rotork Pakscan IIE System Manual
Publication S177E V2.0 Issue 03/05
Pakscan IIE Master Station
System Manual
Pakscan IIE System Manual
2 of 132 Publication S177E V2.0 Issue 03/05
As we are continually developing our products their design is subject to change without notice.
© The contents of this document are copyright and must not be reproduced without the written
permission of Rotork Controls Ltd.
The name Rotork is a registered trademark
Windows is a registered trademark by Microsoft Corporation
Modbus is a registered trademark by Modbus IDA
Software Level
This manual relates to Pakscan IIE master stations fitted with software
versions
V25 (5206-014) software version 5.8 or greater
Loop Driver (5206-034) software version 5.2 or greater
Contents
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Contents
Glossary of Terms...........................................................................................................................7
Abbreviations ..................................................................................................................................7
How to use this Manual ..................................................................................................................9
Software level ..................................................................................................................................9
1 INTRODUCTION.................................................................................................11
1.1 Related Documents..............................................................................................................11
2 EQUIPMENT DESCRIPTION..............................................................................13
3 STORAGE PROCEDURE...................................................................................15
4 OVERVIEW OF PAKSCAN.................................................................................17
4.1 Field Control Units...............................................................................................................17
4.2 Control and Indication.........................................................................................................18
5 FUNCTIONS........................................................................................................19
5.1 Cable Fault Protection - Loopback system.......................................................................19
5.2 Current Loop Start Up Operations.....................................................................................19
5.2.1 Loop Configuration ..................................................................................................20
5.2.2 Normal Running Operation......................................................................................20
5.3 Modbus Serial and Ethernet Interfaces .............................................................................21
5.4 Local User Interface (LCD and Keypad) ............................................................................21
6 INITIAL SETTING UP..........................................................................................23
6.1 Jumper Settings...................................................................................................................23
6.2 External Links.......................................................................................................................25
6.3 Display Screen Contrast .....................................................................................................26
7 INSTALLATION AND CONNECTION.................................................................27
7.1 Mounting...............................................................................................................................27
7.2 Mains Power .........................................................................................................................27
7.3 Field Wiring...........................................................................................................................28
7.3.1 Screen Connections ................................................................................................29
7.4 Loop Checks.........................................................................................................................29
7.4.1 Loop Continuity........................................................................................................29
7.4.2 Screen Continuity ....................................................................................................30
7.4.3 Cable Capacitance ..................................................................................................30
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8 LOCAL USER INTERFACE................................................................................33
8.1 Front Panel Indication LEDs...............................................................................................33
8.2 LCD Screen and Keypad.....................................................................................................34
8.3 Keypad Security...................................................................................................................35
8.3.1 Using a PIN..............................................................................................................35
8.4 Menu Structure.....................................................................................................................35
8.5 Master Station Status ..........................................................................................................38
8.5.1 Master Station Commands......................................................................................39
8.5.2 Master Station Alarms - Text Description................................................................40
8.6 Configuration Mode Screen................................................................................................41
8.7 Diagnostic Menus ................................................................................................................42
8.7.1 Top Diagnostic Display............................................................................................42
8.7.2 Modbus Port Diagnostic Displays............................................................................43
8.7.3 Printer port diagnostic display .................................................................................44
8.7.4 Loop Diagnostic Display..........................................................................................45
8.7.4.1 FCU Map and Failure Counts ..................................................................47
8.7.4.2 Loop Speed Test......................................................................................48
8.7.4.3 FCU Address Fault Details.......................................................................49
8.7.5 Hot Standby Inter Unit Diagnostic Display...............................................................50
8.8 Setup Menus.........................................................................................................................51
8.8.1 Top Setup Menu......................................................................................................51
8.8.2 Port Setup Menus....................................................................................................52
8.8.2.1 Alarm Linkage ..........................................................................................53
8.8.3 Data transfer to Standby Unit ..................................................................................54
8.8.4 Loop Setup Menu ....................................................................................................55
8.8.4.1 Further Loop Options ...............................................................................56
8.8.5 Unit Address Setup Menu........................................................................................57
8.8.6 Tag Setup Menu......................................................................................................58
8.8.7 Date and Time Setup...............................................................................................59
8.8.8 ESD Options Setup Menu .......................................................................................60
8.8.9 Keypad Security Options.........................................................................................61
8.9 Field Unit Menus ..................................................................................................................62
8.9.1 Actuator Field Unit Status Display...........................................................................62
8.9.1.1 IQ Actuator Second Status Page .............................................................63
8.9.1.2 IQ and IQT Historic Torque Displays .......................................................64
8.9.2 Flowpak Actuator Field Unit Status Display.............................................................65
8.9.3 General Purpose Field Unit Status Display.............................................................66
8.9.3.1 Second Page for General Purpose Field Unit..........................................67
8.9.4 IQ Analogue Input Field Unit ...................................................................................68
8.9.5 Communications Failure Display.............................................................................69
8.9.6 Field Unit Status Secondary Data ...........................................................................70
8.9.7 Field Unit Alarm – Text Description.........................................................................71
9 SETTING PARAMETERS...................................................................................73
9.1 Initial Decisions....................................................................................................................73
9.2 Serial Communication Ports...............................................................................................74
9.3 Loop Data..............................................................................................................................75
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9.4 Tag Names............................................................................................................................76
9.5 Date and Time.......................................................................................................................76
9.6 ESD Configuration...............................................................................................................77
9.7 Security Access Level.........................................................................................................77
9.8 Final Checks.........................................................................................................................77
10 SETTING A HOT STANDBY PAIR PARAMETERS...........................................79
10.1 Copy Data A to B..................................................................................................................79
10.2 Changes to Terminal Connections.....................................................................................79
10.2.1 Main/Standby Connections......................................................................................79
10.3 Hot Standby Parameter Setting and Options....................................................................81
10.4 The PS300 Keyswitch ..........................................................................................................81
11 INCLUDING A PS410 CONVERTER..................................................................83
11.1 Jumper functions.................................................................................................................84
11.1.1 PS410 port 2 to RS485 setup..................................................................................84
11.1.2 PS410 port 1 to RS232 setup.................................................................................85
11.1.3 LED functions ..........................................................................................................85
11.1.4 RS485 line conditioning...........................................................................................85
11.1.5 2-Wire and 4-wire RS485 communications.............................................................86
12 SETTING UP AND USING THE PS600 ETHERNET MODULE .........................87
12.1 Internal Connections ...........................................................................................................88
12.2 Connecting to the Ethernet Bridge ....................................................................................88
12.2.1 Local Ethernet Connection ......................................................................................89
12.2.2 Direct Ethernet Connection to a PC ........................................................................89
12.2.2.1 Connection using Windows XP................................................................89
12.3 Ethernet Module Status Indicators.....................................................................................90
12.3.1 LED Functionality.....................................................................................................90
12.4 Setting Up the Module .........................................................................................................91
12.4.1 Setting the Serial Connection Fields .......................................................................92
12.4.2 Setting the User Fields for the Web Browser ..........................................................93
12.4.3 Setting the Alarm Messaging Information................................................................95
12.4.4 Setting the Local Area Network Connection Parameters........................................96
12.5 Using the Ethernet Connection ..........................................................................................97
12.5.1 Master Station Overview .........................................................................................97
12.5.2 Master Station Configuration...................................................................................98
12.5.3 Network Diagnostics................................................................................................99
12.5.4 FCU Menu ............................................................................................................ 100
12.5.4.1 Field Unit Status and Control................................................................ 101
12.5.4.2 Field Unit Alarms screen....................................................................... 102
12.5.4.3 IQ and IQT Actuator Torque screen...................................................... 102
12.5.5 FCU Parameters................................................................................................... 103
13 COMMISSIONING THE SYSTEM.....................................................................107
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13.1 Checking Individual Field Units....................................................................................... 107
13.2 Checking the Loop Itself .................................................................................................. 108
13.3 Checking System Performance....................................................................................... 110
13.3.1 Setting the Loop Driver Voltages.......................................................................... 110
13.4 Diagnostic Information..................................................................................................... 111
13.4.1 Loop Configuration ............................................................................................... 111
13.4.2 Loop Communications.......................................................................................... 112
13.4.3 Loop speed reprogramming ................................................................................. 112
13.4.4 Checking Host Communications .......................................................................... 113
13.5 Final Checks...................................................................................................................... 113
13.6 Commissioning Aids ........................................................................................................ 114
14 MASTER STATION SOFTWARE VERSION ....................................................115
15 SET UP DATA RECORDS................................................................................ 117
15.1 Loop Map ........................................................................................................................... 118
16 TECHNICAL SPECIFICATIONS.......................................................................121
16.1 Master Station ................................................................................................................... 121
16.2 Actuator Field Units.......................................................................................................... 121
16.3 GP Field Unit...................................................................................................................... 122
16.4 2-Wire Loop ....................................................................................................................... 122
16.5 External Connections ....................................................................................................... 124
16.5.1 Loop Connections and Digital I/O......................................................................... 124
16.5.2 Serial Ports ........................................................................................................... 125
16.6 Printer Messages .............................................................................................................. 127
16.7 Maintenance ...................................................................................................................... 127
16.8 Master Station Dimensions.............................................................................................. 128
17 GENERAL SAFETY INFORMATION................................................................129
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Glossary of Terms
Address The unique address for a field unit on the Pakscan loop, range 1-240
Loop The digital, twisted pair 2-wire data communication link
Field Unit The Pakscan option card fitted to the actuator, or complete General Purpose field
unit
Master/Slave The method of communication used on the field loop. The master station controls
the data exchange on the highway
Node A single device (address) on the Pakscan loop
RS485 The electrical properties as defined by the IEA485 standard, 2-wire twisted pair.
RS232 The electrical properties as defined by the IEA232 standard
Abbreviations
Comms Communications
FCU Pakscan Field Unit
RAM Random Access Memory
ROM Read Only Memory
RTU Remote Terminal Unit
SW Software
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Contents
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How to use this Manual
In order to make the best use of the information in the following pages we suggest you use this
manual as follows:
Familiarise yourself with the hardware - section 4 will show you all the parts
Read sections 4 to 12 before attempting to commission the system
Refer to section 6 to check the internal link settings
Section 8 relates to the front panel LED’s, keypad and LCD screen
Make sure you understand how to connect the system - section 7 tells you how
Set up the Software selected parameters - also see section 9
With a Hot Standby system check the information in section 10
Commissioning the system is explained in section 13
If you have RS485 Converter units, read section 11 carefully
Ethernet connections are explained in section 12
Record the information about your system on data sheets such as those outlined in section
15, or use Rotork MasterTools to document the system. Pakscan Ethernet systems can
also record the master station data to file from the web server application.
Software level
This technical manual relates to Pakscan IIE master stations with software version 5206-014 V5.8 or
later for the main V25 processor and version 5206-034 V5.2 or later for the loop processor.
MasterTools
The software utility, MasterTools, runs on a PC and maybe downloaded from www.rotork.com.
With this utility a complete record of the Pakscan loop, the field units and master station settings
can be made and retained either as an electronic file or the data may be printed out.
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Introduction
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1 INTRODUCTION
This document describes the procedures for setting up commissioning and running a Pakscan IIE
system. If the unit is to be stored for a period of time prior to its use, then please refer to section 3 for
information about storage of electronic equipment.
The Pakscan IIE master station hardware is a stand-alone unit requiring only the connection of power
and suitable field units to operate. This manual describes the Pakscan IIE master station only. Please
refer to the documentation relating to the field units for information on that part of the system.
The Pakscan IIE system is compatible with all Pakscan II and IIE field units and setting tools. The
Pakscan IIE is equipped with either serial communication ports, or Ethernet ports, or both through
which the master station can be controlled and operated from another device. The communication
protocol supported by these ports is Modbus RTU and Modbus TCP and details of the function codes
and data base organisation established within the master station are contained in the associated
protocol documents.
1.1 Related Documents
There are a number of documents for the Pakscan system that relate to the Pakscan IIE master
station these include:
General
(1) Field Test Unit Technical Manual (Paktester) S178E
(2) Master Station Test Unit Technical Manual (Pakreader) 5161-021
(3) Pakscan IIE RS485 Converter Technical Manual 5218-023
Serial Communications
(4) Pakscan Modbus Interface Specification S171E
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Equipment Description
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2 EQUIPMENT DESCRIPTION
The master station is an assembly of a computer card, a current loop interface card, a power supply
card, and a front panel with an LCD screen and 16-key keyboard, fitted to a standard 19-inch rack.
The rack will contain some or all of the items identified in Fig. 1.
PS100 CPU and Display Module (two off in Hot Standby systems)
PS210 Power Supply module (unless the hardware is supplied by 24V dc)
PS300 Switch module for Hot Standby systems only
PS410 RS485 Converter (optional)
PS601/2/3/4 Ethernet port converter
The rack can accommodate two master stations, when viewed from the front these are referred to as
M/S A on the left and M/S B on the right. The 19-inch rack is always fully wired to accommodate all
variations of assembly within it. Some applications may require external links on the connectors and
terminal blocks and these will normally be fitted before despatch. It is advisable to check that any links
that may be required for a particular application are in place. When PS601 or PS602 Ethernet servers
are fitted there will be links to the Port 1 or Port 2 connectors and these will not be available for host
connections.
All master stations have their own dedicated power packs, each operating from an independent input.
In the case of a dual or hot standby system there maybe two independent supplies to the rack.
Optional additional cards may be fitted to the master station rack for converting the communications
hardware between RS232 and RS485, and in the case of a Hot Standby a switch unit is also included.
If the master station includes Ethernet connectivity then there are internal servers fitted inside the
rack. Where no cards are fitted blanking plates are used to cover the resulting space.
Two master stations may optionally be interconnected to form a dual redundant system. In this
configuration, one unit controls the loop, whilst the other acts as a 'hot standby'. Changeover between
the units can be automatic or manually triggered.
MASTER STATION A MASTER STATION B
PS210 - Power Supply
PS100 - CPU & Display Module
PS410 - RS232/RS485 Converter
PS300 - Keyswitch
PS60X - Ethernet Server (Internal)
Fig 1: Pakscan IIE Master Stations in a 19 inch rack
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On the rear are the following items, repeated for both M/S A and M/S B.
Power Connector (IEC) for use with a.c. powered units (when a 24V dc supply is used this
is replaced by a terminal block). There is a 1 Amp slow blow fuse adjacent to the power
connection.
26 screw terminals for Field Connections, of these 25 only are used, and terminals 1 to 21
are directly linked internally to the 25 way D type connector (pins 1 to 21) above the
terminal block.
Two 9 way D type connectors for Comms Port 1, a male and a female. This port is always
RS485, 2-wire.
A single 9 way D type female connector for Comms Port 2. This port is always RS232.
There are two further connectors, 9 way D type female, for Ports 3 and 4. These are only
used if the optional RS232/485 Protocol Converter Module, PS410, is fitted, as described in
section 11.
One trailing RJ45 female socket for connection to the Ethernet server when one is fitted.
For host computer communications either serial or Ethernet connections can be used. The data format
for information exchange is Modbus RTU (for serial ports) or Modbus-TCP (for Ethernet LAN
connection). There are multiple data bases within the master station and these are explained later in
this manual.
Support for a printer to log alarms is provided. Each entry can be tagged with the time and date. There
are contact outputs for various alarm conditions, and provision for an Emergency Shutdown (' ESD')
input. Emergency Shutdown may be invoked by breaking the circuit between two terminals at the
master station causing an 'ESD' message to be broadcast on the current loop. Field units and
actuators may be set up to carry out an appropriate action, e.g. close a valve.
Fig 2: Pakscan IIE Master Stations – rear view
PORT 1
RS485
PORT 2
RS232
FIELD CONNECTIONS
PORT 3
PORT 4
RS485
PORT
EXP
PORT 3
PORT 4
RS485
PORT
EXP
PORT 1
RS485
PORT 2
RS232
FIELD CONNECTIONS
MAINS INPUT
90 - 264 Vac
FUSE 1A
MAINS INPUT
90 - 264 Vac
FUSE 1A
MASTER STATION B MASTER STATION A
Data Label
Field Terminals and D-type Connector
Comms Port 1 (2xD-type)
Comms Port 2 (D-type)
Ethernet (RJ45)
IEC Power Connector
Storage
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3 STORAGE PROCEDURE
On receipt the hardware should be examined for signs of damage and to ensure that the expected
equipment is present. Identify all the parts.
If the unit is to be stored for a period of time then normal conditions for keeping electronic hardware
must be provided.
The ambient conditions should remain in the following bands at all times:
Temperature: 10 - 30 degrees Centigrade
Humidity: Not to exceed 80% R.H.
The equipment should not be stacked, though it may be stored in any orientation. The original packing
should be retained. DO NOT LOSE THE MANUALS.
If it is to be kept for a prolonged period then an electrical exercise test is recommended every 6
months, for 24 hours. The master station internal battery has a shelf life of 3 years.
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Pakscan Overview
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4 OVERVIEW OF PAKSCAN
The Pakscan system is a control and monitoring
package comprising a master station, 2-wire serial
data cable wired in a ring or loop and a number of
connected actuators with Pakscan field units fitted.
The fieldbus loop can have up to 60, 120, 180 or
240 field units connected depending on the
capability of the master station, and the cable can
be up to 20 km long. The length of the 2-wire cable
(loop length) can be considered as the
circumference of a circle starting and finishing at
the master station.
The master station is a single module in a 19-inch
rack. It may have a supporting, identical, standby
unit. Details of setting a Hot Standby pair are
covered in Section 10. In essence, the Hot Standby
simply comprises two identical master stations each
of which is set identically to its partner. In some
cases two master stations are fitted into one 19inch rack (there is space for two). These can be
considered as two independent units.
The current loop is single fault tolerant and can
withstand either an open circuit, short circuit or
ground connection fault and still maintain
communication with all the field units. Subsequent
faults do not stop the complete system from
working and the parts that remain connected to the
master station will continue to be in communication
with it.
In addition to controlling the loop, the master station
also provides the external interface to the system.
It supports 2 serial ports for communications to host
computers, as well as providing a local user
interface. Alternatively, one of the serial ports may
be used to drive a printer to log alarms. In the
Pakscan Ethernet version one or both the serial ports are replaced with a standard 10Base-T Ethernet
ports. When a single Ethernet port is available the remaining serial port may be either RS232 or
RS485 depending on the option chosen.
4.1 Field Control Units
A range of field control units ('FCU’s') is available to cater for specific application areas. These may be
summarised as follows:
Fig 3: Pakscan IIE System Diagram
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Integral type field control units mounted within a Rotork actuator electrical housing such
as the IQ, IQT or Q range actuator.
Externally mounted field control unit. Various packages are available, including 'Pakbox',
weather-proof box, or rack mounting. The unit may be used for either actuator control
applications, or for general purpose applications such as pumps, blenders etc. Its
complement of I/O is 8 digital inputs, 4 changeover relay outputs, 2 analogue inputs and
1 analogue output.
4.2 Control and Indication
The field units each report information to the master station that can be viewed on the integral LCD
display, or collected from the serial communication port of the master station for use on another
display system. The reported data is already organised and requires no configuration by the user;
each field unit automatically reports all its available data.
Commands to operate the output devices may be sent over the system, the initiation of the command
can either be from the integral keypad (under the correct access code) or from the serial or Ethernet
data link. Once again the organisation of these commands is already configured and the user only has
to address the correct register to implement the command.
Functions
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5 FUNCTIONS
5.1 Cable Fault Protection - Loopback system
Communication between the master station and the field control units is via a twisted pair 2-wire cable
carrying a 20 mA current in a loop. In normal operation the current flows round the loop on one wire
and returns via the master station on the second wire. If high-speed operation with ‘doubling on’ is
selected the current returns inside the master station and the second wire is not used.
Each field control unit has the capability to connect the 2 wires together (apply a loopback circuit), and
this mechanism is used to divert the current in the event of a loop fault. With field units each side of a
loop fault 'in loopback', the system can still communicate with all field units by operating the system as
2 segments. If there are 2 loop faults, those field units between the faults will be isolated.
A loop cable fault may be an open circuit, a short circuit, or an earth fault.
5.2 Current Loop Start Up Operations
The Pakscan IIE controls the current on the loop to communicate with the attached field units. Loop
communication divides into two parts: configuration (when the master station decides whether the loop
is complete, and if not, where the faults are), and normal operation.
Fig 4: Loopback system
Master Station
Port B
Port A
Add 2
Add 4
Add 3
Add 1
In OutOutIn
Master Station
Port B
Port A
Add 2
Add 4
Add 3
Add 1
In OutOutIn
Normal operation Broken loop operation
Cable
Fault
LB on LB on
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5.2.1 Loop Configuration
The loop configuration phase is entered after power-up, after a loop fault is detected, or after a loop
configure command is received.
Configuration consists of the following steps:
1. Wait for all the field units to go into loopback. The time is dependent on the baud rate.
2. Issue a command from Port A to ask a field unit in loopback for its address. This finds the
first field unit.
3. Use that address to tell the field unit to remove its loopback.
4. Repeat steps 2 and 3 until no more field units are found.
5. Attempt to send a message right round the loop and receive it back at the sending end.
This tests the integrity of the complete loop.
6. If the loop is complete stop here. If the loop has a problem execute steps 7 to 10.
7. Repeat steps 2 to 4 from Port B.
8. Again wait for all field units to go into loopback.
9. Remove loopbacks one field unit at a time from Port A until only the last field unit is left in
loopback.
10. Repeat step 9 for Port B.
Loop configuration will identify and mark as out of service any field unit found which has an address
that is zero, an address that is the same as one which has already been found, or which has an
address, which is too high. An address that is too high is one outside the range selected for the master
station.
The master station has the facility to double the loop Baud rate. If this facility is enabled, via the
Keypad, the master station will issue a broadcast command to all the field units to get them to double
the baud rate they are using, once it has detected that the loop is complete.
5.2.2 Normal Running Operation
In normal operation, the master station polls each field unit for any changed data it has to report. Most
of the time, field units have no changes to report, and traffic on the loop is kept to a minimum. Field
units are polled in address order. Data that might be reported includes changes to digital inputs, alarm
changes, or significant changes to an analogue input.
If a field unit, which previously responded on the last scan, fails to respond correctly the master station
will retry twice to get a reply. On subsequent scans only a single attempt is made to get a response.
All field units up to the address preset in the master station database are polled. Thus new field units
which are powered-up on a working loop will be identified by the master station, provided they are
within the selected address range, and future scans will poll the new field unit for data.
Commands to field units (open, close, etc.) are interleaved between polls to individual field units. This
ensures they are sent as soon as a slot is available. When the current transaction is completed the
command will be next.
A check is made at the end of each scan to see if a loop fault has occurred. For a complete loop with
no loopbacks present a test message is sent round the loop; for a broken loop (loopbacks in use)
Functions
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communications failure to the last field unit on either side is taken as an indication of a fault. In the
event of a new fault, loop re-configuration is initiated.
5.3 Modbus Serial and Ethernet Interfaces
The Pakscan IIE master station is provided with two interfaces for data exchange with external host
systems. These may be a combination of one serial and one Ethernet, two serial or two Ethernet
connections. In addition one port can be selected for serial printer use. For Ethernet connections one
or more PS601, PS602, PS603 or PS604 modules must be fitted. In all cases the interfaces behave
similarly and always use Modbus RTU or Modbus TCP for the data communication protocol.
The master station's use of the Modbus RTU protocol is described in detail in the protocol documents
listed in section 1 (Related Documents). The master station may operate slightly differing protocols
data bases from each of its two ports. The protocols available are indicated on the set up screen
display, (see screen displays section). Modbus TCP behaves in a similar manner to Modbus RTU and
the register locations are the same for both protocols.
The two serial ports can both issue commands to field units via the master station, and to the master
station itself. Three separate registers of field unit alarms are maintained by the master station, one for
each serial or Ethernet port and one for the front panel display. This ensures that alarms cannot be
missed by any of the interfaces. If the host system is reading alarms from both the serial data bases it
must consider each one separately and perform the read and accept routines for each serial link.
Accepting an alarm on either serial interface does not accept the alarm on the display, or vice versa.
The alarm handling on the Modbus TCP Ethernet link is different. If the host protocol is selected as
Yokogawa then the alarm handling is exactly as for the RTU serial data and alarms are held until
accepted. If the protocol is selected as Generic then the Web Server will be populated with data; alarm
handling is similar to the other serial data bases, but now either the web server or the external
Ethernet host can accept the alarm on the associated data base. Effectively there is one alarm register
for the IP address and both the web server and host access the same register and accept the same
register.
5.4 Local User Interface (LCD and Keypad)
The Local User Interface allows the master station to be interrogated directly for its own status and
diagnostic information, and for field unit status. Various parameters may also be configured from the
front panel and commands sent to field units. The available screens are illustrated later in this manual.
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Jumpers and Links
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6 INITIAL SETTING UP
The factory default settings for the jumpers and links inside the master station will be satisfactory for
most applications. However there are some cases where special settings could be required. Before
applying any power to the master station check that the internal settings of the jumpers match the
system requirements. These jumpers will have been factory set to the default positions, or to user
specified positions, prior to dispatch.
In addition to the internal jumpers there may be a need to fit external links to achieve satisfactory
operation of the installed unit, for example with Hot Standby units. These links can be fitted prior to
installation.
6.1 Jumper Settings
The PS100 CPU and Display module contains a number of jumpers to set some of the parameters for
the performance of the unit. These are factory set and should generally not require adjustment at any
time. However there are links that may need to be fitted to match specific applications. There are no
jumper links on the power board, display board or loop driver board that require customer adjustment.
The diagram Fig. 5 is a top view of the PS100 module showing the different circuit boards. Fig. 6
shows the layout of the V25 card of the module. This is the PCB located to the left of the display
screen when viewed from the front; it is clearly distinguished by the battery on the board.
The function and default settings of the jumpers is listed in the table, please note that some select the
type of integrated circuit used, and therefore may vary from one unit to another.
Front Display
V25 CPU
board
Loop Driver
board
Power
board
Display
board
Rear Connectors
Fig 5: The PS100 card positions
Pakscan IIE System Manual
24 of 132 Publication S177E V2.0 Issue 03/05
Jumper No Description Function Setting
J1 Reset jumper Normal operation
Override reset
Hold in reset
A
Not fitted
B
J2 RAMWR jumper Normal operation
Full RAM access
Link 1 - 2
Not fitted
J3 CTR CLK2 jumper CTR CLK2 Freq - A
ISAF – B
J4 MEMWR MEMWR Flash - B
EPROM – A
J5 RAM (A12) jumper A12 Fitted
J6 ROM (A17) jumper A17 Fitted
J7 IRQ jumper IRQ enable
IRQ disable
Not fitted
Fitted
J8 CTS jumper CTS enable
CTS disable
Link 1-2
Link 2-3
J10 ROM (A18) jumper A18 Fitted
J11 ROM (A15) jumper A15 Fitted
J12 to J15 Digital input jumpers Un-isolated
Isolate channel
Link 1-2 & 3-4
Link 2-3
J17 & J18 RS485 termination jumpers
J17 = data, J18 = RTS
Termination
No Termination
Fitted
Not fitted
J19 RAM (A16) jumper A16 Fitted
J20 & J25 RS485 bias jumper RS485 bias data Fitted
J21 & J26 RS485 bias jumper RS485 bias RTS Fitted
J24 FPGA write jumper Enable local FPGA write Fitted
J27 CTS1 jumper CTS1 enable (RS485 only) Fitted
J28 Battery jumper Disconnect battery
Connect battery
None
Fitted
J29 INTP2 jumper Enable INTP2 Fitted
Fig 6: Master Station V25 card internal links
J29 J7
J12
J13 J14
J15
J8
A BA B
J11
J6
J10
J4
J1
A B
J24
J5
J19
A B
J2
J28
J27
Battery
A
B
J
3
J26J25
J21
J
2
0
J
1
7
J
1
8
5
2
0
6
-
0
1
4
V
X
.
X
Jumpers and Links
25 of 132 Publication S177E V2.0 Issue 12/04
J8 – CTS Function Select for Port 2
Link 2-3 (default setting) causes the master station to ignore the RS232 CTS line on Port 2. If the link
is placed in 1-2, then the connected serial device may control the output of the master station on Port
2. This may be required if Port 2 is operating a printer.
J17 and J18 – RS485 Termination
These allow for two terminating 100 ohm resistors to be connected to the RS485 lines to prevent
signal reflections. These jumpers are not normally fitted as if there are too many terminating resistors
connected the line function will deteriorate due to the electrical loading. However all RS485 data
highways should include terminating resistors at either end of the highway, i.e. at the host and at the
last device.
J20 and J25 / J21 and J26 – RS485 Bias
These allow for four biasing resistors (470 ohm) to be connected to the RS485 lines to pull them apart.
These jumpers should not normally fitted as if there are too many bias resistors connected the line
function will deteriorate due to the electrical loading. However all RS485 data highways should include
bias resistors in a single location. If a PS412 stand-alone converter is used in the system then the pull
apart resistors in that unit will already be connected.
J28 - Battery Backup
Link 2-3 connects the battery, linking 1-2 isolates the battery. If the battery is disabled, or removed, for
any length of time, e.g. greater than 1 hour, the settings on the master station may be lost. The battery
maintains the type of station, the clock, and any user set parameters.
6.2 External Links
Some of the functions of the master station are settable by external connections. These connections
may come from other pieces of plant where a contact opening or closing forces a master station
action, or they may be fixed for the application.
The function and setting of these links is described here.
Terminal 10 & 11 – ESD (Emergency Shutdown)
The Pakscan system may be configured (on software version 5206-014 V3.2 or higher) for a global
command to 'ESD' all the connected devices. One source of the ESD command is connected as an
input to these terminals.
When configured to do so, the system will issue continuous ESD commands to the Loop whenever
these two terminals are unconnected. A remote ESD contact, process normal closed, may be
connected. If the contact opens, then an ESD is issued.
If the ESD function via these terminals is not required then it may be removed from the configuration
or, if it remains an enabled option, a link MUST be fitted between these terminals.
Note: The battery should never be disconnected except in extreme circumstances.
Pakscan IIE System Manual
26 of 132 Publication S177E V2.0 Issue 03/05
Terminal 22 & 23, Terminal 24 & 25
If the master station is not part of a hot standby pair, that is, it is a single stand-alone unit then two
links
MUST be fitted. (A hot standby pair always includes the PS300 switch module in the centre of the
rack.)
If the rack does not contain a PS300 Switch module:
Link terminal 22 to 23
Link terminal 24 to 25
6.3 Display Screen Contrast
On the front of the master station there is a multi-turn potentiometer that is used to adjust the contrast
of the LCD display. Adjusting clockwise increases the contrast.
Fig 7: Master Station front panel
Field Alarm
New
Alarm
Addr
Fault
Host Active
Masterstation
Active
Alarm
PS100
PS100
Standby
Port
A
Port
B
Contrast
Menu
123
654
789
0
*
LOAD
CLEAR
Configuration
Contrast
adjustment
Installation and Connection
27 of 132 Publication S177E V2.0 Issue 03/05
7 INSTALLATION AND CONNECTION
The master station is now ready for installation and connecting to the loop.
7.1 Mounting
The master station rack should be mounted
horizontally in a suitable frame or cabinet. The
height of the front should be between 1.0 m
and 1.7 m above the floor so that the screen
may be viewed and the keys accessed. There
should be no equipment in front of the master
station. At the rear ensure sufficient space is
provided to access the terminals and
connectors.
Ideally both front and rear access to the unit
should be provided. However if rear access is
not possible, ensure sufficient cable length is
allowed for the rack to be withdrawn and
placed safely when checks to the connections
are required.
All connections are to the rear of the rack.
7.2 Mains Power
The individual master stations in the rack each
require their own power feed. When ac power
is used this is connected by an IEC connector.
The unit will operate on an ac supply between
90 and 264 volts, 43 to 440 Hz, single phase.
[For dc systems a suitable dc supply must be
arranged (24 V dc nominal, range 21-30 V dc),
this is connected to the screw terminals on the
rear of the unit, and each master station still
requires its own supply feed.]
It is essential that an Earth connection is made
to the master station via the IEC connector,
and/or the safety earth stud.
System Terminals
SWITCH 1 2 3 4 5 6 7 LAMP SWITCH
123456
7
Masterstations A Masterstations B
Safety Earth
Signal Earth
1.0 m
1.7 m
Comms Ports
Fig 8: Typical system cabinet
Pakscan IIE System Manual
28 of 132 Publication S177E V2.0 Issue 03/05
7.3 Field Wiring
The field wiring includes the loop wires to the field units. The loop cable should have an overall
electrical screen. Particular attention should be paid to the connection of the screen on this cable.
The wiring should be in accordance with the diagram Fig. 9. (For connecting up a Hot Standby system
refer to section 10.)
Note that the system is a current loop, and that Port A Out, (terminal 12), connects via all the field
units to Port B In, (terminal 16), whilst Port B Out, (terminal 15), connects similarly to Port A In,
(terminal 13). If a coloured pair, red and blue, is used this results in say the red wires being in
terminals 12 and 16, with the blue wires in 13 and 15. The order is red, blue, blue, red.
Fig 9: Typical System Wiring Diagram
Actuator Terminals
ABC
Scr
A
c
t
u
a
t
o
r
T
e
r
m
i
n
a
l
s
A
B
C
S
c
r
Actuator Terminals
ABCScr
Emergency
Shutdown
17
16
15
14
13
12
11
10
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Field
Connector
Port A Out
Port A In
Port B Out
Port B In
These links must be fitted
when there is no PS300
Switch Module in the rack
LNE
Mains
Supply
Port 1
RS485
Port 2
RS232
Ethernet
RJ45
Signal Earth Bar
Screen of 2 wire loop connected
directly to earth at one end only
LK1
NB2
Power
Supply
PS210
Processors
and
Display
PS100
Pakscan IIE Master Station
PS602
Installation and Connection
29 of 132 Publication S177E V2.0 Issue 12/04
7.3.1 Screen Connections
The screen terminal 14 is connected internally to the supply earth pin, and the chassis. Terminal 17 is
connected to earth via a capacitor, (to meet the CE specification for EMC emission standard), or
directly to earth if link LK1 for master station A or hot standby systems, or LK2 for master station B, is
fitted. If no alternative clean earth bar is provided then the screen will have to connect to the supply or
safety earth.
If you choose to use the internal earth point on terminal 14 or 17 you must ensure that a safety earth is
connected to the master station. Connect the screen of the cable on one side only, say Port A using
terminal 14. DO NOT CONNECT THE SCREEN ON BOTH ENDS OF THE CABLE IF LK1 (LK2 for
station B) IS FITTED. If you connected the loop directly to earth at two or more points, an earth loop
will result that will probably degrade the loop communications.
If your system includes a Signal Earth bar then connect the screen of one of the loop cables to this bar
only. Do not link the bar to the master station earth via the cable screen and terminal 14.
7.4 Loop Checks
Once the loop is fully wired there are a number of checks that should be made before power is applied
to any of the connected field units, actuators, or the master station. These simple tests will always help
in the setting to work of the system.
7.4.1 Loop Continuity.
With all the field units connected, but none of them powered up, check the continuity of the 2 cores of
the cable using a simple resistance (ohm) meter. [The most common errors in installing the system
occur on the field wiring.]
1. Disconnect all the loop wires and the screen from the master station.
12
13
14
15
16
17
Port A Out
Port A In
Port B Out
Port B In
LK1
12
13
14
15
16
17
Port A Out
Port A In
Port B Out
Port B In
LK1
Safety Earth
Safety Earth
Signal Earth
Safety Earth
Safety Earth
Fig 10: Typical Screen Connection
Note: The screen must only be connected directly to earth at one point, and at one end of
the cable.
Pakscan IIE System Manual
30 of 132 Publication S177E V2.0 Issue 03/05
2. Measure, and note down, the resistance of each core (the core connected to A and B will
have a higher resistance than the core connected to the common).
3. Check the resistance between the cores, this should be a high resistance as they are not
connected together. (Note that if a field unit has power to it, then the internal circuitry will
connect the two cores together.)
4. Join the 2 wires that will be connected to Port B together and measure the total resistance of
the whole loop cable - note this down as you will need it for reference later.
7.4.2 Screen Continuity
With the Port B cables still connected together make sure that the screen is isolated from the loop
cores themselves, there should be a high resistance between screen and cores.
5. Check the screen is continuous by measuring the resistance of the screen between the two
ends.
6. Check that the screen is isolated from earth by measuring the resistance between the screen
and your screen earth point.
7.4.3 Cable Capacitance
The capacitance between the cores, and to the screen, is critical to the system performance. Too high
a capacitance for the selected loop baud rate will result in poor communications, or even
communication failure.
7. Disconnect the join between the 2 cores that connect to Port B, the cores and screen are now
all separated.
8. With the digital meter set to capacitance, measure the core to core capacitance, and note it
down.
9. Also measure the core to screen capacitance, which will probably be slightly higher, for cable
core 1.
10. Measure the capacitance between core 2 and the screen.
If any problems are encountered during these tests rectify them before proceeding. The results should
be noted on a form such as that shown overleaf.
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