Flowserve Logix MD+ ValveSight User Manual

with HART®

ValveSight™ Diagnostics DTM Manual

Logix® MD+ Positioners

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

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Table of Contents

LOGIX MD+ .................................................................... 3

QUICK START GUIDE ................................................... 4

S

YSTEM REQUIREMENT

DTM I

NSTALLATION

C

REATE A FIELD NETWORK

DTM L

ICENSING

..................................................................................................... 6

......................................................................................................... 8

.............................................................................................. 10

............................................................................................................ 16

BASIC DASHBOARD ................................................... 17

ADVANCED DASHBOARD .......................................... 20

ANNUNCIATOR PANELS ............................................ 25

A

LARMS ANNUNCIATOR

M

ANAGEMENT ANNUNCIATOR

E

VENT HISTORY

.................................................................................................. 26

........................................................................................ 43

............................................................................................................. 55

HEALTH ....................................................................... 58

V

ALVE HEALTH

P

OSITIONER HEALTH

A

CTUATOR HEALTH

C

ONTROL HEALTH

T

RAINING

.............................................................................................................. 59

Friction .............................................................................................................. 64

Bellows Cycles & Travel ................................................................................... 72

....................................................................................................... 76

Teperature & Humidity .................................................................................... 82

Pilot Relay ........................................................................................................ 84

Piezo Voltage .................................................. ................................................. 88

........................................................................................................ 90

Actuator Pnuematic Leak ................................................................................. 94

Supply Pressure ................................................................................................ 97

Actuation Ratio .............................................................................................. 100

Actuator Cycles & Travel ................................................................................ 102

........................................................................................................ 106

Deviation ........................................................................................................ 110

Position Alerts ................................................................................................ 113

Command Frequency ..................................................................................... 116

Command Amplitude ..................................................................................... 119

Position Frequency ......................................................................................... 122

Position Amplitude ......................................................................................... 125

................................................................................................................... 128

ON-LINE DIAGNOSTICS ............................................ 130

D

ATA MONITOR

T

RENDS

C

ONTINUOUS STROKE TEST

.......................................................................................................... 131

...................................................................................................................... 137

............................................................................................ 142

OFF-LINE DIAGNOSTICS .......................................... 144

R

AMP TEST

................................................................................................................. 145

Ramp Compare ............................................................................................... 155

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

S

TEP TEST

................................................................................................................... 160

Step Test Compare ......................................................................................... 167

HDRL T

EST

................................................................................................................. 171

HDRL Compare ............................................................................................... 179

P

ARTIAL STROKE TEST

Partial Stroke Compare .................................................................................. 189

Partial Stroke Schedule .................................................................................. 193

................................................................................................... 183

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CALIBRATION ........................................................... 195

S

ENSOR CALIBRATION

C

OMMAND CALIBRATION

C

ALIBRATION ERRORS

................................................................................................... 196

.............................................................................................. 202

................................................................................................... 206

CONFIGURATION ...................................................... 213

C

ONFIGURATION MANAGEMENT

DTM L

ICENSE MANAGEMENT

P

OSITIONER UPGRADE MANAGEMENT

P

OSITIONER UPGRADE

L

OCAL INTERFACE

C

ONTROL

.................................................................................................................... 237

Position Shutoff .............................................................................................. 238

Soft Limits ....................................................................................................... 240

Positioner Gain ............................................................................................... 242

Pressure Control ............................................................................................. 245

Stroke Characterization ................................................................................. 247

I

NFORMATION

Actuator ......................................................................................................... 260

Valve Body ...................................................................................................... 262

Valve Trim ...................................................................................................... 264

Positioner & HART® Information ................................................................... 266

C

ARD SLOT

U

NITS

................................................................................................................. 268

Multi-Function Card ....................................................................................... 269

........................................................................................................................ 277

.................................................................................................. 229

......................................................................................................... 231

Stroke Characterization (Custom) ................................................................... 254

............................................................................................................. 259

Analog Output Calibration ............................................................................... 271

Discrete Output (DO) ........................................................................................ 275

.................................................................................... 214

........................................................................................ 223

............................................................................ 225

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

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Welcome to the Logix MD+

Welcome to the Flowserve ValveSight® DTM for the Logix MD+ series digital positioners. This package offers unparalleled functionality for configuring, calibrating, maintaining and diagnosing control valve operation.

This package follows the standard FDT/DTM conventions. The Frame application controls the menu bar at the top of the page and the Frame connection tree at the far left of the frame window.

The DTM application contains a menu tree on the left side showing the available pages for configuring, calibrating, maintaining and diagnosing control valve operation.

At the top of the DTM window, the device tag is shown, and some basic information for the actuator and valve that is currently connected to the system.

The bar right below the device information contains two icons, one to toggle the menu bar on and off and the other to show this help.

At the bottom of the page below the Flowserve logo is an icon indicating the status of the connection to the field device. If the icon has a green check and the tow plugs touching it indicates that communications are taking place and the device shown at the top of the page is online. Two green arrows to the right of the connection symbol are visible when the DTM is requesting information from the device.

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Quick Start Guide

GENERAL INFORMATION This Document

This document details the installation and functions of the ValveSight® Device Type Manager (ValveSight DTM) for the Logix® MD+ series of digital positioners including the Logix 520MD+.

Qualified Personnel

Qualified personnel are people who, on account of their training, experience and instruction and their knowledge of relevant standards, specifications, accident prevention regulations and operating conditions, have been authorized by those responsible for the safety of the plant to perform the necessary work and who can recognize and avoid possible dangers.

Additionally, product users and maintenance personnel should thoroughly review the Logix MD+ Series Digital Positioner Instruction, Operation, Maintenance and Safety Manual prior to installing, operating, or performing maintenance on the valve or positioner.

System Disclaimer

The installation instructions herein show an example of how to install, navigate, or commission the ValveSight Logix MD+ DTM in a WINDOWS 7 64 bit operating system, using the fdtCONTAINER FRAME Application. Any variation of operating system and/or FRAME application may result in a different procedure to install, operate, or commission the ValveSight Software.

Terms Concerning Safety

The safety terms DANGER, CAUTION and NOTE are used in these instructions to highlight particular dangers and/or to provide additional information on aspects that may not be readily apparent.

To avoid possible injury to personnel or damage to valve parts, DANGER and CAUTION notes must be strictly followed. Modifying this product, substituting nonfactory parts or using maintenance procedures other than outlined could drastically affect performance and be hazardous to personnel and equipment, and may void existing warranties.

NOTE: indicates and provides additional technical information, which may not be very obvious even to qualified personnel.

CAUTION: Indicates that minor personal injury and/or property damage can occur if proper precautions are not taken.

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DANGER: Indicates that death, severe personal injury and/or substantial property damage can occur if proper precautions are not taken.

Compliance with other, not particularly emphasized notes, with regard to transport, assembly, operation and maintenance and with regard to technical documentation (e.g., in the operating instruction, product documentation or on the product itself) is essential, in order to avoid faults, which in themselves might directly or indirectly cause severe personal injury or property damage.

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System Requirement

Computer System

The ValveSight® DTM has been successfully tested with the following Operating System with a minimum of 512 M RAM:

• Windows XP

• Windows 7

Power Supply

• Non-filtered, 4-20 mA

Modem

• IFAC HART Modem

• Viator RS 232 Serial HART Modem

• UX Multiplexor

Communication DTM

• CodeWrite COMM DTM

• M&M – OEM HART COMM DTM (recommended)

• Yokogawa COMM DTM

• ABB COMM DTM

FRAMES

The ValveSight Logix MD+ DTM has been successfully tested in the following FRAME Applications:

• fdtCONTAINER FRAME Application

• PactWare (Point to Point) FRAME Application

DD Testing

The DD has been successfully tested on the following system components:

• HART Tokenizer Version 6

• SDC-625

• 475 HandHeld

Certifications

• Logix MD+ DTM Certification with FDT Group will be performed after field trial tests.

• DD Certification with the HART foundation will be performed after field trial tests.

System Assumptions

This Quick Start Guide document will assume that you already have the FRAME Application and Communication DTM installed.

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DTM Installation

Please log in to the Flowserve FTP Site (ftp://fcdftp) or open the CD to download the Logix MD+ ValveSight DTM, FdtCONTAINER, or HART COMM DTM Installs. These installs will allow you to install the ValveSight Logix MD+ DTM, FRAME application, and COMM DTM respectively. NOTE: This document will ONLY cover the installation of the Logix 520MD+ ValveSight DTM.

Follow the installation instructions

Frame and COMM DTM Install

If you do not have the FRAME Application or the HART Communication DTM installed, check the two boxes below and follow the installation instruction for both Frame and Communication DTM, else uncheck the already installed component.

Runtime Libraries

The ValveSight installation will check to see if the computer already has the necessary Microsoft Libraries, else it will prompt you to install the Libraries. Select

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

“Yes” on the following pages.

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Resuming ValveSight Install

Once the install complete the installation and the Dongle and the Microsoft Runtime Libraries it will resume the installation of the DTM. Click Next

Accept the Agreement

Read and accept the agreement, then click next.

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Select DTM destination Browse and select the location where the DTM will install:

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Follow and complete the installation as prompted.

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ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Create a Field Network

HART Modem

• If the modem is a serial port, move on to the next step

• The USB Modem requires that you install the driver for it. Make sure you

remember what slot you put the USB Driver, in case you unplug and plug in a different slot you will need to install the driver for the different slot.

• Right Click on My Computer and select Manage.

• Click on Device Manager and select Ports

• Check what port the modem was installed

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Create a Field Network

The remainder of the Quick Start Guide will give instructions on how to create a Field Network using the fdtCONTAINER FRAME Application.

Device Catalog

Double click on the FDT Container, which is the M&M • Frame to open it. You will see a widow on the right of the page called “Device Catalog”. At the bottom of the page, click on Update. This should allow the Frame to identify both the COMM DTM and the ValveSight DTM.

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Add the COMM DTM

On the left side of the page you will see a window “Network View”. Right click on the My Network icon. Select “Add…”

To configure the communication port, right click the OEM HART Communication DTM in the “Network Views” window. Select “Configuration”.

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Set Port Address

• Select the correct port where the modem is installed.

• Check with the modem manufacturer to select the correct “Access Mode”.

• Under the “Communications Mode”, set the correct “Access Mode”

• Click the Apply or Ok button to apply modem configuration changes.

Add ValveSight Logix MD+ DTM

To add the ValveSight Logix MD+ DTM, right click on the OEM HART Communication DTM in the “Network Views” window and select “Add”.

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ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Select the “LogixMD+”

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Optional: Save the project to your desktop or somewhere easy to remember. This will save you time so you do not have to create a field network in the future.

Starting the ValveSight MD+ DTM

To launch the ValveSight DTM, ensure the modem is connected to a device and the device is powered on. Right click on the “HART Channel 0> LogixMD+” and select “Go Online”

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Double click the “HART Channel 0> LogixMD+”, or right click and select Online Parameter

Troubleshooting

If communications is not established:

1. Verify the HART modem is functional. Some HART modems will report a positive self-check, but still be non-functional.

2. If another primary master is connected in the system, use a communication DTM other than the M&M fdtCONTAINER. This communication DTM does not support a primary master other than itself.

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ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

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DANGER: Using certain features of the DTM can result in valve movement and the inability to operate the valve until the operation is complete. Notify proper personnel that the valve may stroke, and make sure the valve is properly isolated before proceeding.

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DTM Licensing

License ValveSight

To take advantage of the full diagnostic capabilities of ValveSight®, license the Advanced ValveSight DTM for the Logix MD+.

Steps to license the Advance DTM:

1. In the menu tree, select “Configuration” -> “DTM License Management”

2. Write “beta” in the “Feature code:” (make sure it is all lower case)

3. Click the “Activate / Deactivate”

NOTE: The ValveSight Advance License will only apply to the specific PC.

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ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

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Basic Dashboard

The Basic Dashboard is a high level view of the status of the positioner. It is the main view of the ValveSight® DTM.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Command and Position

This area contains a graphical representations of the valve command and position. The blue bar tracks the final command value (after adjustments for characterization curves). The green position bar indicates the current measured position of the valve. The smaller pointers show the settings of the travel alert settings (these can be changed on the Travel Alerts page located under Alarms/Alerts). Grayed out zones at the top or bottom of the graphs indicate the settings of soft travel limits.

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Input Source

Select the analog or digital control mode. In analog mode, the positioner will position the valve according to the 4-20 mA supplied current. In digital mode, the positioner will position according to the value entered in the Digital Input field.

Pressure

Supply, port A and port B pressures are seen in this box. If the Supply Pressure field is yellow or red, there is a problem with the supply pressure to the positioner. The fields in the Pressure box are only active if the positioner is upgraded to have Advanced or Pro diagnostics.

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Ambient Temperature

The temperature and relative humidity inside the positioner are shown here. The units for temperature can be changed in the Positioner Configuration - Units page.

Dip Switch Configuration

The box shows the current configuration of the DIP switches on the front of the positioner. These switches should be set on the positioner before calibration. The configuration that is set by the DIP switches can be overridden in the software using the DTM. (See the Basic/Local Interface page of the DTM). If this is the case, an X will be shown in the box to the right of the item. Be careful when changing the configuration in software because performing a position calibration (Quick-Cal) will reset the configuration according to the physical DIP switch settings. See you instructions for the positioner for a detailed explanation of the switches.

HART Status

Communication with the DTM is displayed here. The Transmit field displays a data packet transmitted to the positioner. The Receive field shows data packets received from the positioner. These are constantly updating. If they appear static, there may be a problem with communications.

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Advanced Dashboard

The Dashboard view is the main diagnostic view of the ValveSight® DTM. Generally, the color green signifies a healthy condition, yellow signifies some degradation has taken place, and red signifies a problem that needs to be addressed right away. You can identify problems right away by observing any red areas on this page.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Command and Position

This area contains a graphical representations of the valve command and position. The blue pointer tracks the final command value after adjustments for characterization curves, Soft Limits, and Tight Shut Off. The green position bar indicates the current measured position of the valve. The smaller pointers show the settings of the travel alert settings (these can be changed on the Travel Alerts page located under Alarms/Alerts). Grayed out

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zones at the top or bottom of the graphs indicate the settings of Soft Limits. The command chart also displays the settings for travel limits and position Tight Shut Off (Minimum Position Cut Off (MPC)) limits. If the positioner has been configured for Tight Shut Off this will show up in the field below the position bar. The Pressure Lock field indicates if the positioner is locked on a steady command by controlling the pressures, or tracking a moving command signal.

Input Source

The command source can be changed to analog or digital mode. In analog mode, the positioner will position the valve according to the 4-20 mA supplied current. In digital mode, the positioner will position the valve according to the value entered in the Digital Input field.

HART Status

The status of HART communication with the DTM is displayed here. The Transmit field displays a data packet transmitted to the positioner. The Receive field shows data packets received from the positioner. These are constantly updating. If they appear static, there may be a problem with communications.

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Health Status

The Health Status box has health indication bars for Valve, Position, Actuator, and Control which are displayed in 4 bar graphs in the center of the dashboard. These are powerful, visual diagnostic tools. Information from all of the diagnostic indications are rolled up into these health bars. As the graphs turn color (from green to yellow to red) they indicate developing issues. The health of the four key components of a control valve can be identified quickly by looking at the color of the bar. If the bars only show green then everything is operating within normal limits and no further action is required. If the bar is partially yellow it is pointing out a degraded condition. The further the bar goes to the right the more serious the degradation. If the bar is red then action should be taken immediately because the ability to control may be compromised. To learn more about any of the 4

health areas, click the double arrows ( ) button at the end of the bar. This leads to the detailed health status page for that particular item.

NOTE: Health Status bars are only available with the Advanced ValveSight® license viewing positioners with Advanced or Pro diagnostics. See the licensing and upgrade pages under Positioner Configuration in the DTM for more information.

Dip Switch Configuration

The box shows the current configuration of the DIP switches on the front of the positioner. These switches should be set on the positioner before calibration. The configuration that is set by the DIP switches can be overridden in the software using the DTM. (See the Basic/Local Interface page of the DTM). If this is the case, an X will be shown in the box to the right of the item. Be careful when changing the configuration in software because performing a position calibration (Quick-Cal) will reset the configuration according to the physical DIP switch settings. See you instructions for the positioner for a detailed explanation of the switches.

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Pressure

Pressure values are shown here. The units for pressure can be changed in the Positioner Configuration - Units page. The pressure gages for Port 1 and Port 2 read directly from the pressure sensors in the positioner. For single acting configurations, the Port 2 gage is not be active. Should the DTM view a device with no pressure sensors, all 3 gauges will be inactive. Pressure sensors are calibrated in the factory. A pressure calibration is not required unless there has been sever pressure or thermal stress on the positioner. See the Calibration - Sensor Calibration page.

NOTE: Pressure gauges are only available while viewing positioners with Advanced or Pro diagnostics. See the Positioner Upgrade page under Positioner Configuration in the DTM for more information.

Temperature

This gage shows the temperature on the circuit board in the positioner. The units for temperature can be changed in the Positioner Configuration - Units page.

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ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

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Humidity

This gage shows the Humidity on the circuit board inside the positioner. Since the positioner should be run with a dry air supply, this value should be near zero most of the time. Elevated humidity inside the positioner may significantly shorten the life of the positioner. Sensor accuracy is +/-10% RH. The sensors are calibrated in the factory. No other calibration is required.

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ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

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Annunciator Panels

Annunciator Panels allow quick viewing of the current state and history of diagnostic indicators and allows masking of alarms, warnings and alerts. This selection automatically redirects to the Alarms Annunciator page.

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Alarms Annunciator

The Alarm Annunciator page displays the status of all

diagnostic indicators. The status is shown in by the indicator "light". The checkboxes allow masking of indicators.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given below. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

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ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Legend

Each indicator group box may contain the following components:

• An "LED light" indicates health status. Warning and alarm limits (set by the user in many cases) determine the conditions when the color will turn from green to yellow to red. The most sever of the indicators on this page will be shown in the health bar on the Dashboard.

• Dark Green circle indicates a healthy condition where no attention is needed.

• Light Green indicates an occurrence of a normal activity that does

not affect the health of the valve system.

• Yellow circle indicates that an active warning, alert or mode is present.

• Red circle indicates that an active alarm or state is present that could seriously limit the operation of the valve.

• Gray circle indicates that the feature or condition is not available because the configuration of the hardware or software does not support it.

• A checkbox indicates the masked status. Check to mask. If a particular indicator is masked, it will not be shown in the active indicator field at the top of each screen, affect the status of the health bars on the main dashboard, be sent in command 48, or be seen on the blinking LEDs on the positioner. It will however continue to show on this page.

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Cycles & Travel Status

Valve Cycles

• Definition: The valve cycle limit has been exceeded.

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ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

• Implications: Each cycle represents two reversals of the direction of valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the packing tightness, and checking linkages for wear, misalignment, and tightness. After maintenance, reset the cycle accumulator.

Valve Travel

• Definition: The total accumulated valve travel limit has been exceeded.

• Implications: The travel is accumulated in both directions. The travel counting criterion and limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the packing tightness, and checking linkages for wear, misalignment, and tightness. After maintenance, reset the travel accumulator.

Actuator Cycles

• Definition: The actuator cycle limit has been exceeded.

• Implications: Each cycle represents two reversals of the direction of

valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the actuator seals and lubrication. After maintenance, reset the travel accumulator.

Actuator Travel

• Definition: The total accumulated actuator travel limit has been exceeded.

• Implications: The travel is accumulated in both directions. The travel counting criterion and limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the actuator seals and lubrication. After maintenance, reset the travel accumulator.

Bellows Cycles

• Definition: The bellows cycle limit has been exceeded.

• Implications: The bellows may be reaching the end of its fatigue

life. Each cycle represents two reversals of the direction of bellows movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking bellows for cracking or leaking. After maintenance, reset the cycle accumulator.

Bellows Travel

• Definition: The bellows cycle limit has been exceeded.

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ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

• Implications: The bellows may be reaching the end of its fatigue life. Each cycle represents two reversals of the direction of valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking bellows for cracking or leaking. After maintenance, reset the cycle accumulator.

Pilot Cycle

• Definition: The pilot relay cycle limit set by the user has been exceeded.

• Implications: The pilot relay cycles indicate the activity level of the pilot relay as it maintains a valve’s position. Excessive cycles can contribute to a worn relay which can lead to high air consumption.

• Possible Solutions: Inspect for high air consumption and signs of wear.

Pilot Travel

• Definition: The total accumulated pilot relay travel (% of full relay span) set by the user has been exceeded.

• Implications: The pilot relay travel indicates the activity level of the relay as it maintains a valve’s position. Excessive travel can contribute to a worn pilot relay which can lead to high air consumption.

• Possible Solutions: Inspect for high air consumption and signs of wear.

Feedback Loop Status

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Position Deviation

• Definition: The device is not controlling at the set point.

• Implications: The difference between the command and the actual

position has been greater than the user-set limit for longer than a userset time.

• Possible Solutions: Review active alarms and warnings to find root causes of this alarm. The deviation settings can be changed in the Valve Health page of the DTM.

Position Sensor Fail

• Definition: The feedback arm may be disconnected from the valve assembly.

• Implications: The feedback arm may be disconnected from the valve assembly or the sensor has failed.

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Flowserve Logix MD+ ValveSight User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual