Flowserve 2000 User Manual

0 (0)

Valtek StarPac II

Intelligent Control System

Valtek Logix Series 2000

Digital Positioner

GENERAL INFORMATION

The following instructions are designed to assist in unpacking, installing and performing maintenance as required on Valtek® StarPac® II Intelligent Control Systems and LogixTM 2000 Digital Positioners. Product users and maintenance personnel should thoroughly review this bulletin prior to installing, operating, or performing any maintenance on the valve.

More detailed operation instructions are included in the StarPac II / Logix 2000 Manual; refer to them when more information is needed.

Separate Valtek Installation, Operation, Maintenance instructions cover the valve (IOM 1 or IOM 27) and actuator (IOM 2 or IOM 31) portions of the system and other accessories. Refer to the appropriate instructions when this information is needed.

To avoid possible injury to personnel or damage to valve parts, users must strictly adhere to WARNING and CAUTION notes. Modifying this product, substituting non-factory parts, or inferior parts, or using maintenance procedures other than outlined could drastically affect performance and be hazardous to personnel and equipment, and may void existing warranties.

WARNING: Standard industry safety practices must be adhered to when working on this, or any, process control product. Specifically, personal protective and lifting devices must be used as warranted.

Unpacking

1. While unpacking the StarPac II / Logix 2000 unit, check the packing list against the materials received. Lists describing the system and accessories are included in each shipping container.

2. When lifting the system from the shipping container, position lifting straps to avoid damage to tubing and mounted accessories. Systems with valves up to eight inches may be lifted by actuator lifting ring. On larger systems, lift unit using lifting straps or hooks through the yoke legs and outer end of body.

WARNING: When lifting a valve/actuator assembly with lifting straps, be aware the center of gravity may be above the lifting point. Therefore, support must be given to prevent the valve/actuator from rotating. Failure to do so can cause serious injury to personnel or damage to nearby equipment.

3. In the event of shipping damage, contact your shipper immediately.

4. Should any problem arise, contact your Valtek Control Valve representative.

Valtek No. 133389

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

42-1

Preferred StarPac II / Logix 2000 Grounding

StarPac II User Interface Terminal

Grounding Screw for

Electrical Ground of Conduit

No Shield Connection at

StarPac II User Interface Terminal

Shields

Instrument

Ground

Shields

Instrument

Ground

Figure 1: Shielded Wire Diagram

+ 24V

- 24V

AIB, Extender or RS232/RS485 Converter

+ RS485

- RS485

+ Analog Output

- Analog Output

DCS + Analog Input

- Analog Input

Tools required for StarPac II / Logix 2000

Maintenance and Start-up

1. Multi-meter w/alligator clips, probes & jumpers

2. 4-20 mA analog calibrator with power supply

3. RS-232-485 communication and cabling

4. Windows

compatible PC

5. Standard 6-inch flat screwdriver

6. Standard phillips screwdriver

7.1/4-inch flat screwdriver

8. Small wire cutter (flush cut) & wire strippers

9. Needle-nose pliers

10.1/16-inch allen wrench

11. Vise grips

12. Small vise grips

13.1/2-inch nut driver

14.5/32-inch allen wrench

15. Large crescent wrench (minimum 15-inch)

16. 8-inch channel lock pliers

17.3/32-inch screwdriver

18. Wrist grounding strap

19. Antistatic bag or packaging

20. EPROM remover (PLCC type)

21. Electrical tape

22. Feedback shaft tool and drive module pressure calibration connectors (supplied with feedback module kit)

INSTALLATION Valve Installation

The StarPac II / Logix 2000 Intelligent Control System valve is installed in the same manner as a conventional control valve and according to industry standards. Refer to the appropriate valve installation, operation, maintenance instructions for proper installation procedures.

If the StarPac II is being installed in an insulated process line, do not place more than four inches of insulation around the pressure or temperature sensors; otherwise the sensors may not operate properly. In addition,

NEVER

insulate the unit electronics assembly or remote-mounted temperature/pressure sensors (when used).

CAUTION: Do not insulate the StarPac II / Logix 2000 electronics housing or remote-mounted pressure or temperature sensors; otherwise excessive heat may build up and affect operation.

Wiring and Grounding Guidelines

This section will help you achieve a maximum “noise -free” environment and performance with a StarPac II / Logix 2000 unit.

Shielding Versus Grounding

All signals to the StarPac II / Logix 2000 unit should be in shielded cables. Shields must be tied to a ground at only one end of the cable to provide a place for environmental electrical noise to be removed from the cable. A ground wire (unlike a shield) is attached at both ends to provide a continuous path for electrical conductivity.

Grounding Screw

The green grounding screw by the user interface terminal block should be used to provide the unit with an adequate and reliable earth ground reference. This ground should be tied to the same ground as the electrical conduit. Additionally, the electrical conduit connecting to the unit should be earth grounded at both ends of its run.

used to terminate signal shield wires.

24VDC Power

The 24 VDC connection points will work best with shielded twisted pair wire with the shield wire connected

The green grounding screw must not be

42-2

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Air Lines to Cylinder Actuator

Electronics Module with Keypad and Local Display

User Access Terminal Behind Lower Door

Temperature Sensor

Process Pressure Sensors

Figure 2: StarPac II / Logix 2000 Intelligent Control System Components

only at the source. The input power is isolated within the unit and may be referenced to whatever level is necessary.

connected to earth ground.

RS-485 Communication

RS-485 wiring requires the use of a shielded twisted pair cable, which is grounded only at the source and not in the unit. (For maximum performance, wire should have a characteristic impedance of 120 ohms.) The RS-485 input is fully isolated, using opto-isolators.

The RS-485 allows only a 7 to 12 V common mode voltage differential between stations. Valtek's RS-232 to RS-485 converter is not a grounded connection. PC's with internal RS-485 cards, on the other hand, are often grounded. If another ground communication device is on the network, a fault condition will almost certainly exist due to transient and steady state differences in ground potential.

4 - 20 mA Command Input, Auxiliary Input, and Feedback Output

These signals are isolated but shielded twisted pair wire should be used to reduce crosstalk from other signals. The shield should be connected only at the source.

Discrete Inputs and Outputs

These signals are isolated, but because they are frequently used to switch high voltage (120 VAC), they should be run in separate shielded wire paths away from the other StarPac II / Logix 2000 signals.

The 24 VDC power supply should not be

Position Feedback Arm

Electronics Conduit

AIB and RS-232 to RS-485 Converter Connection

When connecting a StarPac II / Logix 2000 unit to a communication device, no shield or ground connections exist. Hence, the 24 VDC power and RS-485 communication shield drain wires must be connected to a convenient ground near the AIB or converter.

Wiring The StarPac II / Logix 2000 System

All electrical connections must be done according to local and industry electrical codes. Valtek recommends a shielded cable be used for the RS-485 command signal wire (e.g., Belden 9841 or equivalent).

When connecting multiple StarPac II / Logix 2000 units, a parallel daisy-chain wiring pattern is used. Connect unit's branch lines to main line, keeping branch lines as short as possible. The total length of wiring should not exceed 4,000 feet (1,200 meters) without use of repeaters.

Avoid devices producing electrical 'noise' while installing the cable.

CAUTION: The following procedure should be performed on the bench or with the unit isolated so that unexpected valve stroking will not adversely affect the process.

WARNING: The following procedures may cause the valve to stroke, causing pressures and temperatures to vary from their norms. Notify appropriate personnel that the valve may stroke unexpectedly. Valtek suggests that the system be isolated from the process, if installed in line.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

42-3

1. Upper door assembly

2. Door screw (4)

3. Upper door gasket

4. Lower door assembly

5. Door screw (2)

6. Lower door gasket

7. Inner door/keypad assembly

8. Inner door screw (4)

9. Feedback cover assembly

10. Cover screw (4)

11.Driver cover assembly

12. Cover screw (4)

13. Hydrophobic filter cover

14. Cover screw (2)

15. Hydrophobic filter

16. Hall potentiometer assembly

17. Potentiometer bracket

18. Flex couple

19. Bracket screws (2)

20. Torsional spring

21. Feedback shaft

22. Shaft O-ring

23. Retaining ring

24. Screw, hard stop

25. Feedthrough assembly

26. Feedthrough O-ring

27. Board screw (2)

28. Block screw (2)

65 66

74 75

29. Isolator (4)

30. Filter (2)

31. Adapter O-ring, lower (2)

32. Pressure sensor adapter

33. Adapter O-ring, upper (2)

34. StarPac II / Logix 2000 board assembly

35. Board stiffener

36. Board assembly screw (3)

37. Board stiffener screw

38. Board assembly screw (3)

39. Board assembly screw

40. Personality card

41. Personality card screw (4)

42. Rubber grommet (2)

43. Housing assembly

Figure 3: Exploded View

44. Regulator set screw

45. Regulator housing screw (4)

46. Regulator housing

47. Spring button

48. Regulator spring

49. Regulator diaphragm assembly

50. Driver module mounting screw (4)

51. Pilot valve

52. Pilot valve screw (4)

53. Pilot valve gasket

54. Regulator filter

55. Poppet guide

56. Poppet O-ring

57. Poppet

58. Poppet spring

59. Spool

60. Spool clip

61. Driver manifold O-ring

62. Driver spacer

63. Driver bearing

64. Spool return spring

65. Driver piston

66. Magnet

67. Driver manifold diaphragm

68. T-board screw (2)

69. T-board

70. Orifice screw

71. Orifice screw O-ring

72. Orifice O-ring

73. Testing plug (2)

74. Coil O-ring

75. Pressure modulator assembly

76. Spring diaphragm

77. Modulator cover

78. Modulator set screw

79. Modulator screw (3)

80. Inner door screw (2)

81. Inner door screw O-ring (2)

82. Keypad gasket

83. Wire harness

84. 24-pin ribbon cable

85. 14-pin ribbon cable

42-4

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

out -

out +

out -

Analog

out +

Analog

Spare

Com B -

Com B +

Com A -

Com A +

24 VDC -

24 VDC +

Grnd (Blk)

out - (Wht)

out + (Grn)

+5 VDC (Red)

Thrm Coup (Yel)

Thrm Coup (Red)

Analog

1 2 3 4 5 6 7 8 9 10 1112 131415 1617

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Com A +

Com A -

Grnd (Blk)

out - (Wht)

out + (Grn)

in -

Analog

+5 VDC (Red)

in +

Analog

in -

in +

Analog

Spare

Figure 4: User Interface Terminal Pinouts

To connect the wiring to the StarPac II / Logix 2000 unit, refer to Figures 1 and 4, and Table I, then proceed as follows.

1. Open the lower door on the front of the housing.

WARNING: Do not open the electronic housing covers in flammable atmospheres; otherwise, possible injury to personnel or equipment may occur.

2. Connect the required wires to the terminal interface block and computer as described in Figure 4 and Table I. (The system must have 24 VDC power for operation.)

NOTE: The StarPac II / Logix 2000 unit remembers the operating mode setting (automatic or manual) from the last time the unit had power. When power to the system is turned on again, the unit will resume operation in the previous mode.

Normally the unit arrives from the factory set in the manual analog operating mode. This means a command signal will position the valve the same as a traditional control valve, providing a plug position proportional to the 4 - 20 mA signal.

To avoid upsetting the process because of improper operating mode selection:

• Ensure that the system arrived from factory with the proper operating mode setting in the shop prior to installation by connecting air supply and command signal, then turning on the power and looking at the mode value on the local display, or;

• Set the proper operating mode for the particular application in the shop prior to installation by selecting the desired operating mode from the local interface or in the Tuning/Tune screen of the StarTalk software, or;

Pulse Out

Discrete 2 in

Discrete 1 in

Alarm Contact

Discrete 1 in

• Ensure that the block valves in the process line around the unit are closed and the process is diverted around the unit.

Table I:

User Interface Terminal Connections

Signal Negative Positive

Term. No. Term. No.

24 VDC power 16 17 Valve command signal 24 25 Primary RS-485 14 15

communication link

Secondary RS-485 12 13

communication link Auxiliary input (4-20 mA) 22 23 Analog output (4-20 mA) 1 9 10

Analog output (4-20 mA) 2 7 8 Discrete input 1 – switch/ 33 34

solenoid monitoring

(discrete mode source

input) Discrete input 2 – switch/ 31 32

solenoid monitoring Discrete output 1 (malfunc- 29 30

tion alarm contact) Discrete output 2 (pulse) 27 28

3. Turn on the 24 VDC power to the unit, and verify that it has been correctly wired by checking the following:

• 24 VDC power is at least 300 mA and between 18.0 and 64.0 VDC

• Polarity is correct

• Local display is on; if not, check the power supply.

4. Close the front cover on the housing of the unit.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

42-5

System Communication Default Configuration

StarPac II / Logix 2000 units are shipped from the factory ready for installation and operation. Rarely do the units need to be re-configured prior to operation. Table II lists the factory default communication settings. If these settings are not correct for the equipment being used, proceed to the following sections.

Table II: Factory Default Mode Settings

Description Setting

Address 1 Parity odd Baud Rate 19,200 Modbus Communication Mode RTU RS-485 Termination Resistors Installed

Termination Jumpers

Selecting Correct Address Setting

If the StarPac II / Logix 2000 unit is the only one on the communication network, the default address (1) is fine.

If multiple units will be operating on the same communication network, each unit must have a unique address. Before changing the address, the StarTalk software can be used to determine what devices are on the line. (Remember to include devices that may be temporarily off line.)

If the default address setting needs to be changed, use the 'Comm' option in the configuration menu of the local interface to change the settings.

Selecting Correct Baud Rate Setting

StarPac II / Logix 2000 units support baud rates of up to 57,600 baud. However, both the StarPac II / Logix 2000 system and StarTalk software are shipped from the factory set to 19,200 baud.

If the default baud rate setting needs to be changed, use the 'Comm' option in the configuration menu of the local interface to change the settings.

Selecting Correct Modbus Transmission Mode

Two transmission modes exist in a Modbus system, ASCII and RTU (default). Use the ASCII mode when transmitting information through a device that uses ASCII control codes; for example, a modem. Use the RTU mode when connecting directly to both devices; for example, an RS-485 interface card wired directly to a StarPac II / Logix 2000 system.

If the default Modbus transmission mode setting needs to be changed, use the 'Comm' option in the configuration menu of the local interface to change the settings.

Figure 5: Termination Jumpers and

Personality Module

Selecting Proper RS-485 Termination Resistor Setting

A termination resistor must be installed on the two most remote devices on the network, counting the host computer as any other device.

(For example, a single StarPac II / Logix 2000 unit and the RS-485 driver in the host computer would each require the termination resistor to be installed. If four units were on the network with a host computer, decide which of the two devices have the most combined cable length between them. These two devices should have the termination resistors installed. The termination resistors should be disabled in the devices not considered to be the most remote using the instructions in the next section. Using more than two termination resistors in a network can cause the RS-485 communications to operate erratically or fail.)

To enable 120 ohms termination, insert both jumpers for A and B channels. To disable termination, remove both jumpers from each channel as shown in Figure 5.

SYSTEM MAINTENANCE

Valtek recommends that the StarPac II / Logix 2000 system calibration be checked every six months. If, after checking the unit, a component is determined to be defective, the following section will help with the component replacement.

The following items may be needed to install, start up and calibrate the unit's electronics.

42-6

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

• Power supply: 24 VDC, 300 mA

• Digital volt meter with 4 - 20 mA range

• Air supply: 50 psig minimum, 80-100 psig preferred

• Gauges or the ability to accurately determine pro-

cess pressures and valve air supply pressures

• 4 - 20 mA command source

• Thermocouple calibrator or simulator with 0 to 500°

Celsius range

8. Turn on the air supply to the valve and check for leaks in the reattached actuator tubing lines.

9. Turn on power to the unit. Check the system calibration and perform a Valve Stroke Calibration to reset the position feedback. Refer to the Calibration section of the StarPac II / Logix 2000 manual.

StarPac II / Logix 2000 Positioner Overview

Mechanical Subsystem Maintenance

Refer to the appropriate Valtek Installation, Operation & Maintenance (IOM) instructions for details on repair and maintenance of the control valve actuator components. Please refer to the manufacturers’ manuals for maintenance and operation instructions for non-pneumatic actuators, e.g., electric or electro-hydraulic actuators.

WARNING: The process line must be depressurized and drained of process fluid and decontaminated prior to working on internal valve components. Failure to do so may cause serious injury to personnel.

1. Depressurize the line, decontaminate the valve (if needed) and shut off the air supply to the valve positioner.

2. Disconnect the actuator air tubes from the unit.

3. Disconnect the two mounting bolts that attach the StarPac II / Logix 2000 system bracket.

4. Disconnect the follower arm from the unit base. This is done by removing the follower arm nut and washer and pulling the arm off the shaft. Notice that this shaft connection is keyed and that the shafts are slightly spring loaded.

5. The actuator subassembly is now isolated and is removed by loosening the bonnet bolts and lifting the actuator away from the body.

The tubing holds the StarPac II / Logix 2000 base in place, eliminating the need to disconnect wiring or air connections.

6. Standard valve maintenance may now be done on the actuator or valve body components. Refer to the Valtek IOM instructions for details on such things as trim or packing replacement. If you have to replace the trim, use the same trim number and characteristic as the original trim so the flow calculations are not affected. If a trim size change is needed, contact your Valtek representative to find out about flow characterization options.

7. Reassemble the system by reversing the above steps. Be sure to follow the procedures outlined in the Valtek IOM instructions for valve reassembly. When reconnecting the follower arm, make sure that the arm fits correctly on the keyed shaft and has a positive spring action.

The StarPac II / Logix 2000 is double-acting, capable of supplying air to either side of the actuator piston while exhausting the other side to the atmosphere. Also, the positioner can be mounted on either Valtek linear or rotary actuators without modification to the actuator.

The positioner is pending non-incendive for class I, division II, groups A, B, C, and D; class II, groups E, F, and G. Since the positioner is insensitive to supply pressure changes and can handle supply pressures from 30 to 150 psig, a supply regulator is usually not required; however, an air filter is required due to the close tolerances of the spool assembly.

NOTE: The air supply should conform to ISA Standard S7.3 (a dew point at least 18° F below ambient temperature, particle size below 5 microns, oil content not to exceed 1 part per million).

Positioner Operation

The StarPac II / Logix 2000 Positioner is an electric feedback instrument. Figure 6 shows a StarPac II installed on a double-acting actuator for air-to-open action. Positioning is based on a balance of two signals: one proportional to the modulator input signal and the other proportional to the stem position.

The supply pressure for the positioner modulator is tapped off the main supply and is filtered as it passes through a field-replaceable, coalescing filter element in the module. Next it passes through an internal pressure regulator that regulates it to approximately 22 psig. The air then goes through an orifice that restricts the flow and air consumption (refer to Figure 6).

The air is further controlled to 6-12 psig using a springdiaphragm flapper that is attracted by an electromagnet to a nozzle. A temperature compensated hall effect sensor mounted on a circuit board senses the spool valve position. The hall effect sensor and circuitry create a feedback loop, which determines how much current to send to the electromagnet for a desired spool valve position. The electromagnet in the feedback loop varies the nozzle-flapper spacing, which regulates the output pressure to 6-12 psig proportional to the command input signal.

When these opposing signals are equal, the system will be in equilibrium and the stem will be in the position called for by the command signal. If these opposing

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

42-7

Exhaust Output 1

Pilot Valve Spool

Air Supply

Air-to-open

Configuration

Digital

Position

Algorithm

Figure 6: Positioner Diagram

signals are not equal, the spool valve will move up (or down) and, by means of the modulator, will change the output pressures and flow rate. This will cause the piston to move until the signal of the feedback sensor equalizes with the command signal.

The detailed sequence of positioner operations are as follows: An increase in the command signal forces the modulator signal capsule and spool valve upward. This motion of the modulator also pushes the pilot valve spool upward from its equilibrium position. This opens the pilot valve ports, supplying air to port one and exhausting air from port two. This causes the actuator piston to move upward.

This upward motion of the piston is transmitted back to the positioner through the feedback linkage and hallpot sensor signal changing proportionally to the valve position. The piston continues to stroke upward until the signal of the feedback sensor increases sufficiently to counter the signal being sent to the modulator. At this point, the spool is at its equilibrium position as the pressures in the cylinder stabilize and the air flow to the actuator decreases.

After the piston has reached the required position, the feedback signal will equal the spool position generated in the modulator capsule. The computer will then make small null adjustments to fine-tune the desired position and compensate for changes in dynamic loading.

A decrease in the command signal reverses the described actions causing a proportional downward movement of the actuator piston and stem.

Output 2 Exhaust

Stem Position Sensor

Spool Position Sensor

Nozzle

Electromagnetic Coil

Flapper

Filter

Regulator

Orifice

Position Feedback System

The position feedback linkage of the StarPac II / Logix 2000 system is a critical part of the system. This linkage is also used in the StarPac II to calculate the valve’s C for a given stroke for flow measurement. This linkage should be lubricated and checked periodically for tight, smooth operation. The follower arm should operate smoothly with no binding and have a positive spring loading on the arm. Inspect the follower arm pin for excess wear and replace if needed. The take-off arm attached to the stem clamp must be firmly secured to the stem clamp and perpendicular to the actuator stem. If this takeoff arm is canted or misaligned, problems may occur with positioner calibration and the position reading on the unit may go out of range.

On rotary actuators, make sure the adjustment linkage locknut is tight and has no excessive play in the ball joints. The rotary shaft clamp must be tight and should not freely rotate on the shaft.

Pressure Sensor Replacement

Standard StarPac II pressure sensors are typically installed directly into the control valve body. Before they can be removed, the process line must be depressurized and drained of all fluids and the valve decontaminated.

To replace a pressure sensor, refer to Figure 7 then proceed as follows.

WARNING: The process line must be depressurized and drained of process fluid, and decontaminated prior to working on internal valve components. Failure to do so may cause serious injury to personnel.

42-8

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

+ 16 hidden pages