Flowserve Limitorque Master Station III User Manual

USER INSTRUCTIONS

Limitorque Master Station III

FCD LMENIM5001-02 – 12/13

Installation

Operation

Maintenance

Experience In Motion

Limitorque Master Station III FCD LMENIM5001-02 – 12/13

Contents

1. Introduction 5

2. Function Flowchart 9

3. Quick Startup 12

4. Connections 13

5. System Status 19

6. System Control 22

7. Email Configuration 26

8. System Configuration 30

9. Diagnostics 62

10. Troubleshooting Guide 65

Figures

Figure 1.1 - Introduction 6
Figure 1.2 - Enter User Name 6
Figure 1.3 - Login 6
Figure 1.4 - Main Menu 7
Figure 2.1 - Function Flowchart 10-11
Figure 4.1 - Master Station Rear Panel Connections 13
Figure 4.2 - DCS Port Connection 14
Figure 4.3 - DCS Port Connection with MS2/MS3 Adaptor 14
Figure 4.4 - Master Station Front Panel Connections 16
Figure 4.5 - Debug Port Connection 16
Figure 4.6 - Modbus Redundant Loop Topology 18
Figure 5.1 - The Main Menu Screen 19
Figure 5.2 - System Status 20
Figure 5.3 - Network Status 20
Figure 5.4 - MOV Status 21
Figure 5.5 - MSIII Status 21
Figure 6.1 - Main Menu 22
Figure 6.2 - System Control 23
Figure 6.3 - MOV Control 23
Figure 6.4 - Control Relays 23
Figure 6.5 - Emergency Shutdown 24
Figure 6.6 - Emergency Shutdown in Progress 24
Figure 6.7 - Emergency Shutdown Termination 25
Figure 6.8 - Emergency Shutdown Initiation Complete 25
Figure 7.1 - Main Menu 26
Figure 7.2 - Email Notification Screen 27
Figure 7.3 - SMTP Address 27

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Figure 7.4 - SMTP Configuration without Password 27
Figure 7.5 - SMTP Configuration with Password 28
Figure 7.6 - Add Email Listener 28
Figure 7.7 - Alarm Selections 29

Limitorque Master Station III FCD LMENIM5001-02 – 12/13

Figures (Continued)

Figure 8.1 - Main Menu 30
Figure 8.2 - System Configuration 31
Figure 8.3 - System Settings 32
Figure 8.4 - Version 32
Figure 8.5 - Language Menu 32
Figure 8.6 - Clock 33
Figure 8.7 - Time Zone 33
Figure 8.8 - Screen Saver 33
Figure 8.9 - Configure Hot Standby 34
Figure 8.10 - Configuration Transfer Lockout 34
Figure 8.11 - Tag List 35
Figure 8.12 - User Administration 35
Figure 8.13 - Enter New Username 36
Figure 8.14 - Enter New Password 36
Figure 8.15 - Delete User 36
Figure 8.16 - User Settings 37
Figure 8.17 - Change Password 38
Figure 8.18 - Enter New Password 38
Figure 8.19 - DCS Configuration 39
Figure 8.20 - Serial Port Configuration 39
Figure 8.21 - Configure Ethernet Port 40
Figure 8.22 - Configure DCS Data Table 40
Figure 8.23 - FC-02 Read Input Status 41
Figure 8.24 - Modbus Holding Registers 44
Figure 8.25 - FC-03 Sample Data Table 45
Figure 8.26 - ModBus Coils 49
Figure 8.27 - FC-05/15 Sample Data Table 49
Figure 8.28 - Modbus Holding Registers - One Per MOV 51
Figure 8.29 - Modbus Holding Registers - Two Per MOV 51
Figure 8.30 - FC-06/16 Sample Data Table with ‘One Per MOV’ Selected 52
Figure 8.31 - FC-06/16 Sample Data Table with ‘Two Per MOV’ Selected 52
Figure 8.32 - MOV Network Configuration 56
Figure 8.33 - Active MOVs 56
Figure 8.34 - Polling Priority-Active MOVs 57
Figure 8.35 - File Manager 58
Figure 8.36 - Import Config File 58
Figure 8.37 - Import Tag File 59
Figure 8.38 - Load Configuration from File 59
Figure 8.39 - Export Config File 60
Figure 8.40 - Export Event Log 60
Figure 8.41 - Update Software 61
Figure 8.42 - Restore Factory Defaults 61
Figure 9.1 - Main Menu 62
Figure 9.2 - Diagnostics 63
Figure 9.3 - Event Log 63
Figure 9.4 - Comm/FC Logger 64
Figure 9.5 - Polling Statistics 64

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Figures (Continued)

Figure 10.1 - Surge Protection Access 67
Figure 10.2 - Main AC Power Input Module 67
Figure 10.3 - Removing Main AC Input Power Module 68
Figure 10.4 - AC Surge Protector 68
Figure 10.5 - Removing Fuse Holder 68
Figure 10.6 - AC Fuse Holder 69
Figure 10.7 - Network Surge Protector 69
Figure 10.8 - Removing Network Surge Protector 69

Tables

Table 1.1 - Network Topology Cable Specifications 8
Table 4.1 - Network Channel A Connection 15
Table 4.2 - Network Channel B Connection 15
Table 8.1 - Status Bit Definitions 41-43
Table 8.2 - Function Code -02 Example Message Breakdown 44
Table 8.3 - Function Code -03 Example Message Breakdown 45
Table 8.4 - Register Definitions 46-48
Table 8.5 - DDC-100 Coil Assignments, Modbus 05 Command Usage for Digital Outputs 50
Table 8.6 - Function Code -05 Example Message Breakdown 50
Table 8.7 - Function Code -15 Example Message Breakdown 51
Table 8.8 - Function Code -06 First Command Message Breakdown 52
Table 8.9 - Function Code -06 Second Command Message Breakdown 53
Table 8.10 - Function Code -06 Message Breakdown 53
Table 8.11 - Function Code -16 Message Breakdown 54
Table 8.12 - Valid Command Register Operations 54
Table 8.13 - Valid Argument Register Operations 55

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Limitorque Master Station III FCD LMENIM5001-02 – 12/13

Introduction

1.1 Overview

The next-generation master station is designed and manufactured by Flowserve Limitorque specifi­cally for use with the Limitorque line of (Modbus) electric actuators. The Master Station III (MSIII)
acts as a single-source controller for up to 250 actuators with full redundancy, e-mail alert notifica­tion, and multi-lingual support.

The Master Station III is a plug-and-play solution that provides complete control, monitoring, and
diagnostics of Limitorque electric actuators through a simple touch-panel display serving as a Human
Machine Interface (HMI).

1.2 User Role Overview

The Master Station requires users to login. Four user role levels are configurable for each user: View,
Control, Configure, and Administrator. Each role includes the rights of the lesser roles (i.e., Control
includes View’s rights, and Configure includes Control’s rights and View’s rights).

VIEW: the user can view the network status and the activity log. No control or configuration
functionality is available.

CONTROL: in addition to View rights, the user has the ability to control MOVs.

CONFIGURE: in addition to Control rights, the user has the ability to configure the Master Station and

the Network.

ADMINISTRATOR: in addition to Configure rights, the user has the ability to add or delete users, as
well as modify user settings.

These roles can be changed by an Administrator user. See Section 8.2.4, User Administration for
details.

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Limitorque Master Station III FCD LMENIM5001-02 – 12/13

1.3 Login

When the Master Station completes the boot process, it loads the Introduction screen (Figure 1.1).

Figure 1.1 - Introduction

Touching any part of the screen will load the Enter User Name screen (Figure 1.2).

NOTE: If the screen is blank and the green LED is illuminated, the unit is in screen saver mode.
Touch the display to exit the screen saver mode.

Figure 1.2 - Enter User Name

Once the user name has been entered, the Enter Password screen will be displayed (Figure 1.3).

NOTE: Each user name must have a unique password.

Figure 1.3 - Login

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Passwords and user names are set via the User Administration menu, under System Configuration.
The correct password entry for the respective user name will advance the screen to the Main Menu
(Figure 1.4).

In the event that passwords are lost or forgotten, please contact your Limitorque service coordinator
at [phone].

1.4 Main Menu

Once logged in, the user will see the Main Menu (Figure 1.4).

Figure 1.4 - Main Menu

From here, the menu options are displayed based on the current user role. Each button represents a
separate logical section of the Master Station:

SYSTEM STATUS (ALL USERS): View information related to the network status, status of the Master
Station, and MOV status.

SYSTEM CONTROL (CONTROL, CONFIGURE, AND ADMINISTRATOR): Access to MOV control and
emergency shutdown functions.

EMAIL CONFIGURATION (CONFIGURE AND ADMINISTRATOR): View and change settings related to
email alerts.

SYSTEM CONFIGURATION (CONFIGURE AND ADMINISTRATOR): Configure the main functions of
the Master Station. User Administration functions in this section are accessible only to Administrator
users.

DIAGNOSTICS (CONFIGURE AND ADMINISTRATOR): Activate event logging, communication data
analysis, or polling statistics.

REBOOT: Restart the Master Station.

SHUT DOWN: Turn off the Master Station.

EXIT: Log out of the Master Station user mode.

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Limitorque Master Station III FCD LMENIM5001-02 – 12/13

1.5 Technical Data

1. Power supply: 100-240 VAC 50/60HZ or 24 VDC. Maximum current is 1.5 A.

2. Operating temperature: 0-60°C (32-140°F)

3. Enclosure: Desktop/Shelf housing (standard), 19” rack mountable (optional), NEMA 4/4X
wall-mountable (optional), or mounted in a stand-alone cabinet (optional). Standard
dimensions are 16” (w) x 8.25” (h) x 18.5” (d)

4. Human machine interface: 5.6” diagonal, 640x480 resolution, lighted, TFT color graphic LCD.
Supports multiple languages: English, Spanish, Italian, German, and French.

5. Electromagnetic Compatibility (EMC) Compliance:

a. Emissions/Immunity – EN 61326-1:2006
b. Harmonics – EN 61000-3-2
c. Flicker – EN 61000-3-3

6. Communication protocol – MSIII to Field Units: Modbus RTU

7. Communication protocol – MSIII to Host System: Modbus RTU or Modbus TCP/IP

8. Network topology – Bi-directional redundant loop or multi-drop/daisy chain

9. Physical layer – MSIII to field units: EIA-485 (RS-485)

10. Physical layer – MSIII to Host System: TIA-232 (RS-232) / EIA-485 (RS-485) /EIA-422

(RS-422) / Ethernet

11. Unit redundancy options: MSIII module redundancy, isolated power connections (standard)

12. Communications Rate – MSIII to field units: 19.2 Kbaud max (Serial)

Host System to MSIII: 115.2 Kbaud max (Serial)
Host System to MSIII: 100 Mbits per second max (Ethernet)

Maximum recommended host system polling rate at 9.6 Kbaud
and above:

125 register reads / 500 ms
44 register writes / 500 ms

Table 1.1 - Network Topology Cable Specifications

Network Topology

(kbit/s)

Multi-drop/Daisy Chain
(with 24 field units)

Redundant Loop
(with 240 field units)

Max. Segment Length

(Belden 3074F with
no repeaters, meters)

1200 30

1200 289.2

Max. Cable Length

(kilometers)

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Function Flowchart

The following flowchart graphics illustrate the functions of the Master Station III.

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Figure 2.1 - Function Flowchart

Limitorque Master Station III FCD LMENIM5001-02 – 12/13

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Figure 2.1 - Function Flowchart (continued)

Limitorque Master Station III FCD LMENIM5001-02 – 12/13

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Limitorque Master Station III FCD LMENIM5001-02 – 12/13

Quick Startup

3.1 Master Station Quick Startup Instructions

1. Connect earth ground (#14AWG minimum) wiring, MOV network cables (Belden

#3074F/#9841/#3107), and power cable.

2. Apply power to the Master Station.

3. Wait for the Master Station to display the start-up screen.

4. Touch the screen, then enter user name “FLOW”. Select Enter.

5. Enter password “100” when prompted. Select Enter.

6. Next select “System Configuration” then “Redundant Configuration”.

7. Set the requested mode to “Disabled”, startup mode to “Active”, and redundancy mode

to desired setting.

8. Next select the “back” button and in the “System Configuration” select “User Administration”.

9. Set up user accounts per Section 8.2.4.

10. Select “MOV Network Config” and set up per Section 8.2.6.

11. Select “DCS Configuration” and set up per Section 8.2.5.

For remote DCS control, the three primary registers of interest are:

- 46001: Register for HS Status (Read Only): 0=idle, 1=standby, 2=hot

- 46002: Register for Host System to toggle (Write Only): 3=toggle state

- 46191: Register for Internal Program Execution Heartbeat/Watchdog (Read Only):
Updates every scan, 8-bit integer

12

Further adjustments may be made by following the procedures outlined in this manual.

12. Tap the “Back” button to return to the “System Configuration” screen.

13. Select “Redundant Config” and change the requested mode to “Active”.

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Limitorque Master Station III FCD LMENIM5001-02 – 12/13

Connections

4.1 Master Station Rear Panel Connections

Figure 4.1 - Master Station Rear Panel Connections

8

7

6

1. Ethernet Ports, RJ-45 connectors. One port is designated for MNET (Modbus Ethernet TCP/
IP). The other port is for the webserver. Either port may be used for either function as they are
connected to the same CPU.

5

9

1

2

3

4

2. Main DCS Port. DB-9 Female connector. Port may be RS-232 or RS-422 or RS-485. Each electrical
standard uses a different wiring convention.

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Limitorque Master Station III FCD LMENIM5001-02 – 12/13

Figure 4.2 - DCS Port Connection

NOTE: For cases where an existing Master Station II is being replaced with a Master Station III, an
adaptor is required for communications over RS-485 or RS-422. Pin changes to support an existing
MSII setup are detailed in Figure 4.3. Consult factory if an adaptor is needed.

Figure 4.3 - DCS Port Connection with MS2/MS3 Adaptor

3. Auxiliary 24 VDC power connection for Main.

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4. Main power switch and connector for 120 – 240 VAC.

5. Electrostatic Ground. A good quality earth ground MUST be attached to the Master Station. An
effective local, low-impedance earth ground (less than 5 ohms) is required.

Limitorque Master Station III FCD LMENIM5001-02 – 12/13

6. Hot Standby unit main power switch and connector for 120 – 240 VAC.

7. Auxiliary 24 VDC power connection for Hot Standby.

8. Hot Standby DCS Port. DB-9 Female connector. Port may be RS-232 or RS-422 or RS-485. Each
electrical standard uses a different wiring convention.

9. Network Connections- Channel A and B. Connections for the network wiring for channels A and B.
See Tables 4.1 and 4.2 below for connection details.

NOTE: Each module (Main or Hot Standby) can support any combination of the two power inputs (Main
120-240 VAC, 24 VDC).

Table 4.1 - Network Channel A Connection

Connector MX/QX UEC-3-DDC

DATA-A1 (+) 13 TB4 D-S
DATA-A1* (-) 14 TB4 D-S*
Shield N/C

Table 4.2 - Network Channel B Connection

Connector MX/QX UEC-3-DDC

DATA-A2 (+) 5 TB3 D-M
DATA-A2* (-) 4 TB3 D-M*
Shield 3

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Limitorque Master Station III FCD LMENIM5001-02 – 12/13

9

5

3

8

1

2

7

4

6

DSR

DTR

RTS

RXD

DCD

CTS

DB-9

RS 232

TXD

GND

N/C

4.2 Master Station Front Panel Connections

Figure 4.4 - Master Station Front Panel Connections

2

4

16

863175

1. Ethernet Port, RJ-45 connector. Can be used for MNET (Modbus Ethernet TCP/IP) or for the
webserver.

2. Hot Standby Ethernet Port, RJ-45 connector. Can be used for MNET (Modbus Ethernet TCP/IP) or
for the webserver.

3. USB Ports.

4. Hot Standby USB Ports.

5. Printer / Debug Port. DB-9 Female connector. RS-232 port. Used for Master Station diagnostics.

Figure 4.5 - Debug Port Connection

6. Hot Standby Printer / Debug Port. DB-9 Female
connector. RS-232 port. Used for Master Station
diagnostics.

7. VGA Port. Used for connecting a monitor to the

Master Station Main unit.

8. Hot Standby VGA Port. Used for connecting a

monitor to the Master Station Hot Standby unit.

Limitorque Master Station III FCD LMENIM5001-02 – 12/13

4.3 Master Station Wiring Requirements

The network cable connects the field units to the host controller or Master Station. Belden 3074F,
3105A, or 9841 shielded, twisted-pair cable should be used. The use of other cables may result in a
reduction of internodal distances or increased error rate, and is the user’s responsibility.

BELDEN 3074F SPECIFICATIONS

• Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 4000’(1.2 km)

For loop mode, this is the total length between operating field units. If a field unit loses power, the
relays internal to the field unit connect the A1 Channel to the A2 Channel, which effectively doubles
the length of the cable (assuming a single field unit fails). To ensure operation within specifications
in the event of power failure to field units, this consideration must be added. Example: To ensure
operation within specification when any two consecutive field units lose power, the maximum length
of cable up to 19.2 bkps should not exceed 4000’ (1.2 km) per every four field units.

Key Specifications

• Resistance/1000 ft = 18 AWG (7 x 26) 6.92 ohms each conductor (13.84 ohms for the pair)

• Capacitance/ft = 14 pF (conductor-to-conductor)

• Capacitance/ft = 14 pF (conductor-to-shield)

BELDEN 3105A SPECIFICATIONS

• Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 4000’ (1.2 km)

For loop mode, this is the total length between operating field units. If a field unit loses power, the
relays internal to the field unit connect the A1 Channel to the A2 Channel, which effectively doubles
the length of the cable (assuming a single field unit fails). To ensure operation within specifications
in the event of power failure to field units, this consideration must be added. Example: To ensure
operation within specification when any two consecutive field units lose power, the maximum length
of cable up to 19.2 bkps should not exceed 4000’ (1.2 km) per every four field units.

Key Specifications

• Resistance/1000 ft = 22 AWG (7 x 30) 14.7 ohms each conductor (29.4 ohms for the pair)

• Capacitance/ft = 11.0 pF (conductor-to-conductor)

• Capacitance/ft = 20.0 pF (conductor-to-shield)

BELDEN 9841 SPECIFICATIONS

• Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 3500’ (1 km)

For loop mode, this is the total length between operating field units. If a field unit loses power, the
relays internal to the field unit connect the A1 Channel to the A2 Channel, which effectively doubles
the length of the cable (assuming a single field unit fails). To ensure operation within specifications
in the event of power failure to field units, this consideration must be added. Example: To ensure
operation within specification when any two consecutive field units lose power, the maximum length
of cable up to 19.2 bkps should not exceed 3500’ (1 km) per every four field units.

Key Specifications

• Resistance/1000 ft = 24 AWG (7 x 32) 24 ohms
each conductor (48 ohms for the pair)

• Capacitance/ft = 12.8 pF
(conductor-to-conductor)

• Capacitance/ft = 23 pF (conductor-to-shield)

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4.4 Master Station Network Topologies

Figure 4.6 - Modbus Redundant Loop Topology

MASTER STATION III

Channel A Channel B

Diagnostic Note:

Polarity and level of the network’s data connection
can be checked by measuring voltage between data
and data* terminals. This voltage should be greater
than +200 mV DC with network controller (host)
network ports disconnected. Data terminal is
positive with respect to data* terminal.

Earth Ground Note:

If low impedance earth ground is not available at each
actuator, contact engineering for alternative earth
ground surge protection strategies.

Legend

MOV
13

14
5
4

- Motor-operated valve

- Data A1

- Data A1*

- Data A2

- Data A2*

- Shield

N/C

- No connection

Data terminal is positive with respect to
data* terminal

Notes:

1) Belden 3074F, 3105A, or 9841 shielded cable is recommended.

2) Correct polarity for field unit and network controller
connection is necessary for proper operation.

3) Connections shown are typical. The number of
MOVs shown may not indicate true system size.

4) Earth ground: ground rod

5) Earth ground: ground rod or lug in

actuator if actuator is grounded.

MOV-1

See Note 5

3 3

A1*

14
13A2A1

4

A2*

5

MOV-250

See Note 5

3
14

A1*

13A2A1

4

A2*

5

N/C

N/C

MOV-2

See Note 5

A1*

14
13A2A1

4

A2*

5

MOV-249

See Note 5

3 3

14

A1*

13A2A1

4

A2*

5

N/C

N/C

MOV-3

See Note 5

3

A1*

14
13A2A1

4

A2*

5

MOV-248

See Note 5

14

A1*

13A2A1

4

A2*

5

N/C

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18

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Limitorque Master Station III FCD LMENIM5001-02 – 12/13

System Status

5.1 Main Menu

Upon successful login as a user assigned to any role level, the System Status button on the Main
Menu screen will be present. Simply touching the System Status button will advance the HMI display
to the System Status screen (Figure 5.2). By selecting Exit, the user will end the session and log out.

Figure 5.1 - The Main Menu screen

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5.2 System Status

The System Status main screen (Figure 5.2) allows the user to view the overall status of the MOV
network and Master Station.

Figure 5.2 - System Status

5.2.1 Network Status

The Network Status screen presents an overview of the entire field unit network, up to 25 activated
MOVs per page. Only those MOVs that have been activated will be displayed. See MOV Network
Config in System Configuration screen to activate desired MOVs.

Figure 5.3 - Network Status

The numeric buttons represent addressed MOVs, while the A and B bars represent associated
MOV communication channels A&B. The MOVs and their respective communication channels are
constantly being monitored and will display green if OK and red if faulted. The user can advance to
the MOV Status screen by either touching an addressed MOV or touching the Back button to return to
System Status screen, and then selecting MOV Status.

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5.2.2 MOV Status

The MOV Status screen reveals the actual MOV network address, tag name, unit type, and position. In
addition, it shows the status of the MOV communication channels and the Modbus holding registers
that have been selected to be mapped to the PLC/DCS data table. See Section 8.2.5.3 Configure Data
Table for register content details.

Figure 5.4 - MOV Status

By default the Unit Type is not read from the MOVs and will show up as “Not Available” on the MOV
Status screen. In order to obtain and display the Unit type, the user must make some changes to the
DCS Data Tables as explained in section 8.2.5.3 - Configure Data Tables.

To view the Unit Type:

1. Under ‘Modbus FC 03’ submenu, include Register #11 (Digital Outputs) in the block of
registers being read from the MOVs.

2. Under ‘Modbus FC 02’ submenu, include the four MOV Series bits (from Register #11) in the
set of inputs available for reading.

Returning to the MOV Status screen will now display the Unit Type along with the rest of the MOV
status information.

5.2.3 MSIII Status

The MSIII Status screen provides Master Station status of the following functional components:

1. CPU Module temperature

2. Available memory for logging data

3. CPU Module up-time

Figure 5.5 - MSIII Status

4. Last login time

5. Last configuration change time

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