SMAR fy303 Operation, Maintenance & Instruction Manual

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OPERATION, MAINTENANCE

ND INSTRUCTION MANUAL

Profibus PA Valve Positioner

JUL / 16

FY303ME

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smar

Specifications and information are subject to change without notice.

Up-to-date address information is available on our website.

web: www.smar.com/contactus.asp

www.smar.com

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INTRODUCTION

The FY303 is a Profibus PA valve positioner for Single (spring return) or Double acting Linear motion type control valves e. g. Globe, Gate, Diaphragm, Pinch or Clamp and Rotary motion type control valves e. g. Ball, Butterfly or Plug with pneumatic type actuators e. g. Diaphragm, Piston, Vane, or Bellows. It is based on a field-proven piezo flapper and non-contacting Hall-effect position sensor that provides reliable operation and high performance. The digital technology used in the FY303 enabled the choice of several types of flow characterizations, an easy interface between the field and the control room and several interesting features that considerably reduce the installation, operating and maintenance costs.

The FY303 is part of Smar's complete 303 line of Profibus PA devices.

Some of the advantages of bi-directional digital communications are known from existing smart transmitter protocols: Higher accuracy, multi-variable access, remote configuration and diagnostics, and multi-dropping of several devices on a single pair of wires.

The system controls variable sampling, algorithm execution and communication so as to optimize the usage of the network, not loosing time. Thus, high closed loop performance is achieved.

Using Profibus technology, with its capability to interconnect several devices, very large control schemes can be constructed. In order too be user friendly the function block concept was introduced.

The need for implementation of Fieldbus in small as well as large systems was considered when developing the entire 303 line of Profibus-PA devices. They have common features and can be configured locally using a magnetic tool, eliminating the need for a configuration tool or console in many basic applications.

Get the best result of the FY303 by carefully reading these instructions.

NOTE

In case of using Simatic PDM as the configuration and parameterization tool, Smar recommends that the user does not apply the option "Download to Device". This function can improperly configure the field device. Smar recommends that user make the use of the option "Download to PG / PC" and then selecting the Device Menu, use the menus of the transducer, function and display blocks acting specifically, according to each menu and method for reading and writing.

WARNING

Throughout the operation of the positioner, including self-setup, do not touch the moving parts of valve/actuator/positioner assembly as they may unexpectedly move automatically. Make sure to disconnect supply air before touching any moving parts.

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This manual is compatible with version 1XX, where 1 denotes software version and XX software release. The indication 1.XX means that this manual is compatible with any release of software version 1.

Waiver of responsibility

The contents of this manual abides by the hardware and software used on the current equipment version. Eventually there may occur divergencies between this manual and the equipment. The information from this document are periodically reviewed and the necessary or identified corrections will be included in the following editions. Suggestions for their improvement are welcome.

Warning

For more objectivity and clarity, this manual does not contain all the detailed information on the product and, in addition, it does not cover every possible mounting, operation or maintenance cases.

Before installing and utilizing the equipment, check if the model of the acquired equipment complies with the technical requirements for the application. This checking is the user’s responsibility.

If the user needs more information, or on the event of specific problems not specified or treated in this manual, the information should be sought from Smar. Furthermore, the user recognizes that the contents of this manual by no means modify past or present agreements, confirmation or judicial relationship, in whole or in part.

All of Smar’s obligation result from the purchasing agreement signed between the parties, which includes the complete and sole valid warranty term. Contractual clauses related to the warranty are not limited nor extended by virtue of the technical information contained in this manual.

Only qualified personnel are allowed to participate in the activities of mounting, electrical connection, startup and maintenance of the equipment. Qualified personnel are understood to be the persons familiar with the mounting, electrical connection, startup and operation of the equipment or othe similar apparatus that are technically fit for their work. Smar provides specific training to instruct and qualify such professionals. However, each country must comply with the local safety procedures, legal provisions and regulations for the mounting and operation of electrical installations, as well as with the laws and regulations on classified areas, such as intrinsic safety, explosion proof, increased safety and instrumented safety systems, among others.

The user is responsible for the incorrect or inadequate handling of equipments run with pneumatic or hydraulic pressure or, still, subject to corrosive, aggressive or combustible products, since thei utilization may cause severe bodily harm and/or material damages.

The field equipment referred to in this manual, when acquired for classified or hazardous areas, has its certification void when having its parts replaced or interchanged without functional and approval tests by Smar or any of Smar authorized dealers, which are the competent companies for certifying that the equipment in its entirety meets the applicable standards and regulations. The same is true when converting the equipment of a communication protocol to another. In this case, it is necessary sending the equipment to Smar or any of its authorized dealer. Moreover, the certificates are different and the user is responsible for their correct use.

Always respect the instructions provided in the Manual. Smar is not responsible for any losses and/or damages resulting from the inadequate use of its equipments. It is the user’s responsibility to know and apply the safety practices in his country.

NOTE

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TABLE OF CONTENTS

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GENERAL ...................................................................................................................................................... 1.1

MOUNTING .................................................................................................................................................... 1.1

ROTARY MOVEMENT ................................................................................................................................... 1.1

PNEUMATIC CONNECTIONS ....................................................................................................................... 1.2

ELECTRONIC HOUSING ROTATING ........................................................................................................... 1.6

ELECTRIC WIRING ........................................................................................................................................ 1.6

TOPOLOGY AND NETWORK CONFIGURATION ........................................................................................ 1.7

INTRINSIC SAFETY BARRIER ...................................................................................................................... 1.8

JUMPER CONFIGURATION .......................................................................................................................... 1.8

POWER SUPPLY ........................................................................................................................................... 1.9

AIR SUPPLY REQUIREMENTS ..................................................................................................................... 1.9

RECOMMENDATIONS FOR AN INSTRUMENT AIR SYSTEM ..................................................................... 1.9

ROTARY AND LINEAR MAGNET ................................................................................................................ 1.10

MAGNET REMOTE

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FUNCTIONAL DESCRIPTION - OUTPUT MODULE ..................................................................................... 2.1

FUNCTIONAL DESCRIPTION-ELECTRONICS ............................................................................................ 2.2

INTRODUCTION TO FIELDBUS APPLICATION ........................................................................................... 2.4

FUNCTION BLOCKS ...................................................................................................................................... 2.4

TRANSDUCER BLOCKS ............................................................................................................................... 2.4

PHYSICAL BLOCK ......................................................................................................................................... 2.4

THE LOCAL INDICATOR ............................................................................................................................... 2.4

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TRANSDUCER BLOCK ................................................................................................................................. 3.1

HOW TO CONFIGURE A TRANSDUCER BLOCK ........................................................................................ 3.1

FUNCTIONAL DIAGRAM OF THE POSITIONER TRANSDUCER BLOCK ................................................... 3.2

TRANSDUCER BLOCK STANDARD PARAMETER DESCRIPTIONS ......................................................... 3.3

TRANSDUCER BLOCK SPECIFIC PARAMETER DESCRIPTIONS ............................................................. 3.5

TRANSDUCER BLOCK PARAMETER ATTRIBUTE TABLE ......................................................................... 3.7

TRANSDUCER BLOCK VIEW OBJECT TABLE ............................................................................................ 3.9

FY303 CYCLICAL CONFIGURATION ......................................................................................................... 3.12

HOW TO CONFIGURE THE ANALOG OUTPUT BLOCK ............................................................................ 3.17

POSITION CALIBRATION ........................................................................................................................... 3.20

TEMPERATURE CALIBRATION ................................................................................................................. 3.23

SELF-CALIBRATION ................................................................................................................................... 3.24

DIAGNOSIS .................................................................................................................................................. 3.25

TRANSDUCER DISPLAY - CONFIGURATION ........................................................................................... 3.26

DISPLAY TRANSDUCER BLOCK ............................................................................................................... 3.27

DEFINITION OF PARAMETERS AND VALUES .......................................................................................... 3.28

CALIBRATING USING LOCAL ADJUSTMENT ........................................................................................... 3.30

SELF-CALIBRATION USING LOCAL ADJUSTMENT ................................................................................. 3.34

HALL'S OFFSET COMPENSATION WITHOUT MAGNET PART ................................................................ 3.34

TEMPERATURE COMPENSATION ............................................................................................................ 3.35

PRESSURE SENSORS VERSION (K1 OPTION) ........................................................................................ 3.36

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GENERAL ...................................................................................................................................................... 4.1

DISASSEMBLY PROCEDURE ...................................................................................................................... 4.2

REASSEMBLY PROCEDURE ....................................................................................................................... 4.3

RESTRICTION CLEANING PROCEDURE .................................................................................................... 4.3

CHANGE OF THE FILTER ELEMENTS ......................................................................................................... 4.4

CENTRALIZER DEVICE .............................................................................................................. 1.10

HALL SENSOR ............................................................................................................................ 1.10

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ELECTRONIC CIRCUIT ................................................................................................................................. 4.4

INTERCHANGEABILITY ................................................................................................................................ 4.5

PACKAGE CONTENT .................................................................................................................................... 4.5

EXPLODED

VIEW .......................................................................................................................................... 4.6

SPARE PARTS LIST ...................................................................................................................................... 4.7

DETAILED

CODE WHEN ORDERING OF SPARE PARTS ........................................................................... 4.9

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FUNCTIONAL SPECIFICATIONS .................................................................................................................. 5.1

PERFORMANCE SPECIFICATIONS ............................................................................................................. 5.2

PHYSICAL SPECIFICATIONS ....................................................................................................................... 5.2

ORDERING CODE ......................................................................................................................................... 5.3

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EUROPEAN DIRECTIVE INFORMATION ..................................................................................................... A.1

HAZARDOUS HAZARDOUS

CSA (CANADIAN STANDARDS ASSOCIATION) ......................................................................................................... A.2

APPROVALS (FACTORY MUTUAL)....................................................................................................................... A.2

NEMKO EXAM

(BBG PRÜF - UND ZERTIFIZIER GMBH) .......................................................................................................... A.3

CEPEL

LOCATIONS GENERAL INFORMATION ............................................................................... A.1

LOCATIONS APPROVALS..................................................................................................... A.2

(NORGES ELEKTRISKE MATERIELKONTROLL) ......................................................................................... A.3

(CENTRO DE PESQUISA DE ENERGIA ELÉTRICA) ...................................................................................... A.3

IDENTIFICATION PLATE ............................................................................................................................... A.5

CONTROL

DRAWING .................................................................................................................................... A.7

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RETURNING MATERIALS ............................................................................................................................. B.2

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Section 1

General

Mounting

Rotary Movement

INSTALLATION

The installation carried out in hazardous areas should follow the recommendations of the IEC60079-14 standard.

The overall accuracy of measurement and control depends on several variables. Although the converter has an outstanding performance, proper installation is essential, in order to maximize its performance.

Among all factors, which may affect converter accuracy environmental conditions are the most difficult to control. There are, however, ways to reduce the effects of temperature, humidity and vibration.

The FY303 has a built-in temperatur e sensor to compensate for temperature variations. At the field , this feature minimizes the temperature variation effect.

Locating the positioner in areas protected from extreme environmental changes can minimize temperature fluctuation effects.

In warm environments, the positioner should be installed to avoid, as much as possible, direct exposure to the sun. Installation close to lines and vessels subjected to high temperatures shou ld also be avoided.

Use of sunshades or heat shields to protect the positioner from external heat sources should be considered, if necessary.

Humidity is fatal to electronic circuits. In areas subjected to high relative humidity, the O-rings for the electronics cover must be correctly placed. Removal of the electronics cover in the fiel d should be reduced to the minimum necessary, since each time it is removed; the circuits are exposed to humidity. The electronic circuit is protected by a humidity proof coating, but frequ ent exposures to humidity may affect the provided protection. It is also important to keep the covers tightened in place. Every time they are removed, the threads ar e exposed to corrosion, since painting cannot protect these parts. Code approved sealing methods on conduit e ntering the positioner should be employed.

Although the positioner is virtually insensitiv e to vibration, installation close to pumps, turbines or other vibrating equipment should be avoided.

The mounting of positioner FY303 will depend on actuator type, single (spring return) action or double action and on actuator movement, if it is linear or rotary. Two supports are required for mounting, one for the magnet and the other for the positioner itself. Smar may suppl y them both since they are specified in the order code.

Install the magnet on the valve stem using the magnet support (See Figure 1.2). Install the positioner support on the actuator. The actuator should be in accordance with standar d

VDI/VDE 5845, all you have to do is tighten the f our screws with the lock washers on the standard support.

For special supports, refer to specify instructions. After installing the support on the actuator, it is possible to mount the positioner FY303 on the support by means of the four screws with lock washers.

Make sure that the arrow engraved on the magnet coincides with the arrow engraved on the positioner when the valve is in mid travel.

If the installation of the positioner or magnet should be altered, or if there should be any other modification, the positioner will require a recalibration.

As to the type of valve action, refer to paragraph "Pneumatic Connections".

NOTE

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FY303 - Operation, Maintenance and Instructions Manual

Linear Movement

Install the magnet on the valve stem using the magnet support (See Figure 1.3). Install the positioner support on the actuator. The actuator support may be secured in place as per standard NAMUR/IEC 536-4 or in accordance with user specified boring. Install the positioner on the support and tighten the four screws in the threaded bores located on the side opposite to the pressure gages (See Figure 1.3). Use lock washers in order to prevent screw slackening.

Make sure that the support is not obstructing the exhaustion outlets.

Make sure that arrow engraved on the magnet coincides with the arrow engraved on the positione r when the valve is in mid travel. The magnet mounting in relation to the hall sensor:

1. Must not have attrition between the internal magnet face and the hall sensor salience during the travel (rotary or linear), through the magnet.

2. The magnet and the salience of hall sensor must not be distant.

A minimum distance of 2 mm and a maximum distance of 4 mm is recommended between the magnet external face and the positioner face. For that, a centralizer device (linear or rotary) must be used. The centralizer device is in the positioner packing.

If the installation of the positioner or magnet should be altered, or if there should be any other modification, the positioner will require a recalibration.

Pneumatic Connections

Air supplied to the positioner FY303 shall be quality instrument air, i. e., dry, clean and noncorrosive. Refer to the American National Standard. “Quality Standard for Instrument Air” (ANSI/ISA S7.0.01 - 1996).

The FY303 is supplied with input and outputs air filters; but these filters do not substitute a preliminary instrumentation air treatment. We recommend a periodic cleani ng of such filters each 6 months or less, case the air instrument quality is not good.

Air supply pressure to the FY303 shall be between 1.4 bar (20 ps i) an d 7 bar (10 0 psi). In case suc h requirements can not be fulfilled, the use of an air pressure regulator is acceptable.

Use sealant on threads. Sealants like PTFE (Teflon) tape shall be avoided because they may fragment and eventually obstruct internal parts.

Positioner FY303 may be supplied with pressure gages. There are taps av ailable for IN, OUT1 and OUT2. Before connecting the pressure gages, make sure that all lines be completely purged.

Valve positioner FY303 has two pneumatic outputs. They work on opposite directions to open or close the valve.

The FY303 should fail, for example, because of a power fa ilure. The output identified as OUT1 (output 1) goes to nearly zero; while the output identified as OUT2 (output 2) goes to nearly the air supply pressure.

Pneumatic connections are identified as IN (input) for the air supply, and OUT1 and OUT2 for Output 1 and Output 2 respectively. Use 1/4 NPT connections. Sealant may be used NPT threads. Connect the air supply tubing to the connection identified as IN. Make sure that the air supply pressure does not exceed the maximum rating accepted by the positioner or actuator. The tubing used to connect the positioner FY303 to the actuator shall be as short as possible. The manometer supply is optional.

When ordering the positioner in stainless steel 316, combined with the local pressure gauges, the gauge case is in SS 316. For wet parts and threads in SS 316, please, consult Smar.

Make sure that sealant does not enter the positioner.

There are six exhaust outputs in the FY303, all of them fitted with filters. It is very important that such outputs are neither blocked nor obstructed, because the air must circulate freely.

All filters shall be inspected to make sure they will not obstruct the outputs (Refer to Section 4 Maintenance Procedures).

NOTE

WARNING

NOTE

ATTENTION

1.2

Page 11

Installation

(in)

1.9

2.1

(in)

Double Action - Air to Open (Fail Close)

Connect Output 1 (OUT1) of the positioner to the input identified as OPEN in the actuator, and connect Output 2 (OUT2) of the positioner to the input CLOSE in the actuator.

Double Action - Air to Close (Fail Open)

Connect Output 2 (OUT2) of the positioner to the input identified as OPEN in the actuator, and connect Output 1 (OUT 1) of the positioner to the input CLOSE of the actuator.

Single Action

Connect Output 1 (OUT1) of the positioner to the input of the actuator. Use a plu g to block Output 2 (OUT2).

VALVE POSITIONER

(3.27)

TERMINAL

WIRING

INPUT PRESSURE 1/8-27 NPT

(10.24)

OUTPUT PRESSURE 2 1/8-27 NPT

OUTPUT PRESSURE 1 1/8-27 NPT

(2.17) (1.83)

LINEAR MAGNET

64.5

(2.54)

(0.71)

(1.77)(1.77)(1.77)

(1.53)

HOLE 6.3 (0.25)Ø

(2 PLACES)

OUTPUT 2

1/4-18 NPT

INPUT

1/4-18 NPT

OUTPUT 1

1/4-18 NPT

(0.35)

(4.45)

SOCKET SET PLUG

(2.42)

MOUNTING HOLES FOR M6x1

SCREWS (2 PLACES)

Leave, at least, a 150mm (5.8 in) space, for zero and span adjustments with the magnetic tool.

(2.10) (0.94) (0.94)

ROTARY MAGNET

THREADS FOR SCREWS

6,5

(0.25)

All dimensions are in mm

ELECTRICAL

CONNECTION

EXHAUST ORIFICES

M6x1 (4 PLACES)

)

)( (

(0.94)

22.5

(0.89)

(1.30)

TRAVEL DIMENSION A UP TO 15 mm (0.59) UP TO 30 mm (1.18) UP TO 50 mm (1.97) UP TO 100 mm (3.94)

Note: Dimensions in mm

43 mm (1.7) 67 mm (2.64) 105 mm (4.13) 181 mm (7.12)

*ONLY FOR 50 AND 100 mm TRAVELS.

(0.59)

(2.72)

(0.83)

15 *

(0.59)

(0.87)

(1.54)

(0.51)

(1.97)

(0.954)

1.3

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FY303 - Operation, Maintenance and Instructions Manual

REMOTE HALL SENSOR

Figure 1.1 - FY303 Dimensional Drawing

ROTATY MAGNETY BRACKET

LOCK

VALVE STEM

ROTATY MAGNET

M6x1 SCREWS (4 PLACES)

POSITIONER BRACKET

POSITIONE

Figure 1.2 - Positioner on Rotary Actuator

NOTE

Included in the package content the centralizer device of rotary magnet. See figure 1.13.

1.4

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Installation

LINEAR MAGNET BRACKET

VALVE YOKE

POSITIONER

VALVE STEM

LINEAR MAGNET

CENTRALIZER DEVICE

BRACKET

M6x1 SCREWS

(4 PLACES)

POSITIONER

OUT 2OUT 1

Figure 1.3 - Positioner on Linear Actuator

NOTE

Included in the package content the centralizer device of linear magnet. See figure 1.12.

1.5

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FY303 - Operation, Maintenance and Instructions Manual

Electronic Housing Rotating

The electronic housing can be rotated in order to have a better position of the digital display. To rotate it, use the Housing Rotation Set Screw. (See Figure 1.4).

The local indicator itself can also be rotated. (See Figure 2.4).

Electric Wiring

Reach the wiring block by removing the Electrical Connection Cover. T his cover can be locked by the cover locking screw. To release the cover, rotate the locking screw clockwise. The wiring block has screws on which fork or ring-type terminals can be fastened.

Figure 1.4 - Cover Locking and Housing Rotation Set Screw

For convenience there are two ground term inals: one inside the cover and one external, located close to the conduit entries. (See Figure 1.5).

The FY303 uses the 31.25 kbit/s voltage mode opti on for t he physic al s ig nali ng. A ll other devic es o n the same bus must use the same signaling. All devic es are connected in parallel along the same pair of wires.

Various types of Profibus devices may be connected on the same bus.

1.6

Figure 1.5 - Wiring Block

Page 15

Installation

The FY303 is powered via the bus. The limit for such devices is according to the DP/PA coupler limitations for one bus for non-intrinsically safe requirement. In hazardous area, the number of devices may be limited by intrinsically safe r estrictions, acc ording to the c oupler DP/PA and barriers limitations.

WARNING

HAZARDOUS AREAS

In hazardous areas with explosion proof requirements, the covers must be tightened with at least 8 turns. In order to avoid the penetration moisture or corrosive gases, tighten the O’ring until feeling the O'ring touching the housing. Then, tighten more 1/3 turn (120°) to guarantee the sealing. Lock the covers using the locking screw.

In hazardous zones with intrinsically safe or non-incentive requirements, the circuit entity parameters and applicable installation procedures must be observed.

Cable access to wiring connections is obtained by the two conduit outlets. Conduit threads should be sealed by means of code-approved sealing methods. The unused outlet connection should be plugged and sealed accordingly.

Should other certifications be necessary, refer to the certification or specific standard for installation limitations.

The Figure 1.6 - Conduit Installation Diagra m shows the correct installation of the conduit, in ord er to avoid penetration of water, or other substance, which may cause malfunctioning of the equipment.

WIRES

CORRECT INCORRECT

Figure 1.6 - Conduit Installation Diagram

The FY303 is protected against reverse polarity, and can withstand ± 35 Vdc without damage, but it will not operate when in reverse polarity.

Topology and Network Configuration

Bus topology (See Figure 1.7) and tree topolog y (See Figure 1.8) ar e supported. Both types have a trunk cable with two terminations. The devices are connected to the trunk via sp urs. The spurs may be integrated in the device giving zero spur length. A spur may connect more than one device, depending on the length. Active couplers may be used to extend spur length.

Active repeaters may be used to extend the trunk length. The total cable length, including spurs, bet ween any two devices in the Fi eldbus should not exceed

1900m. The connection of couplers should be kept less than 15 per 250m. In following figures the

DP/PA link depends on the application needs.

1.7

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FY303 - Operation, Maintenance and Instructions Manual

Analog

Ground

Junction

Box

Shield

Spur

Figure 1.7 - Bus Topology

Terminato

Enabled

pur

Terminato

Spur

Intrinsic Safety Barrier

When the Fieldbus is in an area requiring intrinsic safety, a barrier must be inserted on the trunk between the power supply and the DP/PA coupler, when it is Non-Ex type.

Use of SB302 is recommended.

Jumper Configuration

In order to work properly, the jumpers J1 and W1 located in the FY303 main board must be correctly configured.

Junction

Box

+-+

Coupler

Analog

Ground

This jumper enables the simulation mode parameter in the AO block. This jumper enables the local adjustment programming tree.

Figure 1.8 - Tree Topology

1.8

Page 17

SSO

Power Supply

The FY303 receives power from the bus via the signal wiring. The power supply ma y come from a separate unit or from another device such as a controller or DCS.

The voltage should be between 9 to 32 Vdc for non-intrinsic safe applications. A special requirement applies to the power supply used in an intrinsically safe bus and depe nds on

the type of barrier used. Use of PS302 is recommended as power supply.

Air Supply Requirements

Before the air supply is connected to the positioner, we recommend the hose is opened freely for 2 to 3 minutes to allow any contamination to be blown out. Direct the air jet into a large pa per bag to trap any water, oil, or other foreign materials. If this indic ates that the air system is contaminated, it should be properly cleaned.

As soon as the positioner is connected and started, internal air leakage will provide protection against corrosion and prevent the ingress of moisture. For this reason, the air supply pressure should always be kept on.

Recommendations for an Instrument Air System

Instrument air quality shall be superior to that of industrial compressed air. Humidity, airborne particles and oil may impair the instrument operation, either temporarily or perma nently in case of internal parts wearing.

As per standard ANSI/ISA S7.0.01 – 1996 - Quality Standard for Instrument Air, instrument air shall have the following characteristics:

Dew point Size of particles (airborne) Oil content Contaminants

This standard recommends that the compressor intake be located in an area free from process spills and fitted with and adequate filter. It also recommends the use of no n-lubricated type compressors, in order to prevent air contamination by lubricating oil. Where lubricated type compressors are adopted, there shall be used means to make the air oil free.

The figures 1.9 and 1.10 show a typical system for air supply and air quality conditioning.

10°C below minimum instrument temperature 40 µm (maximum) 1 ppm w/w (maximum) free from corrosive flammable gases

Installation

COMPRESSOR

INTAKE

MPRE

AFTERCOOLER

Figure 1.9 - Air Supply System

CONDENSATE

SEPARATOR

WITH DRAIN

AIR RECEIVER

WITH DRAIN

1.9

Page 18

FY303 - Operation, Maintenance and Instructions Manual

OIL AND WATER

MIST PREFILTER

WITH DRAIN

Figure 1.10 - Air Quality Conditioning System

Rotary and Linear Magnet

Magnet models are linear and rotary, for utilization on linear and rotary actuators.

Magnet Centralizer Device

AIR

DRYER

DRY AIR

AFTERFILTER

Figure 1.11 – Linear and Rotary Magnet Models

Centralizer device of linear magnet is used for all type of linear bracket.

NOTE

Figure 1.12 – Centralizer device of linear magnet

Remote Hall Sensor

The remote Hall magnetic sensor is an accessory recommended for high temperature and extreme vibration applications. It prevents excessive wear of the equipment and, conse quently, the reduction of its useful time.

1.10

Centralizer device of linear magnet is used only for universal rotary bracket.

NOTE

Figure 1.13 - Centralizer device of rotary magnet

Page 19

Installation

Figure 1.14 - Remote Hall Sensor

The electric signals on the remote sensor’s connection to que equipment are of low intensity. Therefore, when installing the cable inside the conduit (maximum limit 20 meters length) keep it away from possible sources of induction and/or magnetic interference. The cable supplie d by Smar is shielded for excellent protection against electromagnetic interference, but despite this protection avoid the cable sharing the same conduit with other cables. The connector for remote Hall sensor is easy handling and simple installation.

See the installation procedure:

Figure 1.15 - Connecting the Cable to the Remote Hall Sensor

Figure 1.16 - Connecting the Cable to the Positioner

1.11

Page 20

FY303 - Operation, Maintenance and Instructions Manual

1.12

Page 21

Section 2

OPERATION

Functional Description - Output Module

The main parts of the output module are the p ilot, servo, Hall Effect sensor and the output control circuit.

The control circuit receives a digital setpoint sign al from the CPU and a feedback signal from the Hall Effect sensor.

The pneumatic circuit is based on a well-known and widely adopted tec hnology, which is describe d on item Nozzle-and-Vane and Spool.

Figure 2.1 - Pneumatic Transducer Schematic

A piezoelectric disk as flapper in the pilot stage. The flapper is deflected when the control circuit applies a voltage. A small stream of air flowing throug h the nozzl e is obstr ucted causi ng an i ncre ase in pressure in the pilot chamber; this is called the pilot pressure.

The pilot pressure is too low, with flowing capacity, and for this reason it must be amplified in the servo section. The servo section includes a diaphragm in t he pi lot chambe r and a sm aller one in the spool chamber. The pilot pressure applies a force at the pilot chamber's diaphragm which, in the equilibrium state, will be equal to the force applied by the spool valve at the smaller diaphragm which is in the spool chamber.

Therefore, upon every position change caused by the positioner, the pilot pressure increases or decreases as explained in the pilot stage section; such change in pilot pressure causes an upward or downward valve travel which alters the pressure at output 1 and output 2 until a new equilibrium is reached, which results in a new valve position.

2.1

Page 22

FY303 – Operation, Maintenance and Instructions Manual

Functional Description-Electronics

Refer to the block diagram. The function of each block is described below.

2.2

Figure 2.2 - FY303 Block Diagram

Page 23

Operation

D/A

Receives the signal from the CPU and converts it to an analog voltage proportional the desired position, used by the control.

Control

Controls the valve position according to the data received from the CPU and the Hall effect sensor feedback.

A/D

Receives the signal from the Hall Sensor and converts it to a di gital value proportional to the actual valve position.

Hall Effect Sensor

Measures the position actual and feedback to the control and CPU.

Temperature Sensor

Measures the temperature of the transducer assembly.

Isolation

Its function is to isolate the fieldbus signal from the piezoelectric.

EEPROM

A non-volatile memory which stores configuration data as a backup.

Central Processing Unit (CPU), RAM, PROM and EEPROM

The CPU is the intelligent portion of the positioner, being responsible for the management and operation of block execution, self-diagnostics and commun ication. The program is stored in PROM. For temporary storage of data there is a RAM. The data in the RAM is lost if the power is switched off, however the device also has a nonvolatile EEPROM where data that must be retained is stored. Examples of such data are: calibration and valve configuration.

Communication Controller

A monitor line activity, modulates and demodulates communication signals and inserts and deletes start and end delimiters.

Power Supply

The positioner circuit receives supply from a 9 to 32 Vdc power supply. Use of PS302 is recommended.

Display Controller

Receives data from the CPU and drives the (LCD) Liquid Crystal Display.

Local Adjustment

Local adjustment is provided by means of two magnetic naturall y actuated switches with no external electric or mechanical contact, by using a magnetic screwdriver.

Piezo Flapper Nozzle

The unit flapper nozzle converts the movement of piezoelectric i nto a pneumatic signal to control pressure in the pilot chamber.

Restriction

The restriction and the nozzle form a pressure-divided circuit. Air is supplied to the nozzle throug h a restriction.

Spool

The spool ensures a quick valve positioning by providing a greater air flow than one provided b y the restriction.

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FY303 – Operation, Maintenance and Instructions Manual

Introduction to Fieldbus Application

From a Fieldbus point of view, the FY303 is not an assembly of electronics, housing and sensor forming a positioner, but a network node containing function blocks.

Basically, it contains one output transducer block, one resource block, one dis play transducer block and Analog Output block.

These blocks are models of the functionality that the FY303 provides for a control system. They can loosely be said to make up part of the application that is performed in the FY303.

Function Blocks

Models the basic user configurable functionality of the device. Typically this functionality was previously available in individual devices. For example, the analog output block provides the functionality of what is known as a positioner. It makes the Fieldbus signal ava ilable to the FY303 output hardware. It also optionally performs output reversing.

All information regarding to Function Blocks are available on the “Function Blocks Instruction Manual”.

Transducer Blocks

These are responsible for the interface between the function blocks a nd the FY303 output channel hardware.

Output transducer block

It is responsible for the processing of the output signal, such as output characterization and trim.

Display transducer block

It is responsible for the display and local adjustment.

Physical Block

It is responsible for monitoring the operation of the device. It also contai ns device information such as serial equipment number.

The Local Indicator

The local indicator is required for signaling and operation in local adjustment. The parameters desired by the user to be viewed on the LCD display should be configured in the display block.

Normal Indicator

During normal operation, the FY303 remains in the monitoring mode and the display will always indicate the variable of monitoring configured in the display block. T he user can configure up to six parameters and chooses up to two to switching on the LCD. F or details, please see the general manual. It is recommended configuring the position of the valve in % (percentage).

The possible configuration and monitoring operation are shown on.

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Operation

INDICATES ACTIVE MUL TIDROP MODE

FIX

INDICA T ES T HAT THE CONSTANT

OUTPUT MODE IS ACTIVE

VARIABLE FIELD

INDICATES THE POSSIBILITY

TO CHANGE / ADJUST

VARIABLE / MODE

READOUT IN PERCENT AGE

UNIT AND FUNCTION FIELD

Figure 2.3 - Local Indicator

Upon receiving power, the FY303 initializes the position ind ication on the d isplay, by sho wing model FY303 and its software version (X.XX).

Monitoring

During normal operation, FY303 remains in the monitoring mode. The display sim ultaneously sho ws readout and some other information.

Normal displaying is interrupted when the magnetic tool is placed in orifice marked as “Zero” and the indicator “MD” is showed on the display. After this, withdraw the magnetic tool off the Z orifice and put it in the orifice marked with the “S” letter.

With the tool in the orifice, wait for 3 seconds. Withdraw again the magnet tool and wait for 3 seconds. Put it now in the S orifice and it will app ear the message of “LOC ADJ“ (Local Adjust). Withdraw the tool and put it in the Z orifice. After this, you can browse to all the parameters configured in the display block.

Figure 2.4 - Typical Indicator

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FY303 – Operation, Maintenance and Instructions Manual

2.6

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Section 3

CONFIGURATION

This section describes the characteristics of the blocks in the FY303. They follow the Profibus PA specifications, but in terms of transducer blocks, the output transducer block and display, they have some special features on top of this.

The FY303 contains one Analog Output block, one resource block, one display transducer block and one transducer block.

For explanation and details of function blocks, see the “Function Blocks Manual”. The 303 Smar family is integrated in Simatic PDM, from Siemens. It is possible to integrate any 303

Smar devices into any configuration tool for Profibus PA devices. It is necessary to provide a Device Description or Drive according to the configuration tool. In this manual is taken several examples using Simatic PDM.

Offline Configuration

1. First run “Download to PG/PC” option to assure valid values.

2. Run after the Menu Device option to configure the required parameters using the related menus.

It is not advisable to use the “Download to Device” option. This function can misconfigure the equipment.

Transducer Block

Transducer block insulates function block from the specific I/O hardware, such as sensors, actuators. Transducer block controls access to I/O through manufacturer specific implementation. This permits the transducer block to execute as frequently as necessary to obtain good data from sensors without burdening the function blocks that use the data. It also insulates the function block from the manufacturer specific characteristics of certain hardware. By accessing the hardware, the transducer block can get data from I/O or passing control data to it. The connection between Transducer block and Function block is called channel. These blocks can exchange data from its interface.

Normally, transducer blocks perform functions, such as linearization, characterization, temperature compensation, control and exchange data to hardware.

How to Configure a Transduce r Block

The transducer block has an algorithm and a set of contained parameters. The algorithm describes the behavior of the transducer as a data transfer function between the I/O

hardware and other function block. The set of contained parameters, it means, you are not able to link them to other blocks and publish the link via communication, defines the user interface to the transducer block. They can be divided into Standard and Manufacturer Specific.

The standard parameters will be present for such class of device, as pressure, temperature, actuator, etc., whatever is the manufacturer. Oppositely, the manufacturers’ specific ones are defined only for its manufacturer. As common manufacturer specific parameters, we have calibration settings, material information, linearization curve, etc.

When you perform a standard routine as a calibration, you are conducted step by step by a method. The method is generally defined as guide line to help the user to make common tasks. The configuration tool identifies each method associated to the parameters and enables the interface to it.

NOTE

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FY303 – Operation, Maintenance and Instructions Manual

Functional Diagram of the Posit ioner Transducer Block

Figure 3.1 - Functional Diagram of the Positioner Transducer Block

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Transducer Block Standar d P ar a m e ter De s cri pt ions

Parameter

Transducer Block Description

Serial-number of the actuator belonging to the positioner or the electronic device.

Fail-Safe position for power-loss of t he actuator, the valve:

3 = none / remains in actual position

Name of Actuator-Manufacturer.

Type of actuator:

3 = others

Minimum of time to move from OP EN to CLOSE position (in sec.) for tot al system (positioner, actuator and valve). Measured while commissioning.

Minimum of time to move from CLOS E to OPEN position (in sec.) for total s ystem (positioner, actuator and valve). Measured while commissioning.

Manufacturer specific type identification of the additional component (e.g. a gearbox, booster) mounted Installation date of the additional component (e.g. gearbox, booster) mounted between the actuator and valve

Manufacturer name of the additional component (e.g. gearbox, booster) mounted between the actuator and Serial number of the additional component (e.g. gearbox, booster) mounted between the actuator and valve.

Dead band in percent of travel span. Travel span correspondents to OUT_SCALE.

Date of last configuration of the device.

Type of linearization.

The actual command variable for the final control element in units of OUT_SCALE. Status BAD will drive the actuator to the fail-safe position defined by ACTUATOR_ACTION.

Nominal stroke of the valve in units of OUT_SCALE.

Initiation of a device-specific (manufacturer specific) calibration-procedure.

255 = abort current calibration-procedure

Proportional-action coefficient for both moving directions.

Derivative-action coefficient for both moving directions.

Integral-action coefficient for both moving directions.

position goes to the limit position

With electric actuator, the actuator goes motor-driven to the limit position CLOSE.

When the servo setpoint goes above the defined percent of span, the position goes to the limit position OPEN. With electro-pneumatic actuator, this is done by totally ventilate/fill i ng of the actuator (ref. to fail -safe position.)

The index parameter identifies which element of the table is in the X_VALUE and Y_VALUE parameter currently

ACTUATOR_ SER_NUM

0 = not initialized

ACTUATOR_ACTION

ACTUATOR_MAN

ACTUATOR_TYPE

ACT_STROKE_TIME_DEC ACT_STROKE_TIME_INC

1 = opening (100%) 2 = closing (0%)

0 = electro-pneumatic 1 = electric 2 = electro-hydraulic

Configuration

ADD_GEAR_ID ADD_GEAR_INST_DATE ADD_GEAR_MAN ADD_GEAR_SER_NUM

DEADBAND DEVICE_CALIB_DATE DEVICE_CONFIG_DATE

LIN_TYPE

FEEDBACK_VALUE POSITIONING_VALUE RATED_TRAVEL

SELF_CALIB_CMD

between the actuator and valve.

valve.

Date of last calibration of the device.

0 = no linearization (mandatory) 1 = linearization table (optional) 240 Manufacturer specific 249 Manufacturer specific 250 Not used 251 None 252 Unknown 253 Special The actual position of the final control element in units of OUT_SCALE.

0 = default value; no reaction of the field device (mandatory) 1 = start zero point adjustment (optional) 2 = start self calibration / initialization (optional) 7 = reset total valve travel limit exceeded“ CB_TOT_VALVE_TRAV (optional) and reset Accumulated valve travel“ TOTAL_VALVE_TRAVEL (optional) 10 = reset internal control loop disturbed“ CB_CONTR_ERR (optional) 255 = abort current calibration-procedure (optional)

Smar: 0 = default value; no reaction of the field device 2 = start self calibration / initialization 7 = reset total valve travel

SERVO_GAIN_1 SERVO_RATE_1 SERVO_RESET_1

SETP_CUTOFF_DEC

SETP_CUTOFF_INC TAB_ENTRY

When the servo setpoint goes below the defined percent of span, the CLOSE. With electro-pneumatic actuator, this is done by totally ventilate/fill i ng of the actuator (ref. to fail -safe position.)

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FY303 – Operation, Maintenance and Instructions Manual

Parameter

Transducer Block Description

The X_Y_VALUE parameter contains one value couple of the table

it is necessary to use a certain number of table

TAB_MAX_NUMBER is the maximum size (number of X_VALUE and Y_VALUE values) of the table in the device.

Contains the actual numbers of entries i n the table. It shall be c alculated after the t ransmission of the table is finished.

Result or status of the device-specific (manufacturer specific) calibration-procedure.

12 = Pressure problem.

The modification of a table in a device inf luences the measurement or actuation algorithms of the device. Therefore an indication of a starting and an end point is necessary. The TAP_OP_CODE controls the

Value,

stop an interaction (TAB_OB_CODE 1 and

bility check in the device. The result of this check is indicated in the

> 128 manufacturer specific

Accumulated valve travel in nominal duty cycles.

Limit for the TOTAL_VALVE_TRAVEL in nominal duty cycles.

Lower limit of the valve position in percent of travel span. Travel span correspondents to OUT_SCALE.

Configurable seconds to full span change (closing time of the valve) in seconds.

Configurable seconds to full span change (opening time of the valve) in seconds.

Date of last valve maintenance.

Serial-number of the valve belonging to the positioner or the electronic device.

Type of valve:

2 = rotary moving valve, multi-turn

TAB_X_Y_VALUE TAB_MIN_NUMBER

TAB_MAX_NUMBER TAB_ACTUAL_NUMBER

SELF_CALIB_STATUS

TAB_OP_CODE

TAB_STATUS

For device internal reasons (e.g. for calculation), some times values in minimum. This number is provided in the TAB_MIN_NUMBER parameter.

0 = undetermined (mandatory) 2 = aborted (optional) 4 = error in mechanical system (optional) 11 = timeout (optional) 20 = aborted by means of “Emergency override active“ CB_OVERRIDE (optional) 30 = zero point error (optional) 254 = erfolgreich (optional) 255 = no valid data (optional)

Smar: 0 = Self Calibration OK. 3 = No magnet part detected. 4 = Error in mechanical system. 11 = Timeout.

transaction of the table. 0: not initialized 1: new operation characteristic, first value (TAB_INDEX=1), old curve cleared 2: reserved 3: last value, end of transmission, check table, swap the old curve wit h the new curve, and actualize ACTUAL_NUMBER. 4: delete point of table with actual index (optional), sort records with increasing Charact-Inputassign new indexes, and decrement CHARACT_NUMBER. 5: insert point (Charact-Input-Value relevant) (optional), sort records with increasing Charact-InputValue, assign new indexes. Increment CHARACT_NUMBER. 6: replace point of table with actual index (optional). It is possible to read a table or parts of the table without s tart and

3). The start is indicated by set TAB_ENTRY to 1. It is common to provide a plausi TAB_STATUS parameter. 0: not initialized 1: good (new table is valid) 2: not monotonous increasing (old table is valid) 3: not monotonous decreasing (old table is valid) 4: not enough values transmitted (old table is valid) 5: too many values transmitted (old table is valid) 6: gradient of edge too high (old table is valid) 7: Values not excepted (old values are valid) 8 - 127 reserved

TOTAL_VALVE_TRAVEL TOT_VALVE_TRAV_LIM TRAVEL_LIMIT_LOW TRAVEL_LIMIT_UP TRAVEL_RATE_DEC TRAVEL_RATE_INC VALVE_MAINT_DATE VALVE_MAN VALVE_SER_NUM

VALVE_TYPE

Upper limit of the valve position in percent of travel span. Travel span correspondents to OUT_SCALE.

Name of Valve Manufacturer.

0 = linear moving valve, sliding valve 1 = rotary moving valve, part-turn

Table 3.1 - Transducer Block Standard Parameter Description

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Page 31

Transducer Block Specif ic P ar am eter De s criptions

Parameter Transducer Block Description

Air to Open/Close.

AIR_TO

CAL_POINT_HI CAL_POINT_LO CAL_MIN_SPAN CAL_UNIT FEEDBACK_CAL CAL_CONTROL

BACKUP_RESTORE

SECONDARY_VALUE SECONDARY_VALUE_UNIT CAL_TEMPERATURE

{0, "Open"}, {1, "Close"} The highest calibrated point. The lowest calibrated point. The minimum calibration span value allowed Engineering units code for the calibration values, %(1342). The position value used to correct a calibration. Enable and disable a calibration method. This parameter is used to do backup or to restore configuration data. { 0, "None" }, { 1, "Factory Cal Restore" }, { 2, "Last Cal Restore" }, { 3, "Default Data Restore" }, { 5, "Sensor Data Restore" }, { 11, "Factory Cal Backup" }, { 12, "Last Cal Backup" }, { 15, "Sensor Data Backup" } The secondary value related to the sensor.

The engineering units to be used with the secondary value, °C (1001). The temperature value used to calibrate the temperature sensor.

Configuration

SERVO_PID_BYPASS

SERVO_PID_ERROR_PER SERVO_PID_INTEGRAL_PER SERVO_MV_PER MODULE_SN REVERSALS STROKES AVERAGE_VELOCITY INSTANTANEOUS_VELOCITY TIME_CLOSING TIME_OPENING MAX_RANGE_VALVE HIGHEST_TEMPERATURE LOWEST_TEMPERATURE

Enable and disable the servo PID. {0, "Disable" }, {1, "Enable" } The percent error value for the servo PID. The percent integral value for the servo PID. The percent measured value for the servo PID. The module manufacturer identific ation number. Number of reversals. Number of strokes. The average velocity of valve. The instantaneous velocity of valve. The time to go from 100.0% to 0.0%. The time to go from 0.0% to 100.0%. The maximum range valve. The highest measured temperature. The lowest measured temperature.

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FY303 – Operation, Maintenance and Instructions Manual

Parameter Transducer Block Description

Indicates the status of diagnoses: { 0, "None"}, { 2, "Output Module Not Initialized"}, { 4, "No Valve Movement or Slow Valve Movement or Low Air Supply or No Magnet Detected"}, { 6, "(No Valve Movement or Slow Valve Movement or Low Air Supply or No Magnet Detected)

and (Output Module Not Initialized)"}, { 8, "Travel Limit Exceeded"}, { 10, "Travel Limit Exceeded and Output Module Not Initialized"}, { 12, "Travel Limit Exceeded and (No Valve Movement or Slow Valve Movement or Low Air

Supply or No Magnet Detected)"}, { 14, "(Travel Limit Exceeded) and (No Valve Movement or Slow Valve Movement or Low Air

Supply or No Magnet Detected) and (Output Module Not Initialized)"},

DIAGNOSES_STATUS

{ 16, "Temperature Out of work range"}, { 18, "Temperature Out of work range and Output Module Not Initialized"}, { 20, "Temperature Out of work range and (No Valve Movement or Slow Valve Movement or

Low Air Supply or No Magnet Detected)"}, { 22, "Temperature Out of work range and (No Magnet Detected and Output Module Not

Initialized)"}, { 24, "Travel Limit Exceeded and Temperature Out of work range"}, { 26, "Travel Limit Exceeded and Temperature Out of work range and Output Module Not

Initialized"}, { 28, "Travel Limit Exceeded and Temperature Out of work range and (No Valve Movement or

Slow Valve Movement or Low Air Supply or No Magnet Detected)"}, { 30, "Travel Limit Exceeded and Temperature Out of work range and (No Valve Movement or

Slow Valve Movement or Low Air Supply or No Magnet Detected) and Output Module Not Initialized"},

{ 32, "Output Module Not Detected"}

DIGITAL_HALL_VALUE HALL_COMPENSATED

Value and Status for Hall sensor. Value for Hall sensor after compensation of offset. Enable and disable for offset compensation.

HALL_OFFSET_CONTROL

{0, "Disable"}, {1, "Enable"}

READ_HALL_CAL_POINT_HI READ_HALL_CAL_POINT_LO DA_OUTPUT_VALUE USER_DA_CAL_POINT_HI USER_DA_CAL_POINT_LO PIEZO_ANALOG_VOLTAGE POT_DC MAIN_LATCH

The highest calibrated point for Hall sensor. The lowest calibrated point for Hall sensor. Value and status for DA output. The highest calibrated point for DA output. The lowest calibrated point for DA output. The analog voltage for piezo. The value for POT DC.

MAIN ANALOG SWITCH USED BY HARDWARE.

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Parameter Transducer Block Description

Transport

Indicates the condition of calibration process according to: { 16, "Default value set"},

XD_ERROR

{22, "Applied process out of range"}, {26, "Invalid configuration for request"}, {27, "Excess correction"}, {28, "Calibration failed"}

MAIN_BOARD_SN

THE ELECTRONIC MAIN BOARD SERIAL NUMBER.

This parameter is used to indicate EEPROM saving process.

EEPROM_FLAG

{ 0, "False"}, { 1, "True"}

ORDERING_CODE

Indicates information about the sensor and control of factory production.

Table 3.2 - Transducer Block Specific Parameter Descriptions

Transducer Block Param ete r At t ribute Table

Relative

Index

Parameter Name

Object

Type

Data Type Store Size Access

9 ACT_STROKE_TIME_DEC Simple Float S 4 r C/a 10 ACT_STROKE_TIME_INC Simple Float S 4 r C/a 17 TAB_ENTRY 18 TAB_X_Y_VALUE 19 TAB_MIN_NUMBER 20 TAB_MAX_NUMBER 21 TAB_ACTUAL_NUMBER

22 DEADBAND Simple Float S 4 r,w C/a 23 DEVICE_CALIB_DATE Simple

24 DEVICE_CONFIG_DATE Simple 25 LIN_TYPE

Octet

String

Octet

String

S 16 r,w C/a -

32 RATED_TRAVEL Simple Float S 4 r,w C/a 33 SELF_CALIB_CMD Simple Unsigned8 S 1 r,w C/a 0 34 SELF_CALIB_STATUS Simple Unsigned8 N 1 r C/a 0 35 SERVO_GAIN_1 Simple Float S 4 r,w C/a 36 SERVO_RATE_1 Simple Float S 4 r,w C/a 37 SERVO_RESET_1 Simple Float S 4 r,w C/a 38 SETP_CUTOFF_DEC Simple Float S 4 r,w C/a 39 SETP_CUTOFF_INC Simple Float S 4 r,w C/a 45 TOTAL_VALVE_TRAVEL Simple Float D

4 r C/a 46 TOT_VALVE_TRAV_LIM Simple Float S 4 r,w C/a 47 TRAVEL_LIMIT_LOW Simple S 4 r,w C/a 0

48 TRAVEL_LIMIT_UP Simple Float S 4 r,w C/a 100 49 TRAVEL_RATE_DEC Simple Float S 4 r,w C/a -

Parameter

usage/

Type of

Configuration

Default

Mandatory/

Optional

(Class)

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FY303 – Operation, Maintenance and Instructions Manual

Parameter

Transport

1) 1) 1) 1) 1) 1)

Relative

Index

Parameter Name

Object

Type

Data Type Store Size Access

usage/

Type of

50 TRAVEL_RATE_INC Simple Float S 4 r,w C/a 51 VALVE_MAINT_DATE Simple Octet String S 16 r,w C/a 52 SERVO_GAIN_2 Simple Float S 4 r,w C/a 53 SERVO_RATE_2 Simple Float S 4 r,w C/a 54 SERVO_RESET_2 Simple Float S 4 r,w C/a 55 TAB_OP_CODE 56 TAB_STATUS

57 POSITIONING_VALUE Record DS_33 D 5 r C/a 58 FEEDBACK_VALUE Record DS_33 D 5 r C/a 59 VALVE_MAN Simple OctetString S 16 r,w C/a 60 ACTUATOR_MAN Simple OctetString S 16 r,w C/a 61 VALVE_TYPE Simple Unsigned8 S 1 r,w C/a 62 ACTUATOR_TYPE Simple Unsigned8 N 1 r C/a 63 ACTUATOR_ACTION Simple Unsigned8 S 1 r,w C/a 64 VALVE_SER_NUM Simple OctetString S 16 r,w C/a 65 ACTUATOR_SER_NUM Simple OctetString S 16 r,w C/a 66 ADD_GEAR_SER_NUM Simple OctetString S 16 r,w C/a 67 ADD_GEAR_MAN Simple OctetString S 16 r,w C/a 68 ADD_GEAR_ID Simple OctetString S 16 r,w C/a 69 ADD_GEAR_INST_DATE Simple OctetString S 16 r,w C/a 70 AIR_TO Simple Unsigned8 N 1 r,w C/a Open 71 CAL_POINT_HI Simple Float N 4 r,w C/a % 72 CAL_POINT_LO Simple Float N 4 r C/a % 73 CAL_MIN_SPAN Simple Float N 4 r C/a 1 74 CAL_UNIT Simple Unsigned16 N 2 r C/a % 75 FEEDBACK_CAL Simple Float N 4 r,w C/a % 76 CAL_CONTROL Simple Unsigned8 N 1 r,w C/a Disable 77 BACKUP_RESTORE Simple Unsigned8 S 1 r,w C/a None 78 SECONDARY_VALUE Record DS-33 D 5 r C/a 79 SECONDARY_VALUE_UNIT Simple Unsigned16 N 2 r C/a Celsius 80 CAL_TEMPERATURE Simple Float N 4 r,w C/a Celsius

81 SERVO_PID_BYPASS Simple Unsigned8 S 1 r,w C/a 82 SERVO_PID_ERROR_PER Record DS-33 D 5 r C/a

83 SERVO_PID_INTEGRAL_PER Record DS-33 D 5 r C/a 84 SERVO_MV_PER Record DS-33 D 5 r C/a 85 MODULE_SN Simple Unsigned32 S 4 r,w C/a 86 REVERSALS simple float S 4 r,w C/a 87 STROKES simple float S 4 r,w C/a 88 AVERAGE_VELOCITY simple float D 4 r C/a 89 INSTANTANEOUS_VELOCITY simple float D 4 r C/a 90 TIME_CLOSING simple float D 4 r C/a 91 TIME_OPENING simple float D 4 r C/a

Default

Not

Bypass

Mandatory/

Optional

(Class)

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Page 35

Relative

Parameter

Transport

Index

Parameter Name

Object

Type

Data Type Store Size Access

usage/

Type of

92 MAX_RANGE_VALVE simple float S 4 r,w C/a 93 HIGHEST_TEMPERATURE simple float S 4 r,w C/a 94 LOWEST_TEMPERATURE simple float S 4 r,w C/a 95 DIAGNOSES_STATUS simple Unsigned8 N 1 r C/a None 96 DIGITAL_HALL_VALUE Record DS-33 D 5 r C/a 97 HALL_COMPENSATED simple float D 4 r C/a 98 HALL_OFFSET_CONTROL simple Unsigned8 N 1 r,w C/a Disable 99 READ_HALL_CAL_POINT_HI simple float S 4 r C/a

100 READ_HALL_CAL_POINT_LO simple float S 4 r C/a 101 DA_OUTPUT_VALUE Record DS-33 D 5 r C/a 102 USER_DA_CAL_POINT_HI simple float S 4 r C/a 103 USER_DA_CAL_POINT_LO simple float S 4 r C/a 104 PIEZO_ANALOG_VOLTAGE Record DS-33 D 5 r C/a 105 POT_DC simple Unsigned8 N 1 r,w C/a 128 106 MAIN_LATCH simple Unsigned8 S 1 r,w C/a 12 107 XD_ERROR simple Unsigned8 S 1 r C/a 0x10 108 MAIN_BOARD_SN simple Unsigned32 S 4 r,w C/a 109 EEPROM_FLAG simple Uunsigned8 D 1 r C/a 110 ORDERING_CODE array Unsigned8 S 50 r,w C/a

1) See table handling

2) Should be stored non volatile

Table 3.3 - Parameter Attributes of Transducer Block

Configuration

Default

Mandatory/

Optional

(Class)

Transducer Block View Obj e ct Table

Relative Index Parameter Name VIEW_1 Number of bytes

9 ACT_STROKE_TIME_DEC 10 17 TAB_ENTRY 18 19 TAB_MIN_NUMBER 20 21 TAB_ACTUAL_NUMBER 22 23 DEVICE_CALIB_DATE 24 25 LIN_TYPE 32 33 SELF_CALIB_CMD 34 35 SERVO_GAIN_1 36 37 SERVO_RESET_1 38 39 SETP_CUTOFF_INC 45 46 TOT_VALVE_TRAV_LIM

ACT_STROKE_TIME_INC

TAB_X_Y_VALUE

TAB_MAX_NUMBER

DEADBAND

DEVICE_CONFIG_DATE

RATED_TRAVEL

SELF_CALIB_STATUS

SERVO_RATE_1

SETP_CUTOFF_DEC

TOTAL_VALVE_TRAVEL

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FY303 – Operation, Maintenance and Instructions Manual

Relative Index Parameter Name VIEW_1 Number of bytes

47 48 TRAVEL_LIMIT_UP 49 50 TRAVEL_RATE_INC 51 52 SERVO_GAIN_2 53 54 SERVO_RESET_2 55 56 TAB_STATUS 57 58 FEEDBACK_VALUE

59 60 61 62 63 64 65 66 67 68 69

70 71 72 73 74 CAL_UNIT 75 FEEDBACK_CAL 76 77 78 79 80 CAL_TEMPERATURE 81 SERVO_PID_BYPASS 82 83 84 85 MODULE_SN 86 REVERSALS 87 88 89 90

TRAVEL_LIMIT_LOW

TRAVEL_RATE_DEC

VALVE_MAINT_DATE

SERVO_RATE_2

TAB_OP_CODE

POSITIONING_VALUE

VALVE_MAN ACTUATOR_MAN VALVE_TYPE ACTUATOR_TYPE ACTUATOR_ACTION VALVE_SER_NUM ACTUATOR_SER_NUM ADD_GEAR_SER_NUM ADD_GEAR_MAN ADD_GEAR_ID ADD_GEAR_INST_DATE AIR_TO CAL_POINT_HI CAL_POINT_LO CAL_MIN_SPAN

CAL_CONTROL BACKUP_RESTORE SECONDARY_VALUE SECONDARY_VALUE_UNIT

SERVO_PID_ERROR_PER SERVO_PID_INTEGRAL_PER SERVO_MV_PER

STROKES AVERAGE_VELOCITY INSTANTANEOUS_VELOCITY TIME_CLOSING

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Configuration

Relative Index Parameter Name VIEW_1 Number of bytes

91 92 MAX_RANGE_VALVE 93 HIGHEST_TEMPERATURE 94 95 96 97 98 HALL_OFFSET_CONTROL 99 READ_HALL_CAL_POINT_HI

100 101 102 103 USER_DA_CAL_POINT_LO 104 PIEZO_ANALOG_VOLTAGE 105 106 107 108 109 EEPROM_FLAG 110 ORDERING_CODE

TIME_OPENING

LOWEST_TEMPERATURE DIAGNOSES_STATUS DIGITAL_HALL_VALUE HALL_COMPESATED

READ_HALL_CAL_POINT_LO DA_OUTPUT_VALUE USER_DA_CAL_POINT_HI

POT_DC MAIN_LATCH XD_ERROR MAIN_BOARD_SN

Total length of View Object 13

Table 3.4 - View Object Table Transducer Block

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FY303 – Operation, Maintenance and Instructions Manual

FY303 Cyclical Configurati on

Through the GSD file the master executes all initialization process with the device and this file presents details of hardware revision and software, bus timing of the device and information on cyclical data exchange.

FY303 has one AO function block. It is with this block that the class 1 master will execute the cyclical services and the user should choose the con figur at i o n, accord ing to the appl icat ion .

If the AO block is in AUTO, then the device will receive the value and status of the setpoint of the class 1 master and the user will also be able to write in this value via class 2 master.

In this case, the setpoint status should always be equal to 0x80 (“good") and the following configurations can be chosen:

§ SP

§ SP/CKECKBACK

§ SP/READBACK/POSD

§ SP/READBACK/POSD/CKECKBACK

If the AO blo ck is in RCAS, then the devi ce will receive the value and status of the setpoint only via class 1 master. In this case, the setpoint status should always be equal to 0xc4 (“IA"). The following configurations can be chosen:

§ SP

§ SP/CKECKBACK

§ SP/READBACK/POSD

§ SP/READBACK/POSD/ CKECKBACK

§ RCASIN/RCASOUT

§ RCASIN/RCASOUT/ CKECKBACK

§ SP/READBACK/RCASIN/RCASOUT/POSD/CHECKBACK

See below a typical example with the necessary steps to the integration of a FY303 device in a PA system:

- Copy the GSD file of the FY303 for the search directory of the PROFIBUS configurator, usually named GSD.

- Copy the bitmap file of the FY303 for the search directory of the PROFIBUS configurator, usually named BMP.

- Once the master is chosen, the communication rate must be chosen, remembering that when we had the couplers, we can have the following rates: 45.45 kbits/s (Siemens), 93.75 kbits/s (P+F) and 12 Mbits/s (P+F, SK2) .If we had the link device, it can be up to 12 Mbits/s.

- Add the FY303, specifying the address in the bus.

- Choose the cyclical configuration via parameterization with the GSD file, dependent of the application, as indicated previously. Remember that this choice must be in agreement with the operation mode of the AO block. In these conditions attempt to the status of the setpoint value that should be 0x80 (“good”), when in AUTO mode and 0xc4 (IA) for RCAS mode.

- The watchdog condition can also be activate, where after the communication loss detection for the slave device with the master, the equipment can change to a fail safe condition. As FY303 will be as final element is recommended the configuration of a fail safe value.

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The device

Here, you can

As you can see

was created

as FY303.

see all blocks

instantiated.

the Transducer

and Display are

treated as

special type of

Function

Blocks, called

Transducer

Blocks.

Configuration

The Simatic PDM (Process Device Manager) configuration software from Siemens, for example, can configure many parameters of the Input Transducer block.

Figure 3.1 - Function and Transducer Blocks

To make the configuration of Transducer Block, we need to select the menu "Device" Use this menu:

- To change the device address;

- To make the up/download of parameters;

- To configure the Transducer Block, Analog Output Block and Display Block;

- To calibrate the positioner; made the Auto Setup

NOTE

Auto Setup procedure for FY303 positioner in ACP.

When the positioner FY303 is work i ng with a pneumatic cylindrical actuat or or a valve with high air inertia (slow movem ent) and during the self calibration proc ess (SETUP) is gotten 40% permanently on the LCD, please decrease the ACP_F value using the loc al adjustment. For this proposal, you need to configure the ACP _F parameter on the LCD display, using the local adjustment. Enter into the local adjustment and select one of LCDs (for example LCD_2), then select TRD block and adjust the PRMT parameter to 114 (relative index of this parameter in the Transducer Block). Browse up to UPD parameter to update the local adjustment LCD configuration. Reenter into the local adjustment and then browse up to ACP_F parameter where you can decrease the value. For an initial step, you can decrease it to 60 and then browse up to SETUP parameter and execute the self-calibration process setting this parameter to 2 (Initialize the self-calibration process).

To make the reset by software, to protect the device against writing and to simulate the value from transducer block to analog output block;

Save and restore data calibration. To make the configuration of Transducer Block, we need to select the menu: Device - Offline

Configuration - Transducer.

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FY303 – Operation, Maintenance and Instructions Manual

Servo Control

Te user can set air to

The user can

select the valve

linearization

type: linear,

user defined

(table), EP25,

EP33, EP50,

Q24, Q22,

EQ50.

The user can select

the valve type.

The actuator Fail action

can be: Opening (100%), Closing (0%), not initialized or none.

open or air to close

according to the action.

Configurable seconds to

full span change (closing

time of the valve) in

seconds and Configurable

seconds to full span

change (opening time of

the valve) in seconds.

Parameters:

The gain and reset

depend on valve type.

Figure 3.2 - Offline Configuration - Transducer

Selecting the page Setup, the user configures some data for the internal servo PID of FY303.

3.14

Figure 3.3 - Simatic PDM - Transducer Configuration Setup

Page 41

Configuration

Table handling

There is the possibility to load and re-load tables in the devices. This table is used for linearization mostly. For this procedure the following parameters are necessary:

TAB_INDEX TAB_X_Y_VALUE TAB_MIN_NUMBER TAB_MAX_NUMBER TAB_OP_CODE TAB_STATUS The TAB_X_Y_VALUE parameter contains the value couple of the each table entries.

To make the configuration of Transducer Block, we need to select the menu Device - Offline Configuration -Transducer. The TAB_INDEX parameter identifies which element of the table is in the X_Y_VALUE parameter currently (see the following figure).

Figure 3.4 - Parameters of a Table

TAB_MAX_NUMBER is the maximum size of the table in the device. TAB_MIN_NUMBER i s the minimum size of the table in the device.

The modification of a table in the device influences the measurement algorithms of the device. Therefore an indication of a starting and an endpoint is necessary. The TAB_OP_CODE controls the transaction of the table. The device provides a plausibility check. The result of this check is indicated in the TAB_STATUS parameter.

The User Table is used to make the position characterization in several points. The user can configure up to 21 points in percentage. The valve characteristic curve may be slightly nonlinear. This eventual non-linearity may be corrected through the User Table.

The user just needs to configure the input values and the correspondent output values in %. Configure a minimum of two points. These points will define the characterization curve. The maximum number of points is 21. It is recommended to select the points equally distributed over the desired range or over a part of the range where more accuracy is required. The user needs to set "user defined (table) to valve linearization type.

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FY303 – Operation, Maintenance and Instructions Manual

Allows the reading of

After configuring the points, this key

Enter the input and

output values.

configurable table.

must be pressed to verify if the table

is monotonous increasing.

Figure 3.5 - FY303 Simatic PDM - Transducer Offline Configuration - User Table Screen

The desired flow characteristics may be changed using this function. E.g. If a valve with linear inherent flow characteristic is used and equal percentage applied flow characteristic is selected, the valve will be act as an equal percentage valve.

The adjacent number is the rangeability of the valve. The rangeability of the valve may be found in the manufacturer's documentation. The options for applied flow characterization are: LINEAR, TABLE, EP25, EP33, EP50, QO25, QO33, and QO50

The equation resulting from its curve is:

Y (%) = (X/ (((X (%). /100)*(1-L)) +L)),

Where: Y [%] = Value after the flow characterization curve calculation and X [%] = Position value before

entering in the curve calculation. L = Characterization Factor

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Page 43

The user can set

The user needs to set

The user can set

TIPO L

LINEAR 1.0

EP25 3.5 EP33 4.1

EP50 5.1 QO25 0.27 QO33 0.24 QO50 0.19

How to Configure the Analog Out put Bl oc k

The AO block provides a value to an output transducer block. It provides value, scaling conversion, Fail safe mechanism and other features.

The Analog Output Block is a function block used by devices that work as output elements in a control loop, like valves, actuators, positioners, etc. The AO block receives a signal from another function block and passes its results to an output transducer block through an internal channel reference.

Configuration

the operation mode.

both channel to

transducer.

opening or closing for

the actuator action.

Figure 3.6 - FY303 Simatic PDM - Analog Output Block - Basic Settings - Offline Configuration

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FY303 – Operation, Maintenance and Instructions Manual

Selecting the page Scale/Units, the user has the option to configure the scale and unit for the input and output:

For Fail Safe mode the

options can be: Actuator goes to failsafe position, storing

last valid setpoint and fail safe value is used

as a control regulator

input.

Figure 3.7 - FY303 Simatic PDM - Analog Output Block - Scale/Units - Offline Configuration

The unit and scale for the output will be the same for the transducer block. Note that the allowed units are %, rad, °, mm.

Selecting Advanced Settings page, the user can set the fail safe conditions.

Figure 3.8 - FY303 Simatic PDM - Analog Output Block - Advanced Settings - Offline

3.18

Configuration

Page 45

Information about

The user can set the

block mode operation.

According to the block

Configuration

In terms of online configuration, the user can select at the device menu the Online Configuration for Analog Output block:

mode, the user can set

the setpoint.

the real condition

of transducer and

analog output

block.

Figure 3.9 - FY303 Simatic PDM - Online Configuration Mode Block for AO

Using Feedback page, the user can monitor and check all values related between the analog block and the transducer block:

Check back and alarm

condition.

Figure 3.10 - FY303 Simatic PDM - Online Configuration Feedback for AO

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FY303 – Operation, Maintenance and Instructions Manual

The user can select

To start the lower

Position Calibration

First of all the user should configure the valve type, the servo gain according to the valve. Please, see transducer offline configuration. In general, when the valve is fast, is appropriate to set a gain value about 8. If the valve is slow, is appropriate to set a gain value about 43. It depends on case by case and the valve type.

Then using the Device menu, the user must select Calibration, where we have the options: "Lower/Upper", "Self-Calibration" and "Temperature".

Choosing "Lower/Upper" the user has the window:

lower or upper

calibration.

calibration procedure.

Figure 3.11 - FY303 - Simatic PDM Calibration Lower/Upper

After pressing "Lower Calibration Point", we get a warning:

If the user proceeds, the valve position goes to the lower position and we have the message:

If the valve is stabilized, when the user press "OK", we have a new window that allows him to enter the desired value for the new calibrated point for the lower position. Write 0% in new value. For FY303 it should be always 0%:

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Page 47

Configuration

After entering the desired valve, the position is corrected according to the desired value and the user can make the correction until the right position is reached:

If the calibrated position is correct, press "No" and a new warning appears:

After user confirmation, the positioner comes to the normal operation. The upper calibration procedure is similar than the lower:

After pressing "Upper Calibration Point", we get a warning:

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FY303 – Operation, Maintenance and Instructions Manual

If the user proceeds, the valve position goes to the upper position and we have the message:

If the valve is stabilized, when the user press "OK", we have a new window that allows him to enter the desired value for the new calibrated point for the upper position. Write 100% in new value. For FY303 it should be always 100%:

After entering the desired valve, the position is corrected according to the desired value and the user can make the correction until the right position is reached:

If the calibrated position is correct, press "No" and a new warning appears:

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Page 49

After user confirmation, the positioner comes to the normal operation.

The user can set the

The calibration unit is always percentage (%). I t is also recommendable, before a new calibrat ion, to save the existing trim data by means of parameter BACKUP_RESTORE, using the option "Last Cal Backup".

Temperature Calibrat ion

The parameter CAL_TEMPERATURE can be used to trim the temperature sensor located at the body of positioner in order to improve the accuracy of temperature measurement done by its sensor.

The range accepts from - 40°C to + 85 °C. The parameter SECONDARY_VALUE indicates the value of such measurement.

Using the Simatic PDM, go to the Device menu and select the "Calibration" menu and then "Temperature:

desired calibration temperature point.

Here, the final calibrated

temperature can be

checked.

The user can check the

operation result.

To calibrate, press the key

"write".

Configuration

NOTE

Figure 3.12 - FY303 Temperature Calibration

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FY303 – Operation, Maintenance and Instructions Manual

In normal operation, we

This marked option allows

After selecting the self-calibration

To abort the self-

select this option.

To reset the total valve

Self-Calibration

Using the "Self-Calibration" procedure, the user starts a method of self-calibration for the positioner. For this reason, the option "Start self calibration/Initialization" should be selected at the window below. The self-calibration can take some minutes according to the valve:

have this option indicating

no reaction of the field

device according to the

self-calibration procedure.

procedure, please, press the "Write"

key to begin the procedure.

calibration procedure,

the start of self-calibration

procedure.

travel, select this option.

After selecting the s elf-calibration procedure, the positioner will move the valve during some time to setup the lower and upper position automatically. At LCD interface, the user can see the steps of this procedure in %.

If the procedure gets success we got the following stat us of "Self Cal i bration OK”.

We can have the following options for the status calibration:

- Self Calibration OK

- Aborted

- No magnet part detected

- Error in mechanical system

- Timeout

- Pressure Problem

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Page 51

This value describes the

set value for hardware

The user can see:

compensation. It is an

automatic calculated

value. It is suitable that

the user does not change

this value.

The Hall sensor

value and the

calibrated

points for it.

The value for the DA

converter and the

calibrated points for it.

Configuration

To verify and check the self calibration results the user should select at the main menu the option "Maintenance Self-Calibr at ion Repor t":

Diagnosis

the setpoint value from

AO; the total valve travel

according to the

maximum range value for

the valve; and a general

status for FY303.

Figure 3.13 - FY303 Maintenance Self-Calibration Report

Using the "View" menu and selecting "Diagnosis", the user has accessing to the diagnosis windows, according to the window below:

Figure 3.14 - FY303 Settings

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FY303 – Operation, Maintenance and Instructions Manual

Selecting the "Diagnosis" page, we have:

Using this window, the user can have some items for diagnosing:

- Travel: according to the maximum range valve value, we have the total valve travel and a generation of traveling Limit Exceeded when this value is higher than limit total valve travel parameter;

- Performance: the user can verify the average velocity, the instantaneous velocity, the time closing (when the direction is from 100.0% to 0.0%) and the time opening (when the direction is from 0.0% to 100.0%). These times are according to the configured rate for closing and opening.

- Temp: The user can verify the maximum and minimum temperature;

- Reversals/stroke: we have the possibility to verify both values according to the movement of

valve.

Some factors are important to the performance of movement:

- the air pressure;

- the proportional action (servo gain);

- the integral action (reset);

- the travel rate for closing and opening.

Transducer Display - Configuration

Using the Simatic PDM or any other configuration tool is possible to configure the Display Transducer block. As the name described it is a transducer due the interfacing of its block with th e LCD hardware.

The Transducer Display is treated as a normal block by any configuration tool. It means, this block has some parameters and those ones can be configured according to customer's needs.

Figure 3.15 - FY303 Diagnosis

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Page 53

Configuration

The customer can choose up to six parameters to be shown at LCD display; they can be parameters just for monitoring purpose or for acting locally in the field devices by using a magnetic tool. The seventh parameter is used to access the physical device address. The user can change this address according to his application. To access and configure the Display Block, please, go to the main menu, select "Device Online Configuration - Display Block":

Display Transducer Block

The local adjustment is completely configured by Simatic PDM or any configuration tool. It means, the user can select the best options to fit his application. From factory, it is configured with the options to set the Upper and Lower trim, for monitoring the input transducer output and check th e Tag. Normally, the transmitter is much better configured by Simatic PDM or configuration tool, but the local functionality of the LCD permits an easy and fast action on certain parameters, since it does not rely on communication and network wiring connections. Among the possibilities by Local Adjustment, the following options can be emphasized: Mode block, Outputs monitoring, Tag visualization and Tuning Parameters setting.

The interface between the users is described very detailed on "Programming Using Local Adjustment". It is significantly the resources on this transducer display, also all the Series 303 field devices from Smar has the same methodology to handle with it. So, since the user has learned once, he is capable to handle all kind of field devices from Smar.

All function blocks and transducers defined according Profibus PA have a description of their features written by the Device Description Language.

This feature permits that third party configuration tools enabled by Device Description Service technology can interpret these features and make them accessible to configure. The Function Blocks and Transducers of Series 303 have been defined rigorously according the Profibus PA specifications in order to be interoperable to other parties.

In order to able the local adjustment using the magnetic tool, it is necessary to previously prepare the parameters related with this operation via System Configuration. There are six groups of parameters, which may be pre-configured by the user in order to able, a possible configuration by means of the local adjustment. As an example, let’s suppose that you don’t want to show some parameters; in this case, simply select "None" in the parameter, "Select Block Type". Doing this, the device will not take the parameters related (indexed) to its Block as a valid parameter.

Figure 3.16 – Display Block and Simatic PDM

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FY303 – Operation, Maintenance and Instructions Manual

The option

Definition of Parameters and Values

Select Block Type

This is the type of the block where the parameter is located. The user can choose: Transducer Block, Analog Output Block, Physical Block or None.

Select / Set Parameter Type / Index

This is the index related to the parameter to be actuated or viewed (0, 1, 2…). For each block there are some pre-defined indexes. Refer to the Function Blocks Manual to know the desired indexes and then just enter the desired index.

Set Mnemonic

This is the mnemonic for the parameter identification (it accepts a maximum of 16 characters in the alphanumeric field of the display). Choose the mnemonic, preferably with no more than 5 characters because, this way, it will not be necessary to rotate it on the display.

Set Decimal Step

It is the increment and decrement in decimal units when the parameter is Float or Float Status value, or integer, when the parameter is in whole units.

Set Decimal Point Place

This is the number of digits after the decimal point (0 to 3 decimal digits).

Set Access Permission

The access allows the user to read, in the case of the “Monitoring” option, and to write when "action" option is selected, then the display will show the increment and decrement arrows.

Set Alpha Numerical

These parameters include two options: value and mnemonic. In option value, it is possible to display data both in the alphanumeric and in the numeric fields; this way, in the case of a data higher than 10000, it will be shown in the alphanumeric field.

In option mnemonic, the display may show the data in the numeric field and the mnemonic in the alphanumeric field.

For devices where the software version is higher or equal to 1.10, please see the “Programming Using Local Adjustment”, in the Installation, Operation and Maintenance Procedures Manual.

In case you wish to visualize a certain tag, opt for the index relative equal to "tag". To configure other parameters just select "LCD-II" up to "LCD-VI" windows:

Figure 3.17 - Parameters for Local Adjustment Configuration

3.28

"Write" should be selected in order to execute the upgrade of local adjustment programming tree.

Page 55

When the option

Selecting

"enable" is selected,

the user can

change the physical

device address.

Configuration

The window "Local Address Change" allows the user "enable/disable” access to changing the physical device address.

Figure 3.18 - Parameters for Local Address Configuration

When the user enter into the local adjustment and rotate the parameters using the magnetic tool, after escaping to normal operation, e.g., the monitoring, if the parameter when the magnetic tool is removed has "Access Permission equal to "monitoring", then this last parameter will be shown at the LCD.

"None", only the

last chosen

monitoring

parameter will

be shown at

LCD.

Figure 3.19 - Parameters for Local Adjustment Configuration

Always on the LCD interface will be shown two parameters at the same time, switching between the configured parameter at the LCD-II and the last monitoring parameter. If the user does not want to show two parameters at the same time, it is only necessary to opt for "none" when configure the LCD-II:

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FY303 – Operation, Maintenance and Instructions Manual

With this option,

The user can select the "Mode Block" parameter at the LCD. In this case is necessary to select the index equal to "Mode Block":

the Mode Block

parameter is

shown at the

LCD.

Calibrating using Local Adjustment

3.30

Figure 3.20 - Parameters for Local Adjustment Configuration

The positioner has two holes for magnetic switches, located under the identification plate (See the section "Programming Using Local Adjustment"). These magnetic switches are activated by one magnetic tool.

This magnetic tool enables adjustment of the most important parameters of the blocks. It also enables pre-configuration of the communication.

The jumper J1 on top of the main circuit board must be in place and the positioner must be fitted with the digital display for access to the local adjustment. Without the display the local adjustment is not possible.

In order to enter the local adjustment mode, place the magnetic tool in orifice “Z” until flag “MD” lights up in the display. Removes magnetic tool from “Z” and place it in orifice “S”. Remove and reinsert the magnetic tool in “S” until the message “LOC ADJ” is displayed.

The message will be displayed during approximately 5 seconds after the user removes the magnetic tool from “S”. By placing the magnetic tool in “Z” the user will be able to access the local adjustment/monitoring tree.

Browse to parameter “LOPOS”. After that in order to start the calibration, the user shall activate parameter “LOPOS” with the help of the magnetic tool placed in “S”. For example, it is possible to enter 0%. When the magnetic tool is removed from “S”, the output will be set to a value close to the desired value. The user shall then browse the tree up to parameter FEED (FEEDBACK_CAL), and actuate this parameter by placing the magnetic tool in “S” until reaching the value obtained from the position reference.

The user shall continue to write in this parameter until it reads 0% or the desired lower position value. Browse to parameter “UPPOS”. After that, in order to start the calibration, the user shall actuate parameter “UPPOS” by placing the magnetic tool in “S”. For example, it is possible to enter 100%. When the magnetic tool is removed from “S”, the output will be set to a value close to the desired value. The user shall them browse the tree up to parameter FEED (FEEDBACK_CAL), and actuate this parameter by placing the magnetic tool in “S” until reaching the desired value.

Page 57

Configuration

Codes for XD_ERROR:

Place the

In order to start the

Insert the magnetic

Remove the

The user shall write in this parameter until it reads 100% or the desired upper position value. The LOWER and UPPER should be different.

LIMIT CONDITIONS OF CALIBRATION

LOPOS (Lower Position) UPPOS (Upper Position)

FEED

16: Default Value Set 22: Out of Range 26: Invalid Calibration Request 27: Excessive Correction

Programming using Local Adjus t ment

local adjustment, place the magnetic tool in orifice Z and

wait until letters MD

are displayed.

Always equal 0% Always equal 100%

- 10% =< FEED =< 110%, otherwise XD_ERROR = 22

NOTE

magnetic tool in orifice S and wait during 5 seconds.

magnetic tool

from orifice S.

Figure 3.23 - Step 1 - FY303

tool in orifice S once more and LOC ADJ should be displayed.

Figure 3.24 - Step 2 – FY303

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FY303 – Operation, Maintenance and Instructions Manual

Place the magnetic

In order to start the

In order to

tool in orifice Z. In

case this is the first

configuration, the

option shown on the

display is the TAG

with its corresponding

mnemonic configured

by the Configuration Tool. Otherwise, the option shown on the

display will be the one

configured in the prior operation. By keeping

the tool inserted in

this orifice, the local

adjustment menu will

rotate.

LOPOS, simply insert

the magnetic tool in

orifice S as soon as

LOPOS is shown on

the display. An arrow

pointing upward (-)

increments the valve

and an arrow

pointing downward

(¯) decrements the

valve. In order to increment the lower position valve, keep

the tool inserted in S.

In this option TYPE, is indicated by the numbers 1 or 2, which respectively represent Linear or Rotary valves.

Figure 3.25 - Step 3 - FY303

decrement the lower position valve, place the magnetic tool in orifice Z to shift the arrow to the downward position and then, by inserting and keeping the tool in orifice S, it is possible to decrement the lower position valve.

In order to start the

UPPOS, simply

insert the magnetic

tool in orifice S as

soon as UPPOS is

shown on the

display. An arrow

pointing upward (-)

increments the

valve and an arrow

pointing downward

(¯) decrements the

valve. In order to increment the upper position valve, keep

the tool inserted in

Figure 3.26 - Step 4 – FY303

decrement the upper position valve, place the magnetic tool in orifice Z to shift the arrow to the downward position an then, by insetting and keeping the tool in orifice S, it is possible to decrement upper position valve.

Figure 3.27 - Step 5 – FY303

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Configuration

Place the Insert the magnetic

This option

a) In order to

↑

↓

b) In order to

Option FEED allows

the user to correct

the valve

calibration. In order

to implement the

correction, read the

valve indicated by

the valve and enter

it in this option. This

option makes it possible to correct LOPOS as well as

UPPOS. An arrow

pointing upward

increments the

position valve.

implements the auto setup of the valve, that is, the

lower and upper

position points of

the valve. When setup displays 0

(zero), it indicates

that the setup is

disabled.

magnetic tool in orifice S to shift the arrow to the downward position and decrement the calibration valve in accordance with the valve readout valve. An arrow pointing downward decrements the position valve.

Figure 3.28 - Step 6 - FY303

tool in orifice S and enter the value 2. After this, the auto setup will be started and a flashing message with the word SETUP will show in the display of the positioner. After this process finishes, the local adjustment returns to normal operation.

change the address

value, simply take

off the magnetic

tool from orifice Z

as soon as ADDR

is shown on the

display. An arrow

pointing upward (

increments the

address and an

arrow pointing

downward (

decrements the

address. In order to

increment the

address, insert the

tool in S up to set

the value desired.

)

Every time the Self Calibration is used it is suitable to save it via configuration tool, and to write in the Backup-Restore parameter of the transducer block the sensor Data Backup option.

This Local adjustment configuration is a suggesti on onl y. The user may choose his preferred configuration via configuration tool, simply configuring the display block. (refer to paragraph Display Transducer Block )

Figure 3.29 - Step 7 - FY303

decrement the address value, place the magnetic tool in orifice Z to shift the arrow to the downward position and then, by inserting and keeping the tool in orifice S, it is possible to decrement the address value.

Figure 3.30 - Step 8 - FY303

NOTE

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FY303 – Operation, Maintenance and Instructions Manual

Self-Calibration using Loca l Adjustment

This process is necessary to find the position values at which the valve is considered fully open or close. This operation can be done using the Configuration Tool or the Local Adjustment. The FY303 automatically finds the fully open and closed positions of a valve, but the user may also set a narrower range of operation should he like to. Before making the Auto-Setup, select the type of valve through the parameter VALVE_TYPE choosing between "Linear or Rotary" options.

The setup operation can be started writing "Enable" (2) on the parameter SETUP, so the positioner will execute immediately the operation of auto-setup for approximately 2 to 5 minutes depending on the type of valve, other configured parameters and function blocks used in the positioner.

The process will be finished when the SETUP parameter will indicate "Disable" (0) automatically during the operation of reading.

NOTE

This operation should be performed off-li ne or with the process shut down to be sure that the plant operation is not disturbed, due the valve will be moved between the fully open and close points i n order to reach the better adjustment.

In case of oscillation, decrease the gain of valve, acting on the SERVO GAIN parameter. If the valve could be out-of-control after its operation, please, repeat the Self-Calibration operation again.

NOTE

Hall's Offset Compensation without Magnet Part

Before installing the magnet to the positioner, write "Enable" on the menu Factory Hall Offset at Device menu and wait until the configuration tool set it back to "Disable" indicating end of its process of Hall's Offset compensation.

3.34

Figure 3.31 - Enabling the Hall's Offset Compensation

Figure 3.32 - Disabling the Hall's Offset Compensation

Page 61

Temperature Compensati on

Using the Calibration Temperature Menu at the Device, the user can trim the temperature sensor located at the body of positioner in order to improve the accuracy of temperature measurement done by its sensor. The range accepts from -40°C to +85 °C. The temperature parameter indicates the value of such measurement.

Configuration

Figure 3.33 - Calibrating the Temperature Sensor

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FY303 – Operation, Maintenance and Instructions Manual

Pressure Sensors Version (K1 Option)

The K1 option of the FY303 is available with 3 pressure sensors, namely one for input and two for both outputs.

How to check the pressure sensors installation

In terms of configuration, after identifying the presence of the sensors on the hardware, their installation may be checked via Simatic PDM. To this effect, choose “Factory” on the “Device” menu and select “Press Sensor Install”, as shown below:

Figure 1 – Checking the FY303 Pressure Sensors Installation

Pressure sensor calibration

To check or calibrate the pressure sensor with the Simatic PDM, refer to the “Device” menu and choose “Calibration” and then “Pressure Sensor Cal”, as shown on figure 2.

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Configuration

Figure 2 – Pressure Sensors Calibration

Next step is selecting which sensor is to be calibrated: if the input (Press In), or the output 1 (Out 1), or the output 2 (Out 2). See figure 3.

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FY303 – Operation, Maintenance and Instructions Manual

Figure 3 – Selecting the Sensors for Pressure Calibration

3.38

Figure 4 – Upper Pressure Point Calibration

Page 65

Configuration

After choosing the sensor, click on “Upper” or “Lower” for either point, as shown on figures 4 and 5, where the user must select the calibration unit and report the reference pressure on Sensor Cal Point Hi and Sensor Cal Point Lo, watching on the window bottom the values read by the FY303.

Figure 5 – Lower Pressure Point Calibration

FY303 Performance Graph

Go the “View” menu via Simatic PDM and choose one of the options: “Position Performance Diagram” or “Pressure Diagram”, according to figure 6.

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FY303 – Operation, Maintenance and Instructions Manual

Figure 6 – FY303 Graph Selection

When choosing “Position Performance Diagram”, the PDM will show the respective graph, as on figure 7, where the user may watch the behavior of the real valve position on the SetPoint throughout the action.

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Configuration

Figure 7 – Real Position x SP

Clicking on the scales, the user may adjust them at his discretion and, in addition, zoom in the curve to locate a specific area.

Figure 8 – Scale adjustment

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FY303 – Operation, Maintenance and Instructions Manual

By choosing “Pressure Diagram”, the real position may be drawn by the sensor selected on figure 3, as shown on figure 9. If no sensor was selected, the “Pressure Diagram” option will not be seen on the “View” menu.

3.42

Figure 9 – Real Position x Pressure

Pressure sensors configuration data on the Transducer block

The pressure sensors are characterized on factory procedure, so, if the configuration data must be checked, go the “Device” menu, choose “Transducer Offline” and click on the “Pressure Sensors” tab, as shown on figure 10.

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Configuration

Figure 10 – Sensor Pressure Configuration Data

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FY303 – Operation, Maintenance and Instructions Manual

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Section 4

General

SHOWN ON DISPLAY

COMMUNICATION

NO RESPONSE

TO INPUT SIGNAL

OSCILLATING

SLOW ACTUATOR

TOO FAST ACTUATOR

MAINTENANCE PROCEDURES

FY303 Profibus to Valve Positioners are extensiv ely teste d and inspect ed before d elivery to the end

user. Nevertheless, during their design and development, considerati on was given to the possibility of repairs by the end user, if necessary.

In general, it is recommended that the end user do not try to repair printed circuit boards. Instead, he should have spare circuit boards, which may be ordered from Smar whenever necessary.

DIAGNOSTICS

SYMPTOM PROBABLE ERROR SOURCE

Positioner Connections

Check wiring polarity and continuity.

POSITION

ACTUATOR

RESPONSE

Power Supply

Check the minimum voltage signal equal 9 Volts.

Electronics Failure

Check circuit boards for bad connections and replace them for spare boards.

Network Connection

Check network connections: equipment, power supply, couplers, links, and terminators.

Network Impedance

Check network impedance (power supply and terminators impedance).

Positioner Configuration

Check the configuration of the positioner communication parameters.

Network Configuration

Check the network communication configuration.

Electronics Failure

Try spare parts in the positioner circuits.

Pressure Output Connections

Check up on air leaks.

Air Supply Pressure

Check the air supply pressure. The input pressure to FY303 shall be between 20 psi and 100 psi.

Calibration

Check the positioner calibration points.

Obstructed Restriction and/or Blocked Output

Observe the following procedures described in this Manual: OUTPUT CONNECTIONS and RESTRICTION CLEANING.

Calibration

Adjust parameter Kp. Adjust parameter Tr. Adjustment Parameters are Too Low Adjust parameter Kp. Adjustment Parameters are Too High Adjust parameter Kp.

Table 4.1 - FY303 Diagnostics

If the problem is not presented in the table above follow the Note below:

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FY303 – Operation, Maintenance and Instructions Manual

The Factory Init should be tried as a last option to recover the equipment control when the equipment presents some problem related to the function blocks or the communication. This operation must only be carried out

by authorized technical personnel and with the process offline, since the equipment will be configured with standard and factory data.

This procedure resets all the configurations run on the equipment, after which a partial download should be performed. With exception to the equipment physical address and the GSD identifier number selector parameter. After doing this, all configurations must be remade according to their applications.

Two magnetic tools should be used to this effect. On the equipment, withdraw the nut that fixes the identification tag on the top of the housing, so that access is gained to the "S" and "Z" holes.

The operations to follow are:

1) Switch off the equipment, insert the magnetic tools and keep them in the holes (the magnetic end in the holes);

2) Feed the equipment;

3) As soon as Factory Init is shown on the display, take off the tools and wait for the "5" symbol on the right upper corner of the display to unlit, thus indicating the end of the operation.

This procedure makes effective the entire factory configuration and will eliminate eventual problems with the function blocks or with the equipment communication.

Note that this procedure must be performed by authorized personal only and with the process switched off, since the equipment will be configured with standard and factory data.

Disassembly Procedure

Make sure to disconnect power supply and supply pressure before disassembling the positioner. TRANSDUCER

To remove the transducer from the electronic housing, the electrical connections (in the field terminal side) and the main board connector must be disconnected.

Loosen the hex screw (6) and carefully unscrew the electronic housing from the transducer, observing that the flat cable is not excessively twisted.

Do not rotate the electronic housing more than 270° without disconnecting the electronic circuit from the power supply.

NOTE

WARNING

The numbers indicated between parentheses refer to Figure 5.4 – Exploded View.

4.2

Figure 4.1 - Transducer Rotation

NOTE

Page 73

ELECTRONIC CIRCUIT

To remove the circuit board (5) and indicator (4), first loose the cover locking (13) on the side not marked “Field Terminals”, then unscrew the cover (1).

The boards have CMOS components, which may be damaged by electrostatic discharges. Observe correct procedures for handling CMOS components. It is also recommended to store the circuit boards in anti-static proof cases.

Loosen the two screws (3) that anchor the indicator and the main circuit boar d. Gently pull out the indicator, and then the main board (5).

Reassembly Procedure

TRANSDUCER

Mount the transducer to the housing turning clockwise until it stops. Then turn it count erclockwise until it faces the square of electronic housing to the square of transducer. Tighten the hex scre w (6) to lock the housing to the transducer.

Restriction Cleaning Procedure

The air flows to the nozzle through a restriction. Verify from time to time the restriction cleaning to assure a positioner good performance.

1. Be sure that the air supply of the equipment is blocke d.

Maintenance Procedures

WARNING

2. With an appropriate tool, remove the transdu cer serial n um ber plate. (New models have the plate placed on the opposite side of the transducer).

3. Remove the restriction screw using an adequate tool;

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FY303 – Operation, Maintenance and Instructions Manual

4. Remove the o-ring’s with an appropriate tool;

5. Dive the part in petroleum base solvent and dry it with compressed air (apply the compressed air directly in the smaller orifice for the air to get out through the bigger orifice) .

6. Introduce the appropriate tool (PN 400-0726) into the restriction orifice to prevent any possible obstruction;

7. Mount the o-rings again and screw the restriction in the positioner.

8. The equipment can be supplied with air again.

Change of the Filter Elements

Change the positioner filter elements with a minimum stated period of 1 (one) year. The instrumentation air supply must be clean, dry and non-corrosive, following standards indicated

for the American National Standard “Quality Standard for Instrument Air" ANSI / ISA S7.0.01 - 1996. If the instrumentation air does not comply with the above mentioned standards, the user has to

consider changing the positioner filter elements more frequently. EXHAUST PORT

Air is vented to the atmosphere through the two exhausts ports located behind the transducer nameplate. A foreign object interfering or blocked exhaust port provides a way to increase the output. Cleaning by spraying it with a solvent.

Never use oil or grease in the spool; otherwise the positioner performance will be impaired.

Electronic Circuit

Plug transducer connector and power supply connector to main board (5). Attach the display to the main board. Observe the four possible mounting positions (Figure 4.2). The  mark indicates up position.

NOTE

4.4

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Maintenance Procedures

Interchangeability

Package Content

Figure 4.2 - Four Possible Positions of the Local Indicator

Anchor the main board and indicator with their screws (3). After tightening the protective cover (1), mounting procedure is complete. The positioner is ready to be energized and tested.

Electrical Connections

The plug must obligatorily be installed in th e electric connection not used, preventing the humidity entrance.

WARNING

The standard plug provided with Smar positioner do not have an EExd certification.

Main board can be changed and operate with the transducer. There is an EEPROM in the transducer part that keeps the trim.

When receiving the equipment, verify the package content. The number for items marked with (*) must be in accordance with the number of positioners.

• Positioner

• Adequate Mounting Brackets

- For the positioner

- For the magnet

• Magnetic Tool for Local Adjustment (*)

• Centralizer Transmitter Device (*)

• Cleaning Device for the Restriction (*)

• Operation, Maintenance and Instructions Manual (*)

ACCESSORIES

ORDERING CODE DESCRIPTION

SD1 Magnetic Tool for Local Adjustment BC1 Fieldbus/RS232 Interface PS302 Power Supply FDI302 Field Device Interface BT302 Terminator SB302 Intrinsic DF48 Fieldbus Repeater 400-0726 Needle cleaning Device for the restriction

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PARTS DESCRIPTION POSITION CÓDE

HOUSING (NOTE 1)

COVER (INCLUDES O-RING)

Cover Locking Bolt Sensor Locking Bolt (M6 Without Head Screw) External Ground Bolt Identification Plate Fixing Bolt Orings Cover (NOTE 2) Local Adjustment Protection Cover DIGITAL INDICATOR GLL1438 (for old electronic main board GLL1034) DIGITAL INDICATOR (for new main boards GLL1461)

TERMINAL INSULATOR

MAIN ELECTRONIC CIRCUIT BOARD (include digital indicator and mounting kit)

TERMINAL HOLDING BOLT HOUSING

MOUNTING KIT FOR MAIN ELECTRONIC BOARD (new board GLL1461), (2 bolts with spacers and retention washers) CONNECTION COVER

. Connection Cover Bolt . Buna-N Neck O-ring (NOTE 2) ANALOG BOARD without Pressure Sensor GLL1012 (version K0) ANALOG BOARD for Pressure Sensor GLL1204 (version K1) PIEZO BASE SET

. Base and Block O-ring (NOTE 2) . Restriction . Restriction External O-ring (NOTE 2) . Restriction Internal O-ring (NOTE 2) . Syntherized Bushing . Analog indicator (Gage - Stainless Steel and Brass) (NOTE 5) ASSEMBLED DIAPHRAGM (include hall tube, mechanical part and O-rings) PNEUMATIC BLOCK SET

. Base & Block O-ring (NOTE 2) . Syntherized Bushing . Analog indicator (Gage - Stainless Steel and Brass) (NOTE 5) . Filtering Element . Spool valve . Spool valve Spring . Stainless steel Filter- 1/4" NPT - includes filtering element . Vent Plug - Stainless Steel

HALL COVER SET

. Hall Cover Bolt . Hall Support + Hall Sensor + Flat cable

REMOTE EXTENSION SET

CABLE SET + CONNECTOR

SPARE PARTS LIST

1 and 13

6 7

9 2

11 400-0058 A

5 400-1346 A

15,16 and 17

15 16 18 18

19,20,21,22, 23,24 and 25

19 20 21 22 23 25

27 400-1321 (NOTE 6) B

19,23,25,28,29,30,31 and

19 23 25 28 29 40 30 32

33 (or 36), 34 and 35

34 35

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400-1314-3P (NOTE 6)

400-1307 (NOTE 6)

204-0120 400-1121 204-0124 204-0116 204-0122 204-0114

400-1305 400-1310

204-0119

400-0560

400-1320 (NOTE 6)

400-0073 204-0113 400-0060 400-0840

400-1318 (NOTE 6)

400-0085 344-0165 344-0155 344-0150 400-0033 400-1120

400-1317 (NOTE 6)

400-0085 400-0033 400-1120 400-0655 400-0653 400-0787

101B3403

400-0654

400-1319 (NOTE 6)

400-0092 400-0090

400-1322 (NOTE 6)

400-1325 (NOTE 6)