rotork Paksan P3F Technical Manual
P3F - PAKSCAN FIELD MOUNT
MASTER STATION
TECHNICAL MANUAL
Publication S703E V1.1 Issue 06/09
P3F - Pakscan Master Station Technical Manual
KNOW YOUR MASTER STATION
Power
Supply
Host
Ethernet
Port 3
Host
Ethernet
Port 4
Service
Ethernet
Port
Alarm and
ESD
Terminals
Power
Connector
Current Loop
CPU
Module
option
Future
option slot
Mounting
Brackets
Current
Loop
Connector
DIN Rail
Earth
Stud
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Host Comms Serial
Ports 1 and 2
View with door open
Contents
Contents:
KNOW YOUR MASTER STATION.............................................................................2
INTRODUCTION.........................................................................................................5
1. MOUNTING AND CONNECTING THE MASTER STATION..............................7
1.1 Mechanical Fixing...................................................................................................................7
1.2 Serial Comms Connections ...................................................................................................8
1.3 Ethernet Comms Connections ..............................................................................................8
1.4 Power Connector and Fuse....................................................................................................8
1.5 ESD and Alarm Output Connector........................................................................................9
1.6 Current Loop Connections.....................................................................................................9
2. THE FIELD NETWORK....................................................................................11
2.1 Loop Checks..........................................................................................................................11
2.1 Loop Checks..........................................................................................................................12
2.2 Connecting Up.......................................................................................................................12
3. SORTING OUT THE SERIAL COMMS LINKS.................................................15
3.1 Setting Port 1 and 2 for RS232 or RS485............................................................................15
3.2 When to Use RS232 ..............................................................................................................17
3.3 When to Use RS485 ..............................................................................................................17
4. USING ETHERNET HOST COMMS.................................................................19
4.1 Setting-Up the Ethernet Comms..........................................................................................19
5. THE INTERNAL WEB PAGES.........................................................................21
5.1 Making an Internet / intranet Connection...........................................................................21
5.2 Connecting a Laptop Directly to the Master Station .........................................................21
5.3 5.3 Adjusting the Network Settings of the Laptop / PC....................................................21
5.3 5.3 Adjusting the Network Settings of the Laptop / PC.....................................................22
5.4 Web Page Structure..............................................................................................................23
5.4.1 User Levels.........................................................................................................23
5.4.2 Overall Web Page Layout...................................................................................23
5.5 The Web Pages in Detail.......................................................................................................25
5.5.1 Log In Screen .....................................................................................................25
5.5.2 Master Station ....................................................................................................25
5.5.2 Master Station ....................................................................................................26
5.5.3 View Configuration .............................................................................................28
5.5.4 System Diagnostics............................................................................................29
5.5.5 Master Station Data Logger................................................................................30
5.5.6 Master Station Host Analyser.............................................................................32
5.5.7 Pakscan 2 Loop Diagnostics..............................................................................33
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5.5.8 Option Card Event Logger..................................................................................36
5.5.9 FCU Menu ..........................................................................................................37
5.5.10 FCU Control - IQ/IQT Actuator...........................................................................38
5.5.11 FCU Control - Integral Actuator..........................................................................43
5.5.12 FCU Control - Flowpak Actuator.........................................................................47
5.5.13 FCU Control - General Purpose Field Unit.........................................................49
5.5.14 FCU Control - Other Field Units.........................................................................52
5.5.15 Admin..................................................................................................................54
5.5.16 Users ..................................................................................................................54
5.5.17 Masterstation Config...........................................................................................57
5.5.18 Host Port Configuration......................................................................................61
5.5.19 Alarms.................................................................................................................64
5.5.20 Time....................................................................................................................66
5.5.21 General...............................................................................................................67
5.5.22 Network...............................................................................................................68
5.6 Setting Up the Master station Configuration Using the Web Pages................................70
5.6.1 Master Station Set-up page................................................................................70
5.6.2 Option Module Set-up (including host comms protocols)...................................72
5.6.3 Host Port Settings...............................................................................................72
5.6.4 Setting the IP Address........................................................................................73
6. MAKING THE SYSTEM WORK .......................................................................75
6.1 Commissioning the System.................................................................................................75
6.2 Monitoring and Controlling the Actuators..........................................................................76
GENERAL SAFETY INFORMATION........................................................................79
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Introduction
This manual relates to Pakscan P3F Master Stations
fitted with PS720 Current Loop modules
INTRODUCTION
Pakscan 3 is the latest network control system from Rotork. The Pakscan P3F master station
encompasses the P3 technology in a master station specifically designed for mounting in remote
locations. The P3F enclosure protects the electronics within to IP65 standards and is suitable for use
in those locations where more conventional equipment cannot be located. Compared to the P3, the
P3F is simplified to include only those features demanded by smaller and simpler application s . It is a
single channel system capable of supporting up to 32 actuators or other field units.
Most types of Rotork actuator can be connected to the Pakscan current loop provided they are fitted
with the necessary field unit. Information on the respective actuator field units can be found in the
appropriate manuals. In this guide, the type of actuator is not considered, though reference is made to
both the Integral and IQ actuator types of field unit. The type of field unit does not affect the setting up
of the system.
The P3F master station is supplied as a stand alone unit ready for connection to the actuators and
host control system.
Fig 1: The Pakscan P3F Master Station
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Mounting the Master Station
1. MOUNTING AND CONNECTING THE MASTER STATION
Before fixing the master station in its permanent location, it may be more convenient to set the
comms link switches as discussed in section 3.
The Pakscan P3F master station provides front access for all the user connections including power
feed and the field loop wires to the Current Loop module (PS720). The host communication u se s
screw terminal connections for the serial comms and RJ45 connections for the Ethernet links.
The field wiring for the loop and the master station alarms is taken to screw terminals on plug
in connectors that are fitted from below their appropriate module.
Power wiring is connected using a 3-way plug-in connector with screw terminals in the top of
the master station main circuit board.
Serial comms ports 1 and 2 (RS232 or RS485) connect to an 8-way plug-in connector with
screw terminals on the bottom of the main circuit board.
Ethernet connections use RJ45 connectors on the main circuit board. The service port
connector is intended for connection to a service laptop computer. Host ports 3 and 4 are for
permanent Ethernet connections.
1.1 Mechanical Fixing
.
All dimensions in mm
Hinge on left side of
enclosure
Holes for M8
fixing bolts
Fig 2: Pakscan 3F surface mounting dimensions.
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Room should be left around the enclosure for all the connections and cables, allowing for suitable
bending radius on each lead. Power wiring should be suitably fused or protected with a miniature
circuit breaker (MCB) external to the master station.
The master station should be mounted on a flat surface using the mounting brackets provided. It
should be located in a way that permits easy opening of the front door and access to the internal
connectors and modules.
1.2 Serial Comms Connections
The serial data connections are via the Serial Comms terminal block located on the main circuit board
below the power supply and to the left of the DIN rail. This connector has screw terminals and plugs in
to the mating part fixed on the circuit board. The terminal connections are shown below.
Port 1
Port 2
1
2
3
4
5
6
7
8
Terminal
1 TX
2 RX Data 3 GND GND
4
5 TX
6 RX Data 7 GND GND
8
Fig 3: Serial Comms connector terminal functions
RS232
Connections
Port 1
Data +
Port 2
Data +
RS485
Connections
With RS485 it is possible to arrange a multi-drop data highway for the serial communications,
whilst RS232 must be single point comms.
1.3 Ethernet Comms Connections
Each Pakscan P3F master station has 3 x RJ45 Ethernet connectors for the host communication ports
and the service port. These are marked Port 3 and Port 4 (host communication ports) and Port 5
(service port). A portable computer (laptop) should be connected to Port 5, the service port, to set up
the P3F. Standard Ethernet shielded patch cables should be used with these ports.
1.4 Power Connector and Fuse
The Pakscan P3F has its own internal power supply and a three-way screw terminal connector at the
top of the main circuit board is provided to allow the mains power (85 to 265V AC – 47 to 63 Hz) to be
connected. The master station power fuse is located just below this connector and should be 250V 1A
fuse. For the 24V DC version the same three-way connector is used.
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Mounting the Master Station
Power
1
2
3
1 N (Neutral) 0 V
2 L (Line) 24 V
(85-265V ac)
Terminal ac Connection
dc Connection
(18-36V dc)
3 E (Earth) Earth
Fig 4: Power connector terminal functions
1.5 ESD and Alarm Output Connector
There is a removable screw terminal connector plugged into the main circuit board of the P3F master
station for the connection of ESD hard-wired inputs and for connection to the internal alarm relay
contacts, when required. (On most systems these terminals will not be used; in which case a hardwired link between pins 4 and 5 should be added.)
PS710
CONNECTOR
1
2
Alarm
3
4
5
Emergency
Shutdown
Terminal Function
1 Alarm (common)
2 Alarm (normally closed)
3 Alarm (normally open)
4 Emergency Shutdown
5 Emergency Shutdown
Note that the relay is shown in the ‘Alarm Active’ or ‘power removed’ position.
Fig 5: Alarm/ESD connector terminal functions
1.6 Current Loop Connections
A removable screw terminal connector is located in the bottom of the Current Loop Module for the
connection of the Pakscan IIE current loop to the field mounted actuators.
Terminal Function
1 Port B In
2 Port B Out
3 Port B Screen
4 Port A In
5 Port A Out
6 Port A Screen
Fig 6: Current Loop connections
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Power
Connector
Ethernet
Ports
Fuse
Current
Loop
Hard Wired
ESD
Serial
Ports
Fig 7: View of the Pakscan P3F master station showing the Connectors and Fuse
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Field Network
2. THE FIELD NETWORK
The Pakscan current loop field network must be correctly cabled and connected to the master station.
The values of the field loop resistance and capacitance must be known to determine the loop speed
that can be used. If these are not known then the LOWEST loop speed must be set in each actuator
and the master station to ensure some field network connectivity.
Port A
OUT = Term'l 5
IN = Term'l 4
Up to 32 actuators
per loop
Current loop
- up to 2 0 km
Port B
IN = Te rm' l 1
OUT = Term'l 2
Fig 8: Pakscan P3 Network
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2.1 Loop Checks
The most common errors in installing the system occur on the field wiring.
Loop Continuity
With all the field units connected, but none of them powered up, check the continuity of the 2
cores of the cable and measure its resistance.
Screen Continuity
Make sure that the screen is isolated from the loop cores and that the screen is continuous.
Ensure the screen is connected to a signal earth bar at only one point or to terminals on the
loop driver plug; 3 linked directly to the enclosure earth and 6 linked to the enclosure earth via
an internal capacitor. Both the screens must be connected to the terminals provided, so as to
ensure the product meets the European Directive on EMC.
Cable Capacitance
The capacitance between the cores, and to the screen, is critical to the system performan ce.
Too high a capacitance for the selected loop baud rate will result in poor communications, or
even communication failure.
Maximum Loop Speed
The cable resistance and capacitance must not exceed the permitted maximum values for each
communication speed. The limiting values of R and C for each speed will depend on the
number of field units actually connected. The following table gives the total figures for systems
including the capacitance of the field units. Deduct 2.2nF for each field unit to determine the
maximum cable capacitance allowed at each speed.
Baud Rate R max (ohms)
110 500 4.5
300 500 2.1
600 500 1.54
1200 500 0.6
2400 500 0.3
C max (μF)
Each field unit will add a capacitance of 2.2nF (0.0022µF)
The C max figure given is the maximum value for the network capacitance
including the field unit capacitance.
2.2 Connecting Up
Once the checks are complete, connect the Loop Cables to the PS720 Current Loop module. At this
point leave the actuators all without power except for the one furthest from Loop Port A.
Refer to section 6 for commissioning a Pakscan system.
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Field Network
SERIAL
PORT 1
SERIAL
PORT 2
ETHERNET
PORT 3
ETHERNET
PORT 4
MAINS
SUPPLY
LNE
3
12
POWER
SUPPLY
PROCESSORS
AND
COMMUNICATIONS
ETHERNET PORT 5
(CONFIGURATION)
PS 720 MODULE
(CURRENT LOOP
CONTROLLER)
5
4
3
2
ALARM
1
Screen
6
Port A OUT
5
Port A IN
4
Screen
3
Port B OUT
2
Port B IN
1
EMERGENCY
SHUTDOWN
Actuator Terminals
A
SIGNAL EARTH BAR
If there is a signal earth bar, connect the
screen on one side only to the bar
BC SCR
A
A
c
t
u
a
C
t
o
r
T
B
e
r
m
S
i
C
n
a
R
l
s
Actuator Terminals
ABCSCR
Note: If there is no hard-wired ESD requirement, a shorting link must be fitted across pin 4
and 5 of the 5 pin plug.
Fig 9: Pakscan P3F Current Loop System Block Diagram
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Serial Comms Links
3. SORTING OUT THE SERIAL COMMS LINKS
The Pakscan P3F CPU module has two serial ports. Each of these is configurable for RS232 or
RS485. Where redundant communications to the host system using serial comms is required, then
two RS485 connections are often used.
3.1 Setting Port 1 and 2 for RS232 or RS485
The main circuit board has DIP switches for setting the type of serial port that is presented at the port
terminal block.
Select RS485
Termination
Select Port 1
Function
Fig 10: Pakscan P3F Serial related switches
Select Port 2
Function
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Port Function
The two DIP switches allow each port to be selected between RS 232 and RS485. For RS485
slide the appropriate Port switch up, for RS232 they should be down.
Each of the two ports may be set independently.
Fig 11: Port Function Switches shown in RS232 position
Port Termination Resistors
The two DIP switches are used to connect end of line termination resistors and biasing re sistors
to the RS485 network. All RS485 network highways should be terminated at both ends of the
highway. Each port can be terminated independently.
1k
120
1k
Fig 12: Port Termination Switches shown in Off position
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Serial Comms Links
P
P
F
P
P3F
P
P
F
3.2 When to Use RS232
Pakscan P3F Master Station
PLC
Pakscan
3
rotork
3
Highway 1 – RS232
Highway 2 – RS232
Fig 13: RS232, dual highway, from P3F master station to PLC
When the host PLC or DCS is located near to the Pakscan P3F master station, RS232 comms can be
used with single point to point links. Either Port 1 or Port 2 can be used, though most users would use
Port 1. Two links can be used if redundant communications are required.
For RS232 on - Port Terminations RS232 RS485
Port 1 Off (Down) RS232 (Down)
Port 2 Off (Down) RS232 (Down)
3.3 When to Use RS485
PLC
Pakscan P3F Master Stations
Pakscan
3
Pakscan
3
Fig 14: RS485, dual highway, from P3F master stations to PLC
Highway 1 - RS485
Highway 2 - RS485
rotork
rotork
3
When there are several Pakscan P3F master stations to be connected to the PLC, or the distance
between the Host and the master station is more than 20 metres, an RS485 highway will be best. The
highway will require a multi-drop configuration, as shown on the diagram. The screw connectors in
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the master station make this simple to achieve. When a multi-drop connection is made, care must be
taken to ensure that the cable is not broken if a master station is disconnected.
The master station supplies port termination resistors for each port, which can be enabled where
required.
For RS485 on - Port Terminations RS232 RS485
Port 1
Port 2
Off (Down)
On (Up)
Off (Down)
On (Up
RS485 (Up)
RS485 (Up)
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Ethernet Comms Links
4. USING ETHERNET HOST COMMS
Pakscan P3F master stations come complete with two Ethernet ports for connection to host DCS or
PLC systems. A third Ethernet port is also available for connection to a laptop computer for
configuration purposes. The master station is ready to use with Ethernet and Modbus TCP protocol for
the DCS to access data and control the actuators on the field network. The IP address is already set
and can be changed during setting up the master station
Pakscan
P
3
rotork
PLC
Port 3 Port 4 Port 3
Ethernet Highway 1
Ethernet Highway 2
Fig 15: Ethernet, dual highway, from P3F master station to PLC
4.1 Setting-Up the Ethernet Comms
Pakscan 3F Master Stations
Pakscan P3F Master Stations
P3F
Switch
Switch
rotork
Pakscan
P
3
P3F
Port 4
Ethernet connections require 10BaseT or 100baseT Ethernet Switches to connect the system
together. Patch cords connect the ports on the master to the Switches. Independent highways are
possible by using separate switches on each highway.
The Pakscan P3F master station defaults to the same IP address on both the ports. It is possible to
change the IP address, but the two ports always have the same address.
DHCP Static
Default IP address 10 200 1 1
Subnet mask 255 255 255 0
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The recommended highway organisation is:
Use two main data highway bus’s, each of which connects to all the master stations.
The master is left with a Static DHCP port setting.
The master station can serve up to 10 simultaneous host connections.
With this arrangement either PLC port can always communicate with the master station and the
devices on the loop. Heartbeat data requests on the second highway will always be acknowledged
with a response.
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The Web Browser
5. THE INTERNAL WEB PAGES
The P3F master station includes a set of Web pages that may be remotely accessed via Ethernet.
They can be used for setting up the system, examining the system for any faults or alarms and also for
controlling the actuators on the network (provided the Interlock permission is set to allow this feature).
If the master station is connected to an Ethernet Network it will act as a server and any computer
within that network can connect to the master station. The master station can also be configured and
the field network set up by using these web pages. The host system or PC connected via the Ethernet
Network or directly will need a web browser such as Internet Explorer to access the master station
web pages
5.1 Making an Internet / intranet Connection
Connect the master station to an Ethernet host as described in section 4, or connect via a suitable
router to the internet / intranet. A laptop or PC can be directly connected to port 3 or 4 or to the
configuration connector, if there is no network connection available. Details of directly connecting a
laptop are contained in the section on setting up with a PC, below.
Start the browser and enter the IP address of the master station. The default address is 10.200.1.1, so
the address is http://10.200.1.1. The browser will then access the master station and bring up the
opening page of the master station. In order to log in as a verified user enter a user name of admin
and a password of admin. (These default names should be altered as soon as convenient to prevent
unauthorized access to the system.)
Default IP address 10 200 1 1
Default User admin
Default Password admin
Once entry to the web pages has been made, if no changes to the display or information is made for
10 minutes, the system will automatically log out and the user/password must be re-entered.
5.2 Connecting a Laptop Directly to the Master Station
The simplest direct connection to the master station is by using the Ethernet port on the front of the
main pcb. A standard Ethernet patch cable can be used to link the two directly. The connector will
accept either a standard patch cable or a direct link cable that has a twist between the transmit pair
and receive pair in the cable. A permanent PC connection can also be made directly to the main
Ethernet connector (port 3 or 4). In order to establish a connection it may be necessary to adjust the
settings of the Laptop Internet connection.
5.3
Fig 16: Connecting a Laptop to the Pakscan P3F
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5.3 Adjusting the Network Settings of the Laptop / PC
Ensure nothing is connected to the Ethernet port of the laptop / PC.
Open the Control Panel and select Network Connections.
In the ‘Network Connections’ window, double-click on the ‘LAN or High Speed Internet’ icon
and the ‘Local Area Connection Status’ window will open.
Click on the ‘Properties’ button, and a second window will open. Select ‘Internet Protocol
TCP/IP’ and click on the ‘Properties’ button in this window.
The ‘Internet Protocol TCP/IP Properties’ window will open. Next change the setting to force
the Laptop to adopt a fixed IP address and enter an address for the Laptop / PC of 10.200.1.3
and a subnet mask of 255.255.255.0. Click on the OK button and the window will close.
Click OK on the ‘Local Area Connection Properties’ window and then Close the status windo w.
Finally, close the Network Connections window and the Control Panel.
It may be necessary to reboot the PC to be sure that the new settings take effect correctly.
Connect the cable between the PC and the Pakscan master station.
Fig 17: Changing the Network Connections TCP/IP Properties
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The Web Browser
Start the browser and enter the IP address of the master station. The default address is 10.200.1.1, so
the address is http://10.200.1.1. The browser will then access the master station and bring up the
opening page of the master station. In order to log in as a verified user, enter a username of admin
and a password of admin.
Note that if the IP address of the master station has been changed from the defaults, then the settings
above will not work and have to be modified to suit the actual settings.
5.4 Web Page Structure
The web pages have three access levels, each requiring a password with the correct level set. A user
enters the web server with a particular degree of access to the functions of the server and the master
station.
5.4.1 User Levels
Access Level Function
Allows access to read master station status and settings,
Lowest level Read
plus the option card status and settings and the actuator
and field unit status on the option card network. No
commands or alterations to the system are permitted.
As for read access with the addition of the ability to issue
Write
network commands, swap masters and command
actuators on the option card network to change position.
As for the two lower levels plus the ability to configure the
master station, option cards and all system settings. Set
Highest Level Administrator
and remove user names and passwords, set alarm
reporting parameters, change system addresses and test
system communications.
The Administrator level sets all other user names and passwords. As soon as the system is set up, the
default password should be changed.
5.4.2 Overall Web Page Layout
The web pages are organised using a menu structure with the primary menu on the top of each page.
Within a page there are other controls for parameter alteration or to reveal extended information on
the topic of the particular page.
Navigation between the pages is by selecting another topic on the main menu.
If there is no activity with the mouse to change the display or update the information or selection for 10
minutes the system automatically logs out the user and the username and password must be reentered to continue using the pages.
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Log In
Masterstation
View
Configuration
System
Diagnostics
Master Station
datalogger
Host Analyser
Option Diagnostics
Network
Diagnostics
Option Event Log
FCU Menu
FCU 1 to 32 control
and data
Admin*
Users
* requires Admin level log in
Master station and
Option Configuration
Host Port
Alarms
Time
General
Network
Fig 18: Web Page Menu Layout
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The Web Browser
5.5 The Web Pages in Detail
5.5.1 Log In Screen
Fig 19: Log In Screen
The first screen is the Log In screen on which the user must enter a Username and Password.
Username - a case sensitive identification for an individual or group used to give access to
the system. Usernames are listed for administrators to see on the ‘Add User’ page.
Password - the case sensitive confirmation required before a use rn ame is accepted by the
system. Passwords are not listed on any page in the system and cannot be retrieved, even at
the administrator level.
Select the box with a mouse and enter the appropriate name or password, then click on the login
button. The system will move to the next page if the login is accepted, if it fails the data is cleared from
the boxes and must be re-entered correctly in both boxes before access is granted.
The default user name is admin and password is admin. (These default names should be altered as
soon as convenient to prevent unauthorized access to the system).
User name and
access level.
Menu of available screens to visit
(changes to blue when selected)
for Read and Write access levels.
Log out when finished
by clicking here
(changes to red when
Fig 20: Web Page Header Navigation
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