display Also determines units for P2 03 P2 04 Language Default Setting 00 English Settings 00 English 01 Spanish 02 German P2 05 Default Access Level Default Setting 00 Admin Settings 00 Admin 01 User Sets The Default Access level for the Va ve Tronic Plus where Admin Full Access User Read Only Access P2 06 Admin Pass Code Default Setting 462 Range 0 to 999 Sets the Admin Pass Code P2 07 Set point Access Default Setting 00 Disabled Settings 00 Disabled 01 Enable Enable this setting to allow the User Access Level to change the PID Set point Copyright O 2013 United Process Controls Inc All rights to copy reproduce and trans
51. up Parameter Setting Shows the currently selected parameter value Selecting the data entry field will allow a new value to be entered Once desired value is entered click Set Download Downloads the configuration file to you PC Upload Allows you to upload a configuration file into the Valve Tronic Click Browse to find a configuration file and then click Upload to send the configuration file to the Valve Tronic Plus Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 U ploa d VALVE TRONIC Plus Windows Internet Explorer Gore 192 168 5 24 i Fle Edt Wew Favorites Toos Helo Firmware i Favorites gly second Chance by Shnedo A 5A1404 HIFT Stereo FAT E Degrees Mrutes Seconds E Dmensions Surface Frish I News Travel Weather Ent Suggested Stes Z FreeHomal E Get More Add ons Page Enemas M Do lo Pace Sefety Tose Br a member of ha Waukee Engineering Co sy n l te d PROCESS CONTROLS Engh z Upload Firmware Upload new firmware into flash A firmware image file must be called image bin A firmware backup recovery image file must be called backup bin A ROM image file must be called rom bin Select Image Upload To upload a new firmware into the Valve Tronic Plus Click on Browse to locate the image file and then click on Upload to upload the firmware to the Va ve Tronic Plus WARNING DO NOT rem
52. urrent Time Shows the current date and time set in the unit To change the date and time click on Current Time The time and date set in Current Time is used for the time stamp in the event log Event Log Shows the last 200 events Clear Clears the event log when clicked Download Downloads the Event log in text format when clicked This allows the event log to be sent to the factory or technician if requested during troubleshooting Copyright 2013 United Process Controls Inc All rights to copy reproduce and transmit are reserved Valve Tronic Plus Rev 3 Page 38 CE VALVE TRONIC Plus Windows Internet Explorer Dek Program QO b EEG gt P Fie Edt View Favor age Wi Fevorites f E Second Chance by Shinedo 841404 HIFI Stereo FMT Degrees Mnutes Seconds E Dimensions Surface Fish E News Travel Weather Ent 2 Suggested Sites jFreeHotmal Upgrade Your Browser VAVE TRONCS amp th Page Safety Toos a member of Mn WZ Waukee Engineering Co In ited PROCESS CONTROLS English Espa ol Deutsch Flo Meter Scale P2 01 2 0 Range 1 0 to 99999 9 Display Group P2 00 P2 09 ES Digital O Group anquage P3 00 P3 07 Analog 1 0 Group P4 00 P4 05 Communications Group P5 00 P5 05 internet ar Rios gt Parameter Group Shows a list of parameter groups Parameter Sub Group Shows a list of parameters within a gro

VALVE-TRONIC Plus - United Process Controls

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