OPERATION MANUAL

VALVE CHECKER

G040-123

OPERATION MANUAL CN 20.4.99

C31489
VALVE CHECKER Rev A CN 21.12.05
AUSTRALIA PTY. LTD.
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CONTENTS

Chapter Title Page

1. Description 3

2. Specification 7

3. Quick Start 9

4. Connecting to valve and plant 11

5. Plant mode operation (in line) 12

6. Checker mode operation (stand alone) 15

7. External 24V supply 17

8. Valve performance checks 18

9. Block diagram 20

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1. DESCRIPTION

1.1 The Moog G040-123 Valve Checker is an instrument capable of checking

the flow control function of nearly the complete range of Moog electrical
feedback (efb) proportional and servo valves. Mechanical feedback (mfb)
and pressure control valves are not catered for by the G040-123.

The feature that makes it so versatile is the way it can test a valve while
the valve is still installed in its normal operating plant. This is done at two
levels, “in line” and “stand alone”.

1.1.1 Plant (In Line)

As in fig a) the plant and valve operate normally. In fig b) the Valve
Checker is connected between the plant electronics and the valve such
that all the plant electronics’ signals, to and from the valve, are connected
as normal. The Valve Checker monitors the plant electronics’ signals and
the signals back from the valve, enabling a check of the valve’s
performance.

Plant Valv e
cable cable

Plant Valv e Plant Valve

Electronics Electronics
plant v alv e
Valv e
Checker

Fig a) Fig b)

1.1.2 Checker (Stand Alone)

In this mode the plant command is switched out while the Valve Checker
generates the command to the valve and monitors the signals back from it.
The valve remains installed in the plant but the plant command signals are
disconnected. Checking while still installed in the plant provides the
added benefit of checking the valve by observing the reaction of the plant
to the Valve Checker’s commands.

1.2 The Valve Checker is powered by the plant electronics which also continue
to supply the valve in both plant and checker modes of operation. As well,
there is a +24V DC power connector on the front panel for 24V DC and
± 15V DC powered valves, without connection to the plant electronics’
power.

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1.3 Two cables connect the Valve Checker to the plant electronics and valve.
Each of the Valve Checker models is dedicated to a power supply voltage
and connector type. It is necessary to select the model type that has the
correct connector and supply voltage. The table below shows the model
numbers and their supply/connector types.

Model dash number table:-

Model dash no. Connector Supply

-001 6 + PE 24V
-002 11 + PE 24V
-003 12 pin ± 15V
-004 6 + PE ± 15V
-005 6 pin ± 15V

1.4 There are six functional blocks on the front panel.

1. Q Command 4. Control
2. Spool 5. Enable
3. Power 6. Valve Connector

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1.4.1 Q Command
This block is active only when checker mode is selected. The rotary pot
adjusts the Q command level.

The grey test point gives a 0 to ±10V signal proportional to the actual
voltage or current being delivered to the valve. The rotary selector switch
selects the signal type that is connected to the valve.

The +/- switch connects the valve Q command signal to the non-inverting
(+ve gives P A) and inverting (+ve gives P B) inputs.

1.4.2 Spool

The spool position signal from the valve is always available at the green
spool test point and passed on to the plant electronics regardless of the
mode of operation. The green spool test point gives a 0 to ±10V signal
proportional to the spool signal from the valve. The LED display to the left
of the test point provides a rudimentary indication of the signal. The
centre blue null LED will be illuminated when the spool signal is less than ±
10%.

An understanding of the checker load switch is important for successful

use of the Checker, when the spool signal is a current
(± 10mA or 4-20mA). When the valve has a current output there must be
a path through which the current can flow, for the Checker to be able to
measure the current. When the plant electronics do no provide this load,
or the Checker is not connected to the plant electronics, the Checker load
switch connects a 100 Ohm load to ground (0V) on the spool signal,
enabling a current to flow.

Note that a six position rotary switch is used to select the five feedback
signals. The fifth and sixth positions both select 4-20mA signal.

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1.4.3 Power
1.4.3.1 24V models
The 24V LED illuminates with both plant 24V and the external 24V
supply. The external 24V is connected via the large black connector
below the LED.

The checker LED indicates the internal ±15V supply is healthy. This
supply is used to power only the Valve Checker internal electronics.

The valve and internal ±15V regulators are always powered by the
external 24V, regardless of the presence of plant 24V. When there
is no external supply the plant 24V powers the valve and internal
regulators.

1.4.3.2 ±15V models

The 24V LED illuminates when the external 24V supply is connected.
The plant ± 15V LED’s illuminate when the plant ±15V supply is
present. The checker LED indicates the internal ±15V supply is
healthy.

When the checker is powered from the plant ±15V the valve is
powered from that supply as well.

When external 24V is present, the checker internal regulators are

powered from that supply, regardless of the presence of the plant
supply and the valve in turn is powered form the internal regulators.

1.4.4 Control
This switch selects the two operating modes:

- In Checker mode valve Q commands and valve enable are

generated by the Checker, with the valve generated signals of
spool position, enable OK and valve OK, available to be
monitored on the Valve Checker test points and passed back to
the plant electronics.
- In Plant mode valve Q commands and valve enable are
generated by the plant electronics, with the valve generated
signals monitored in the same way as in checker mode.

Note that a three position rotary switch is used to select between checker
and plant modes. The first and second positions both select plant mode.

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1.4.5 Enable

The enable LED illuminates when the enable signal to the valve is positive.
The enable signal to the valve comes from the plant electronics when plant
mode is selected. When checker mode is selected it comes from the
enable on switch. However, the enable to the valve can be turned off by
selecting master off when either plant or checker mode is selected.

As well as enabling the valve, the enable signal also enables the Valve
Checker output signals derived from either the checker itself, or the plant
electronics.

This provides a safety feature that quickly removes all signals in the event
of damaging or dangerous process movements. Simply selecting master
off turns off all signal lines to the valve.

The enable OK LED illuminates when the enable OK signal form the valve is
positive.

1.4.6 Valve Connector

All the test points in this section are wired directly to the valve connector.
This enables the actual voltage on the valve’s input pins to be measured,
regardless of the mode selected. A knowledge of the valve input
impedance is sometimes necessary to gain benefit from this measurement.

This section also contains the valve OK LED. The valve OK signal is an
output from the valve.

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2. SPECIFICATION

Q Command Outputs ± 10V, ±10mA,

4-20mA

Q Command Test Point 0 to ± 10V

Q Command
Output swing ±10V, ±20mA

Spool Inputs 2.5 to 13.5V, ±10V differential,

±10V single ended, ± 10mA, 4-20mA.

Spool Feedback Test Point 0 to ±10V

Test point size 2.0mm diameter
Supply
± 15V DC ± 9 to ± 18V, ±65 mA at ±15V, excluding valve
24V DC 18 to 36 V, 90mA at 24 V, excluding valve

Weight 1.2kg. includes cables

Dimensions 205 x 138 x 70 high
Cable Length 3.0M
Enable, Enable OK & Valve OK on at 8.5V.
Thresholds off at 6.5V.

EMC EN 50081-1
EN 50082-2

Protective earth EN 60204-1 equal-potential

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3. QUICK START

3.1 Select the Valve Tester model number

Model dash no. Connector Enable Supply

-001 6 + PE Internal 24V
-002 11 + PE Plant 24V
-003 12 pin Internal ± 15V
-004 6 + PE Internal ± 15V
-005 6 pin Internal ± 15V

3.2 Select Operation Mode

Select plant mode for in line testing or checker mode for stand alone
testing.

3.3 External Supply

If using checker mode an external 24V power supply is needed. Supply
requirements are:-

- 2.1mm diameter connector: 24V outside contact, 0V inside contact.

- 18V to 36V range.
- 90mA at 24V to power the valve checker with no load.

3.4 Connect Cables

First select master off on the enable switch. Turn hydraulic pressure and
plant electronics off before disconnecting and reconnecting the valve.

CAUTION Be sure that the power down and power up sequence is orderly
so no damage can be done to the process.

3.5 Select Signal Types

Select the Q command, if using in checker mode, and spool signal
switches to match the valve signal types.

3.6 Run Test

Turn on the enable switch. The valve will now operate and correct
operation can be verified by measuring the Q command and comparing it to
the spool signal.

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3.6 Plant (in line)

Measure Q + and Q – test points in the Valve connector section and

compare this signal to the green test point in the spool section.

3.6.2 Checker (Stand Alone)

Measure the grey test point in the Q command section and compare this
signal to the green test point in the spool section.

3.7 Valve won’t respond?

Check in Valve connector section

- Correct Q+ and Q- signal.
- Correct power supply.
- Correct enable signal, if the valve has an enable.
Check in spool section.
- If spool signal is a mA signal turn on checker load in spool section
to ensure a path for the mA current.
- Correct spool signal selected.
Check in the power section.
- Checker LED is illuminated.
Check in enable section.
- Enable LED is illuminated.
Check in Q command section.
- Correct command signal selected.
- Try reversing the polarity of the +/- switch.

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4. CONNECTING TO VALVE AND PLANT ELECTRONICS

4.1 Disable the process that the valve is controlling by turning off electrical
power and hydraulic pressure.

CAUTION: Be sure that the power down sequence is orderly so no

damage can be done to the process.

4.2 Remove the plant electronic cable from the valve and mate it with the
Valve Checker plant cable.

4.3 Mate the Valve Checker valve cable with the valve.

4.4 Select master off on the enable switch.

Restore power and hydraulic pressure.

CAUTION: Be sure that the power up sequence is orderly so no damage

can be done to the process.

4.5 Verify that the checker power LED is illuminated.

4.5 Select either plant (in line) mode or checker (stand alone) mode on the
control selector switch.
See chapter five for instructions on plant mode operation and chapter six
for instructions on checker mode operation.

CAUTION: Do not spill oil on the Valve Checker. Oil can enter the
housing and damage the internal electronic circuit.

Do not subject the Valve Checker to severe shock or vibration.

Damage to the internal electronic circuit may result.

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5. PLANT MODE OPERATION

±15V model (see Pg 15 for +24V model illustration)

5.1 Connection
Having successfully connected the Valve Checker as per chapter three,
select plant mode on the control selector switch.

CAUTION: Ensure the enable switch is in the master off position and
leave it in this position until all switch selections are made and
the test is ready to proceed.

5.2 Plant Mode

In plant mode the Q command section is inoperative. The Q and enable
commands come from the plant electronics.

5.3 Spool
In the spool section select the appropriate spool signal. When selecting
either 10mA or 4-20mA, check if the plant electronics provides a load that
enables a current signal to flow. If there is no return signal path to ground
(0V) turn on the checker load switch.

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5.4 Enable

Begin the test by turning on the enable switch to enable the valve. The
enable LED should illuminate confirming that the valve and Valve Checker
are enabled. The enable signal is also used in the valve checker to enable
it to operate. On valves that do not have an “enable signal input” the
Valve Checker generates an internal enable signal.

5.5 Valve OK and Enable OK

Enable OK indicates a valid enable signal has been received by the valve.
Valve OK indicates that the valve closed loop is operating within a certain
error band.

Be aware that not all valves have these output signals. If the Valve
Checker being used does not have the two OK test points the signals are
not wired to the Valve Checker and the two OK LED’s will not illuminate.

5.6 Spool Signals

Measure the actual spool signal on the green test point. The voltage on
this test point is standardised to 0 to ± 10V, regardless of the actual
signal type.

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5.7 Valve Connector Test Points

The plant electronics’ command, directly on the valve input pins, can be
measured on the grey valve connector section test points. A knowledge of
the valve input impedance is required to calculate the current level when
the command is a mA signal.

Example

A D66X valve with a ± 10mA Q command, an input impedance of 400

Ohm and the Q- pin grounded will give a Q+ voltage of ±4V. However, if
you measure approximately +13V it is likely there is no current flowing.
If you measure approximately 0V it is likely the command from the plant is
not connected. These test points are useful if a test shows a fault and
you want to be sure that it is the valve and not the Valve Checker causing
it.

Q+ and Q- valve pin numbers:

Valve Q+ pin Q- pin

D66X 12 pin D E
D66X 11 + PE 4 5
D66X 6 + PE D E
D64X 6 pin D E
D633/4 6 pin D E
D633/4 6+ PE D E

5.8 LED Display

The LED display in the spool section shows the amplitude of the signal
selected by the spool signal rotary switch. This display provides a
rudimentary check of the spool signal. The centre blue null LED is
illuminated when the spool position is within ± 10% of null.

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6. CHECKER MODE OPERATION

+24V model (see Pg 12 for ±15V model illustration)

6.1 Checker Mode

Having successfully connected the Valve Checker as per chapter three,

select checker mode on the control selector switch.

CAUTION: Ensure the enable switch is in the master off position and
leave it in this position until all switch selections are made and
the test is ready to proceed.

6.2 Q command pot, initial setting and polarity

Set the Q command pot to its centre zero position and select the signal
type appropriate to the valve being tested. Set the ± polarity switch as
required.

If you are uncertain of the polarity, it is recommended to use + as a

starting point and check the direction of actuator travel in the process
plant, when testing begins.

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6.3 Spool
In the spool section select the appropriate spool signal. If selecting either
10mA or 4-20mA check if the plant electronics provides a load that
enables the current signal to flow. If there is no load, turn on the checker
load switch.

6.4 Enable

Begin the test by turning on the enable switch to enable the valve. The
enable LED should illuminate confirming that the valve is enabled. The
enable signal is also used in the valve checker to enable it to operate. On
valves that do not have an “enable signal input”, the Valve Checker
generates an internal enable signal.

6.5 Q Command
Adjust the Q command pot. Measure the command value, standardised to
0 to ±10V on the grey test point. Compare this value to the actual valve
spool output on the green test point. For correct function they should be
the same; within accuracy limits.

6.6 Checker Accuracy Limits

The accuracy limit of the Valve Checker is ± 0.2V for all signals. This
means that if you read a command of 5.6V the feedback signal could be
between 5.4 and 5.8V and the valve will be functioning correctly.

See pg. 10 for a table of Q+ and Q- valve pin numbers.

6.7 Valve Connector test points

The valve connector section test points enable a measurement directly on
the valve input pins. This is useful if a test shows a fault and you want to
be sure it is the valve and not the Valve Checker causing it. A knowledge
of the input impedance of the valve is necessary to calculate the current
level when the command is a mA signal.

6.8 LED Display

The LED display shows the amplitude of the spool signal. This display
provides a rudimentary check of the signal. The centre blue null LED is
illuminated when the spool position is within ±10% of null.

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7. EXTERNAL 24V SUPPLY

7.1 The Valve Checker can be powered from the plant electronics via the plant
connector or from the front panel 24V connector. When the external 24V
is supplied to this front panel connector three things happen:

- The Valve Checker internal power is derived from this supply.

- The 24V supply to valves powered by 24V comes from this supply.
- The ±15V supply to valves powered by ±15V comes from the
Valve Checker internal regulators, which in turn are powered by the
external 24V.

7.2 Supply requirements are:

- 2.1mm diameter connector: 24V outside contact, 0V inside contact.

- 18V to 36V input range.
- 90 mA at 24V to power the Valve Checker with no valve load.

7.3 Typical 24V maximum supply requirements for some 24V powered valves
are:

- D633 – 1.2A
- D634 – 2.2A
- D66X – 300mA

7.4 Typical 24V maximum supply requirements for some ±15V powered
valves are:

- D66X – 400mA (300mA @ ±15V)

CAUTION: When the external 24V supply is connected, the plant supply is
always automatically disconnected and the valve is then
powered, directly or indirectly, from the external 24V supply.
It is therefore essential that the external supply you connect
has adequate current capacity to power the valve you are
checking.

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8. VALVE PERFORMANCE CHECKS

The Checker can be used to test null, threshold, step response and
hysteresis. Because threshold and hysteresis on electrical feedback (efb)
valves are very low, it can be difficult to get an accurate figure if the valve
is operating within specification. Testing threshold and hysteresis is only
of value if the valve is well out of specification; and then only to confirm
incorrect operation, rather than accurately quantifying it.

8.1 Null
The Spool null position of a flow control (Q) valve is generally the point at
which there is no flow from either port. This is the case with axis cut
spools. However, valves can have overlapped, under-lapped and
combinations of the three types that can make checking null a little tricky.
An accurate understanding of the specified null characteristic of a valve is
essential before any sense can be made of null measurement results.

8.1.1 To check the null of an axis cut, or quasi axis cut spool (3% overlap), set
the Q Command so the actuator controlled by the valve is stationary.
Measure the command. This measurement is the null offset, or null error,
of the valve. It will be difficult to get the actuator to stop for both types
of axis cut spool. A slight creep one way or another is acceptable.

8.1.2 Checking the null on an overlapped vale is a little more difficult. Find a Q
Command that holds the actuator stationary, or near stationary. A small
amount of actuator creep is normal. Increase the Q Command until a
definite actuator velocity is observed. Record this value.
Decrease the Q Command until an equal reverse actuator velocity is
observed. Record this value. The two readings should be equal in
magnitude but opposite in sign. The difference in the magnitude of the
two readings is the null offset.

8.2 Threshold
8.2.1 Threshold on all types of valves is so low that it is difficult to use the
Valve Checker to get an accurate figure. However the procedure outlined
below will enable you to determine if the valve being checked is faulty,
assuming the actuator has low threshold.
- Bring the actuator to a stop with the Q Command.
- Place your finger at the junction of the rod and gland and slowly
move the Q Command back and forth around null. Limit the valve
drive to less than ± 10%.

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 - Using your finger, monitor the motion of the rod as its direction
reverses. The motion should be smooth and free of jerks.

8.2.2 On efb valves with spool position feedback, the same test can be done
while monitoring the spool feedback signal with an oscilloscope or chart
recorder. As the Q Command is smoothly reversed about null, the spool
signal should show no discontinuity.

8.3 Step Response

Set the Q Command to a small value, say 10%. Switch the command on
and off with the enable switch and observe the spool position feedback
signal on an oscilloscope. A alternative method is to set a 10% Q
Command and reverse the command to the valve by switching the ±
switch.

CAUTION: This test may be detrimental to the process or machine, so it

should only be done with care.

8.4 Hysteresis
8.4.1 To check hysteresis on an efb valve i.e. a valve with spool position
feedback, start with the Q Command fully negative. Monitor the spool
signal while changing the Q command towards null over several seconds.
Stop when the spool signal reaches null. During this procedure do not
reverse the direction while changing the Q Command. Measure the
command signal that was required to null the spool signal.

8.4.2 Slowly over a period of several seconds increase the Q Command to the
maximum positive value and then reverse it back towards null. It is
important that the spool signal comes to null while decreasing the
command. The measurements will be invalid if the command is reversed
at any time. Now measure the command signal at null.

8.4.3 The difference between the two null measurements, above, is the
hysteresis.

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8. BLOCK DIAGRAM

J1 VALVE CONNECTOR J2 PLANT CONNECTOR

ENABLE T.P. ENABLE &
J1/8 CONTROL J2/8
ENABLE OK ENABLE OK
ENABLE OK
+
VALVE OK T.P.
J1/11 J2/11
VALVE OK VALVE OK
VALVE OK
8.5V
Factory link for models that test
valves without an enable input.
6.5V
MASTER CONTROL
+15V
ENABLE T.P. ENABLE SWITCH J2/3
PLANT ( ENABLE )
J1/3 OFF
ENABLE
CHRK +15V
ON
ENABLE +15V
RL2

Output enable relay.

J2/5
Q command Q CMD
TPQ+
J1/4 Q+ CMD J2/4
Q+ CMD
CONTROL
PLANT
+/ SWITCH
+10V
J1/5 CHKR +/ 10V
Q CMD
cw
+ +/ 10mA
4-20mA Q CMD
TP Q
+ +/ 10V POT
+/ 10mA
TP 4-20mA
SPL+ T.P. 0 to +/ 10V -10V
J1/6 5K Reconstituted differential
DIFF SPOOL+
SPOOL +/ 10.5v, 7V Vcm, unbalanced
SPL T.P. 5K J2/7
DIFF (SPOOL)
J1/7
DIFF SPOOL
+ 15K J2/6
15K DIFF (SPOOL)+

+
CHECKER LOAD
Factory link for checker
models with only 4-20mA Provides a load for spool current signal if plant is
single ended not connected or does not provide a load.
+/ 10mA
spool signal. 50R
Spool current
sample resistor.
J1/12 50R J2/12
SPOOL ( SPOOL )

4-20mA SPOOL TP LED DISPLAY

0 to +/ 10V
+/ 10mA
+/ 10V
11 LEDs
+/ 10V DIFF
2.5 TO 13.5V +

POWER

J2/9
TP +15V +15V PLANT
J1/9
+15V VALVE
J2/10
TP 15V 15V PLANT
J1/10
15V VALVE

J1/1 TP 24V
+24V +15V 15V
+24V PLANT PLANT
J1/2 OV T.P. Factory links
OV Supply regulator
LK2 & 3 made for
DC1
24V CHECKER J2/2
+15V + + 0V
LK2
Power to J2/1
CHECKER 0 +24V PLANT
checker.
FRONT PANEL SOCKET
15V LK3
Contact opens
when a plug is
inserted into socket.
Relay senses 24V and powers +/ 15V supply
regulator from 24V when 24V is persent. PLUG
RL1 &3 are not present in 24V checkers. RL1 & 3 CONTACT

PROTECTIVE EARTH

OPERATION MANUAL CN 20.4.99

C31489
VALVE CHECKER Rev A CN 21.12.05
AUSTRALIA PTY. LTD.
20 of 20
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G040-123
manual.doc