Yokogawa YVP20S User Manual

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User’s Manual

YVP Management Software ValveNavi

IM 21B04C50-01E

Yokogawa Electric Corporation

IM 21B04C50-01E

5th Edition

YVP Management software ValveNavi

IM 21B04C50-01E 5th Edition

CONTENTS

1. INTRODUCTION ...................................................................................... 1-1

1.1 About This Manual .......................................................................................... 1-1

1.2 Software License Agreement ......................................................................... 1-2

1.3 About This Software ....................................................................................... 1-3

1.4 Important Safety Warnings ............................................................................. 1-3

1.5 Trademarks, Copyrights, and Patents............................................................ 1-4

2. INTRODUCTION TO ValveNavi ................................................................ 2-1

2.1 What is ValveNavi? .......................................................................................... 2-1

2.2 ValveNavi Specifications ................................................................................ 2-1

2.3 Combination of ValveNavi & YVP ................................................................... 2-1

2.4 What is FOUNDATION® Fieldbus? ................................................................. 2-2

2.4.1 Guide to a successful Foundation fieldbus installation....................... 2-3

Toc-1<Int> <Ind> <Rev>

3. INSTALLATION OF HARDWARE AND SOFTWARE ............................... 3-1

3.1 What you need to get started with ValveNavi ................................................ 3-1

3.2 Reference Model Process............................................................................... 3-2

3.2.1 Wiring requirements ......................................................................... 3-3

3.3 Installing NI-FBUS ........................................................................................... 3-4

3.3.1 Configure the NI-FBUS interface card safely for different tasks ......... 3-4

3.3.2 Installing the Device Descripfions (DD) with NI-FBUS Interface

Configuration Utility........................................................................... 3-6

3.3.3 Location of DD files and .DCT file ..................................................... 3-7

4. ValveNavi ADMINISTRATION ................................................................. 4-1

4.1 Hardware and Software Requirements .......................................................... 4-1

4.2 Installing ValveNavi ......................................................................................... 4-1

4.3 Trial Period ...................................................................................................... 4-2

4.4 Licensed User Process ................................................................................... 4-3

4.5 Logging on with Registration ......................................................................... 4-4

4.6 Setting Up User Accounts .............................................................................. 4-5

4.6.1 System Administration, Passwords, and Privilege Levels ................. 4-5

4.6.2 Start the Administration Program ...................................................... 4-5

4.6.3 Privilege Levels................................................................................. 4-6

4.7 Finish ValveNavi .............................................................................................. 4-8

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5. FOUNDATION FIELDBUS OVERVIEW .................................................... 5-1

6. QUICK TOUR OF ValveNavi .................................................................... 6-1

Toc-2

5.1 Reference Model Process Used in This User’s Manual ................................. 5-1

5.1.1 P & I D .............................................................................................. 5-2

5.1.2 Function block links........................................................................... 5-3

5.2 Device Operational States and Block Modes ................................................ 5-5

5.3 Block Modes .................................................................................................... 5-7

5.4 Examples of IVI Operational States ............................................................... 5-9

5.5 Changing Operational States ....................................................................... 5-12

6.1 Introduction ..................................................................................................... 6-1

6.2 Fieldbus Device Tree ....................................................................................... 6-2

6.3 Menu Bar and Tool Bar .................................................................................... 6-3

6.3.1 Menu items ....................................................................................... 6-3

6.3.2 Toolbar icons .................................................................................... 6-3

6.4 Control Valve Faceplate .................................................................................. 6-4

6.5 Companion Device Display Frame ................................................................. 6-5

6.6 Status Frame ................................................................................................... 6-5

6.7 Accessing Services in ValveNavi ................................................................... 6-6

6.8 Setup Wizard ................................................................................................... 6-7

6.8.1 Actuator Wizard ................................................................................ 6-8

6.8.2 Tuning Wizard ................................................................................... 6-9

6.8.3 Travel Calibration Wizard ................................................................ 6-10

6.8.4 Position Control Limits - Wizard....................................................... 6-11

6.8.5 Finish - Setup Wizard ...................................................................... 6-12

6.9 Configuration Services ................................................................................. 6-13

6.10 Calibration Services ..................................................................................... 6-14

6.11 Diagnostic Services ...................................................................................... 6-15

6.12 Operation State ............................................................................................. 6-16

6.13 Device Query ................................................................................................. 6-17

6.14 PID Control Dialog ........................................................................................ 6-18

6.15 Rescan ........................................................................................................... 6-19

6.16 About ............................................................................................................. 6-19

6.17 Online Help .................................................................................................... 6-20

7. INTEGRATED VALVE INTERFACE (IVI)................................................... 7-1

7.1 Device Selection ............................................................................................. 7-3

7.1.1 The Pop-Up Menu In Device Selection .............................................. 7-4

7.1.2 Setting Device as LM or Basic Device ............................................... 7-5

7.2 Control Valve Faceplate .................................................................................. 7-6

7.2.1 Selected Device................................................................................ 7-6

7.2.2 Block Actual Mode ............................................................................ 7-7

7.2.3 Position............................................................................................. 7-7

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7.2.4 Other Status ..................................................................................... 7-7

7.2.5 Temperature, Pressure, and I/P Graphs ............................................ 7-8

7.3 Companion Device.......................................................................................... 7-8

8. SETUP WIZARD ...................................................................................... 8-1

8.1 Introduction to Setup Wizard .......................................................................... 8-1

8.2 Actuator Wizard ............................................................................................... 8-2

8.3 Tuning Wizard .................................................................................................. 8-3

8.4 Travel Calibration Wizard ................................................................................ 8-5

8.5 Position Control limits Wizard ........................................................................ 8-6

8.6 Finish-Setup Wizard ........................................................................................ 8-8

9. CONFIGURATION SERVICES ................................................................. 9-1

9.1 Configuration - General .................................................................................. 9-1

9.1.1 Device Info ........................................................................................ 9-2

9.1.2 Block Tag Info ................................................................................... 9-3

9.1.3 Others Installed ................................................................................ 9-3

9.2 Configuration - Position ................................................................................. 9-4

9.2.1 Servo Parameters ............................................................................. 9-4

9.2.2 Position Limit .................................................................................... 9-5

9.2.3 Limit Switch Threshold ...................................................................... 9-6

9.2.4 Fault Control ..................................................................................... 9-6

9.2.5 Servo Alarms (I/P Module Operating Point Fault Control) .................. 9-6

9.2.6 Advanced ......................................................................................... 9-7

9.2.7 Configuration - Advanced Position .................................................... 9-7

9.3 Configuration - Actuator ................................................................................. 9-8

9.3.1 Valve Action ...................................................................................... 9-8

9.3.2 Actuator Type .................................................................................... 9-8

9.3.3 Relay Type ........................................................................................ 9-9

9.3.4 Valve Type ........................................................................................ 9-9

9.3.5 Continuous Data Limit....................................................................... 9-9

9.3.6 Model And Serial Number of Valve ................................................. 9-10

9.4 Configuration - AO Block.............................................................................. 9-11

9.4.1 Limits .............................................................................................. 9-11

9.4.2 Configuration - AO Block Options .................................................... 9-12

9.5 Configuration - PID Block ............................................................................. 9-13

9.5.1 PID Parameters .............................................................................. 9-13

9.5.2 Limits .............................................................................................. 9-14

9.5.3 PV Scale......................................................................................... 9-15

9.5.4 Configuration - PID Options ............................................................ 9-15

9.6 Configuration - Options ................................................................................ 9-17

9.6.1 Characterization Frame .................................................................. 9-17

9.6.2 Pressure Frame .............................................................................. 9-21

9.6.3 Others Frame ................................................................................. 9-21

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10. CALIBRATION SERVICES .................................................................... 10-1

Toc-4

10.1 Calibration - Range ....................................................................................... 10-1

10.1.1 Find Range Result .......................................................................... 10-2

10.1.2 GO ................................................................................................. 10-2

10.1.3 Auto Stop Limits .............................................................................. 10-2

10.1.4 Manual Stop Limits ......................................................................... 10-3

10.2 Calibration - Tuning ....................................................................................... 10-4

10.2.1 Auto Tune ....................................................................................... 10-5

10.2.2 Auto Tune Result ............................................................................. 10-6

10.2.3 Search Stops and Auto Tune In One Step ....................................... 10-6

10.2.4 Manual parameter adjustment ........................................................ 10-7

10.3 Travel Calibration .......................................................................................... 10-8

10.3.1 Calibration Result ......................................................................... 10-10

10.3.2 Apply Calib ................................................................................... 10-10

10.3.3 Pick Target Position for Calibration ............................................... 10-10

10.4 Calibration - Advanced Position Servo Tuning Parameters ...................... 10-11

11. PID BLOCK SERVICES ......................................................................... 11-1

11.1 States and Modes ......................................................................................... 11-2

11.2 Tuning Parameters ........................................................................................ 11-3

11.3 Simulation Function...................................................................................... 11-4

11.3.1 Simulation State ............................................................................. 11-4

12. TRENDING SERVICE ............................................................................ 12-1

12.1 Trend Selection ............................................................................................. 12-3

12.2 Scope Settings .............................................................................................. 12-4

12.3 Saving and Opening Trend Files .................................................................. 12-5

12.4 Changing Valve Position while Trending ...................................................... 12-6

12.5 Closing the Trend Service ............................................................................. 12-6

13. SAVING, DOWNLOADING, AND CLONING A CONFIGURATION......... 13-1

13.1 Open File ....................................................................................................... 13-1

13.2 Save to File .................................................................................................... 13-2

13.3 Download ...................................................................................................... 13-3

13.4 Copy a Configuration to a New Positioner .................................................. 13-5

14. DIAGNOSTIC SERVICES ...................................................................... 14-1

14.1 General .......................................................................................................... 14-1

14.2 Self Check ..................................................................................................... 14-3

14.3 Signature ....................................................................................................... 14-5

14.3.1 Actuator Signature .......................................................................... 14-6

14.3.2 Extended Actuator Signature .......................................................... 14-9

14.3.3 High Resolution Actuator Signature .............................................. 14-11

14.3.4 Step Response Test ...................................................................... 14-11

14.3.5 Positioner Signature ..................................................................... 14-20

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14.3.6 Signature Selection ...................................................................... 14-22

14.3.7 Signature Setting .......................................................................... 14-23

14.3.8 Signature Measurement ............................................................... 14-24

14.3.9 Signature Graphs ......................................................................... 14-25

14.3.10 Graph Scale Setup ....................................................................... 14-27

14.3.11 Signature Summary ...................................................................... 14-28

14.3.12 Signature Notes ............................................................................ 14-29

15. QUERY SERVICES ................................................................................ 15-1

16. REPORTING SERVICES ....................................................................... 16-1

16.1 Configuration Report .................................................................................... 16-1

16.2 Communication Error Log ............................................................................ 16-2

17. FAILSAFE HANDLING .......................................................................... 17-1

17.1 Introduction ................................................................................................... 17-1

17.2 Failsafe Active Latched ................................................................................ 17-1

17.3 Failsafe Clear Latched .................................................................................. 17-2

17.4 Failsafe Clear Non-Latch .............................................................................. 17-2

17.5 To Exit Failsafe .............................................................................................. 17-3

17.5.1 If the Deviation Error Failsafe is set ................................................. 17-3

17.5.2 If the failsafe is caused by internal diagnostics ................................ 17-8

APPENDICES ............................................................................................... App-1

Appendix A Glossary and Acronyms ..................................................................... App-1

Appendix B Configuring DI Blocks to TB Channels .............................................. App-6

Appendix C Setting a Failsafe Strategy.................................................................. App-7

REVISION RECORD

IM 21B04C50-01E

Blank Page

1. INTRODUCTION

This User’s Manual gives instructions on handling of YVP Management Software “ValveNavi”(Model: YVP20S).

This software is to be used to setup the YVP110 advanced valve positioner; therefore, it is indispensable for users to read, understand and follow the instructions on the YVP110 user’s manual (IM 21B04C01-01E) BEFORE actually starting the operation.

It is also highly recommended to become well-informed about Foundation Fieldbus Communication by reading the materials as follows.

Referential materials issued by Yokogawa Electric Corp.

TI 38K02A01-01E Fieldbus Book - A Tutorial

TI 38K03A01-01E Fieldbus Technical Information

For the continuous usage of the software, the registration is required. Please read the corresponding part in this manual and complete the necessary procedures.

1.1 About This Manual

1-1

• This manual should be delivered to the end user.

• The information contained in this manual is subject to change without prior notice.

• The information contained in this manual, in whole or part, shall not be transcribed or copied without YOKOGAWA’s written permission.

• In no case does this manual guarantee the merchantability of the positioner or the software or its adaptability to a specific client needs.

• Should any doubt or error be found in this manual, submit inquiries to your local dealer.

• Changes to specifications, structure, and components used may not lead to the revision of this manual unless such changes affect the function and performance of the products.

IM 21B04C50-01E

1.2 Software License Agreement

Following is the software License Agreement which should be agreed by users before start using the software. The agreement will be shown when you install the software.

Yo k ogawa Electric Corporation Software License Agreement

This is a legal agreement between you and Yokogawa Electric Corporation. By selecting Accept or by using the software, you agree to be bound by the terms of this agreement. If you do not agree to the terms of this agreement, select Not Accept.

1. Grant of License: This License Agreement permits you (Licensee) to use one copy of the specified version of the software identified above (Software) on any single computer.

2. Copyright: The Software is owned by Yokogawa Electric Corporation (Licensor) and its suppliers and is protected by Japan copyright laws and international treaty provisions. Therefore, Licensee must treat the Software like any other copyrighted material except that Licensee may either (a) make one copy of the Software solely for backup or archival purposes, or (b) transfer the Software to a single hard disk provided Licensee keeps the original solely for backup or archival purposes. Licensee may not reverse engineer, decompile or disassemble the Software.

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3. Limited Warranty: Licensor warrants that the Software will perform substantially in accordance with the accompanying printed materials for a period of ninety (90) days from the date of receipt. If the Software contains any material errors, malfunctions, or defects, Licensor shall exert a good faith effort either to correct or replace the Software, at the election of Licensor, which remedy shall be the exclusive remedy of Licensee for such errors, malfunctions or defects. If a reasonable amount of effort of Licensor or its supplier will not correct the error, then Licensor will have no further obligation to remedy such errors, malfunctions or defects.

LICENSOR MAKES NO OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PA RTICULAR PURPOSE, WITH RESPECT TO THE SOFTWARE AND ASSOCIATED DOCUMENTATION.

IN NO EVENT SHALL LICENSOR BE LIABLE TO LICENSEE FOR INDIRECT, SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES (WHETHER DENOMINATED IN CONTRACT, TORT, STRICT LIABILITY IN TORT, NEGLIGENCE OR OTHER THEORIES) OR FOR LOST PROFITS OR INCREASED EXPENSES ARISING OUT OF THIS AGREEMENT OR THE USE OF THE SOFTWARE AND ASSOCIATED DOCUMENTATION.

IN NO EVENT SHALL THE TOTAL LIABILITY OF LICENSOR FOR DAMAGES TO LICENSEE EXCEED THE SUM PAID BY LICENSEE TO LICENSOR FOR THE SOFTWARE AND ASSOCIATED DOCUMENTATION.

IM 21B04C50-01E

1.3 About This Software

This software is intended for use only with Yokogawa YVP positioners. The positioners are intended for use with industrial compressed air systems only. Ensure that an adequate pressure relief provision is installed if application of system supply pressure could cause downstream equipment to malfunction. Installation should be in accordance with local and national compressed air and instrumentation codes.

Positioners certified for use in explosionproof/flameproof or intrinsically safe installations MUST:

a) Be installed in accordance with local and national codes for hazardous area

installations;

b) Be maintained only by qualified personnel with adequate training on hazardous area

instrumentation; and

c) Be maintained only by qualified personnel with adequate training in the use of

Foundation fieldbus.

This software is not intended for use in life support systems. This software is not intended for use in safety shutdown systems. Substitution of positioner parts and components may lead to unsafe operation or compromise performance.

Items sold by Yokogawa Electric Corp. are warranted to be free from defects in materials and workmanship for a period of one year from the date of shipment, provided said items are used according to Yokogawa’s recommended usages.

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Yo k ogawa reserves the right to discontinue manufacture of any product or change product materials, design, or specifications without notice.

1.4 Important Safety Warnings

These instructions contain WARNING, CAUTION, IMPORTANT, and NOTE where necessary to alert you to safety related or other important information. Please read these instructions carefully BEFORE this instrument is installed or maintained.

Although WARNING hazards is related to personal injury, and the CAUTION hazards involve equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process system performance which may lead to personal injury or death. Therefore, comply fully with all WARNING, CAUTION, and IMPORTANT notices.

WARNING

indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

CAUTION

indicates a potentially hazardous situation which, if not avoided, could result in injury or damage to the instrument.

IM 21B04C50-01E

IMPORTANT

indicates a potentially hazardous situation which, if not avoided, may result in damage to the instrument or a system failure.

NOTE

Indicates important facts and conditions.

1.5 Trademarks, Copyrights, and Patents

YOKOGAWA and YVP are registered trademarks of Yokogawa Electric Corporation. HART is a registered trademark of the HART Communications Foundation. Pentium is a trademark of Intel Corporation. Internet Explorer and Windows are trademarks of Microsoft Corporation. FOUNDATION is a trademark of the Fieldbus Foundation, Inc. NI-FBUS is a trademark of National Instruments, Inc. Netscape and Navigator are trademarks of Netscape Communications Corporation. Masoneilan is a trademark of Dresser, Inc. Other company names and product names used in this manual are the registered trademarks or trademarks of their respective owners.

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IM 21B04C50-01E

2. INTRODUCTION TO ValveNavi

2.1 What is ValveNavi?

ValveNavi is a Windows software tool that makes it easy to configure, calibrate, and operate Foundation fieldbus pneumatic control valve positioners YVP110 with internal process control and limit switches. It fully supports the Foundation fieldbus specifications.

2.2 ValveNavi Specifications

Tab le 2.1 ValveNavi Specifications

2-1

Product name

Compatible OS

Interface Cards supported

Application Interface Software

Connection

Positioners supported

Blocks supported

Companion Device

Online Help

Configuration capability

Query capability

Trending

YVP Management Software (R2.3)

Windows 2000 service pack 4, XP service pack 2, or Vista service pack 1

National Instruments

AT-FBUS, PCI-FBUS, or PCMCIA-FBUS Interface card

NI-FBUS Communication Manager V. 3.0 or later For Vista V. 3.2.1 or later

Direct connected to segment.

Model YVP110-F

Resource Block (RB) Transducer Block (TB) with Device Description AO, DI, OS PID (optional)

Model YVP110-F

HTML help files viewed with browser

Device tag, node address, block tag, Transduser Block (TB) parameters

All block parameters

A polling method

2.3 Combination of ValveNavi & YVP

T001.eps

The table in below shows the limitation of the functions according to the combination between each revision of YVP110 and ValveNavi.

Tab le 2.2 Supported Functions by Release Number

Dev Rev

Without software

download functions

With software

download functions

✔: Applicable *1: Not applicable to link master and signature functions *2: Not applicable to double acting actuator ⌵Ⲑ〈: Not applicable

✔

N/A

R2.1

✔

R2.2

✔

IM 21B04C50-01E

R2.3

✔

T002.eps

2.4 What is FOUNDATION® Fieldbus?

The Fieldbus Foundation summarizes the technology:

FOUNDATION fieldbus is an all-digital, serial, two-way communications system that serves as a Local Area Network (LAN) for factory/plant instrumentation and control devices. The fieldbus environment is the base level group of the digital networks in the hierarchy of plant networks. FOUNDATION fieldbus is used in both process and manufacturing automation applications.

Unlike proprietary network protocols, FOUNDATION fieldbus is neither owned by any individual company, or regulated by a single nation or standards body. The technology is controlled by the Fieldbus Foundation, a not-for-profit organization consisting of more than 100 of the world’s leading controls and instrumentation suppliers and end users.

While FOUNDATION fieldbus retains many of the desirable features of the 4-20 mA analog system, such as a standardized physical interface, bus-powered devices, and intrinsic safety options, it offers a host of additional benefits to users.

● Device Interoperability

With interoperability, one fieldbus device can be replaced by a similar device with added functionality from a different supplier on the same fieldbus network while maintaining specified operations. This permits users to “mix and match” field devices and host systems from various suppliers. Individual fieldbus devices can also transmit and receive multivariable information, and communicate directly with each other over a common fieldbus.

2-2

● Enhanced Process Data

With FOUNDATION fieldbus, multiple variables from each device can be brought into the plant control system for archival, trend analysis, process optimization studies, and report generation. This access to accurate, high resolution data enables processes to be finetuned for better manufacturing throughout and reduced plant downtime. These efficiencies add up to higher plant performance and profitability.

● Expanded View of the Process

Modern fieldbus devices, with powerful, microprocessor-based communications capabilities, permit process errors to be recognized faster, and with greater certainty. As a result, plant operators are notified of abnormal conditions or the need for preventive maintenance, and can make better production decisions. Problems that detract from operating efficiency are more quickly corrected, enabling yields to go up while raw material costs and regulatory problems decrease.

● Improved Plant Safety

Fieldbus technology will help manufacturing plants keep up with increasingly stringent safety requirements. By providing operators with earlier notification and warning of pending and current hazardous conditions, fieldbus allows for corrective action before an unplanned shutdown. Enhanced plant diagnostic capabilities also reduce the need for frequent access to hazardous areas, thus minimizing the risks to field personnel.

● Easier Predictive Maintenance

Enhanced device diagnostics capabilities make it possible to monitor and record such conditions as valve wear and transmitter fouling. Plant personnel are able to perform predictive maintenance without waiting for a scheduled shutdown, thus avoiding or reducing downtime.

IM 21B04C50-01E

● Reduced Wiring and Installation Costs

FOUNDATION fieldbus’ use of existing wiring and multi-drop connections provides significant savings in network installation costs. This includes reductions in intrinsic safety barrier termination and cable costs, particularly in areas where wiring is already in place. Additional cost savings can be achieved through the decreased time required for construction and start-up, as well as simplified programming of control and logic functions using software control

2.4.1 Guide to a successful Foundation fieldbus installation

There are many levels of skills required for a successful Foundation fieldbus installation. It is beyond the scope of the ValveNavi software user’s manual to cover all phases of fieldbus design and installation. Prior to using the ValveNavi software the fieldbus segment must be running properly, without wiring, installation, power supply, or configuration irregularities. The YVP positioner must be mounted on a control valve. Numerous resources are available to cover each of these installation issues.

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IM 21B04C50-01E

3. INSTALLATION OF HARDWARE AND SOFTWARE

3.1 What you need to get started with ValveNavi

To begin using ValveNavi the following tools and software are needed.

•ValveNavi software on its installation CD-ROM

•A PC running Windows 2000 service pack 4 , XP service pack 2, or Vista service pack 1

• National Instruments AT-FBUS, PCI-FBUS or PCMCIA-FBUS interface card and NIFBUS software V. 3.0 or later, for Vista V. 3.2.1 or later

• Instruction manuals for the NI-FBUS interface card and software

• The Model YVP110 positioner installed on a valve

• The Model YVP110 User’s Manual

•A Foundation fieldbus power supply and power conditioner with terminators

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• Additional fieldbus devices that will be installed on the bus segment (optional)

Before we can describe installation of ValveNavi software we must first describe the process for installing the Foundation fieldbus communications hardware and software. To help to reduce the need for terminology that used in digital communications, we will refer to an example reference process and Foundation fieldbus segment.

IM 21B04C50-01E

3.2 Reference Model Process

Throughout this manual we will use a simplified Fieldbus Reference Model Process. This is an example of a simple process (It is not a practical process) that illustrates many elements of Foundation fieldbus that are required in a successful installation.

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Figure 3.1 ValveNavi Reference Model Fieldbus Segment

This User’s manual is intended to instruct the use of the ValveNavi software with a Yo k ogawa YVP valve positioner. ValveNavi may be used offline but is normally connected to a YVP positioner. Prior to using ValveNavi:

• The positioner must be correctly installed on a valve and connected to an air supply. See the YVP110 User’s Manual(IM 21B04C01-01E).

• The PC running ValveNavi must have a National Instrument AT-FBUS, PCI-FBUS or PCMCIA-FBUS interface card installed and configured in the Windows registry. Carefully follow the installation instructions provided with the interface card.

WARNING

Improper setup can interfere with process control.

• NI-FBUS communications manager software must be setup and running.

• The positioner must be assigned a fieldbus node address and a device tag. It is recommended that this be performed while the device is connected as a single device to a test segment, not while connected to an operating control segment. This will require a different configuration of the interface card.

• The entire fieldbus segment must be configured, with all required function blocks softwired and scheduled.

Wiring practices for Foundation fieldbus differs significantly from 4 to 20 mA instrument wiring. Please Refer to the Foundation Fieldbus Application Guide 31.25 kbits/s Wiring and Installation, AG-140 Revision 1.0 or later. However, a few remarks regarding wiring of the devices are included here. The positioner must be installed properly on a segment before the ValveNavi software can be used.

IM 21B04C50-01E

3.2.1 Wiring requirements

Note that there are cable requirements that must be met for reliable installations. The cable used must support the digital data signals without reflections, noise or attenuation. The type A cable should be used whenever possible and especially for long transmission distances or for segments with many branches (spurs).

● Power conditioner

Use a power conditioner for each segment. The conditioner must be foundation fieldbus compliant. The power conditioner functions to isolate the digital signals from the power source.

● Power supply

The YVP positioner complies with the foundation specification voltage requirements of 9 to 32 volts. The power supply must conform to these requirements with consideration for the current drawn by all devices powered by the segment. The YVP maximum current consumption is 17 mA.

● Terminator

Every fieldbus segment requires two (and only two) approved terminators. Terminators are passive circuits that damp signal reflections in the circuit. For simple segments having short runs and few spurs, the terminator location can be at each end of the longest cable. For very short cables both terminators can even be located in the power conditioner.

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IM 21B04C50-01E

3.3 Installing NI-FBUS

ValveNavi software interfaces to the fieldbus segment through an interface card that must be installed in the PC running ValveNavi. The card is supplied with NI-FBUS installation software. ValveNavi is designed to operate only with National Instruments NI-FBUS cards, which are AT-FBUS, PCI-FBUS, or PCMCIA-FBUS.

Prior to using ValveNavi, install the NI-FBUS card and its software in accordance with the instructions provided by National Instruments, Inc. Note that the instructions are different for the AT card used in a desktop and the PCMCIA card normally used with a laptop. Furthermore, the instructions are different for Windows 2000, for Windows XP, and Windows Vista.

Note that there are two NI configuration tools that serve separate purposes:

• NI-FBUS Interface Configuration Utility- This is used to install and set up interface boards. It provides access to IRQ and memory settings needed for Windows. It provides tools for importing DD’s. It is described in the Getting Started manual supplied with the NI-FBUS interface card.

• NI-FBUS Fieldbus Configuration System- This is the tool for configuring the Foundation fieldbus network, including the devices, setting up the control strategy, and schedule. It is described in the NI-FBUS Configurator User Manual installed in the program online help. After opening the NI-FBUS Fieldbus Configuration System, click Help>>Online Help to open the manual in PDF format.

3-4

WARNING

Do not configure the interface as a Link Master when connecting to the segment with an existing host. Disruption of control may result.

3.3.1 Configure the NI-FBUS interface card safely for different tasks

The configuration of a portable PC for use with ValveNavi will vary depending on the immediate task. If ValveNavi will be used to maintain or configure a valve on an existing Foundation fieldbus segment, the PC running ValveNavi must configured carefully so it does not interfere with control communication. Two configurations are described in the following sections.

Tab le 3.1 Two configurations of the NI-FBUS Interface Card

To configure a positioner in the Foundation fieldbus segment with a host computer.

To configure a positioner in the segment without other host (Initial Setup, for example).

The NI-FBUS Interface card must be configured as a BASIC DEVICE at a Visitor address.

The NI-FBUS Interface card must be configured as a LINK MASTER DEVICE at a FIXED address (0⫻10 is recommended).

T0301.EPS

NOTE

A Visitor device will not start until connected to a running segment with an active LAS that can assign a node address to the visitor.

IM 21B04C50-01E

● Configuring the interface card to safely connect to the Foundation fieldbus segment with a host computer

If the YVP positioner is connected on a segment that has a host computer, the interface card and PC must be configured as a BASIC DEVICE at a Visitor address. Open the configuration utility (NI-FBUS Interface Configuration Utility) and follow the instructions in the NI manual.

Select Port and click Edit to bring up the Port dialog shown in Figure 3.2. Set the parameters exactly as shown in the figure, and click OK. (The Device Tag can be set to any name that will be meaningful when seen by a remote interface operating on the same segment.)

WARNING

ValveNavi is the tool for setup and maintenance. Do not connect it to the operating process. That may change the mode of YVP and cause unpredictable stop or events on the process. Use it only when the process is OFFLINE.

3-5

Figure 3.2 NI-FBUS Interface configuration utility setting the card as a Basic Device

IM 21B04C50-01E

● Configure the interface card for one to one Communication

The visitor configuration described previously will not work if the only devices that are connected to the segment are YVP positioner and the NI-FBUS interface card, because there will be no link master to schedule messages. It is necessary, therefore, to configure the interface card as a link master, exactly as shown in Figure 3.3. (The interface name and Device Tag may be any convenient names. The names will not be seen by any other interfaces and are not important.)

3-6

Figure 3.3 Configure the interface as Link Master

3.3.2 Installing the Device Descripfions (DD) with NI-FBUS Interface Configuration Utility

The NI-FBUS Interface Configuration Utility must be used to install the DD for the YVP, and also to install the standard dictionary. If you do not have the DD file, you can download it from our web site. Visit the following web site or contact our subsidiaries.

http://www.yokogawa.com/fld

Step 1 Click [Import DD/CFF] and in the new dialog click [Browse]. Select the

desired .ffo file or .cff file and click [Open]. In the import DD dialog click [OK]

Step 2 Repeat for each device that will communicate with ValveNavi.

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3.3.3 Location of DD files and .DCT file

After the DDs have been successfully installed, they will appear in the installation subdirectory of NI-FBUS. The form of the directory tree will be as shown in Table 3.2.

Tab le 3.2 NI-FBUS Installation Subdirectory Structure

NIFBUS (or other install directory name)

Data

594543 (YOKOGAWA's ID)

0001 (for YVP110 without software download function) 02nn.ffo* 02nn.sym 03nn.ffo 03nn.sym 04nn.ffo 04nn.sym 0007 (for YVP110 with software download function) 01nn.ffo* 01nn.sym 02nn.ffo 02nn.sym 03nn.ffo 03nn.sym XXXX (Other device type)

T0302.EPS

3-7

Note: ‘nn’ stands for two-digit value. The number may be changed by revision up.

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4. ValveNavi ADMINISTRATION

In the previous chapter, we described the installation of the Foundation fieldbus communications software and hardware. In this chapter, we will describe the procedures for installing ValveNavi software.

The ValveNavi installation procedures outlined in this chapter assume a working knowledge of Microsoft Windows, the Yokogawa YVP positioner, and of Foundation fieldbus communications and function block technology. For further information about the YVP positioner, see YVP110 User’s Manual (IM 21B04C01-01E).

4.1 Hardware and Software Requirements

ValveNavi runs on a standard IBM-compatible computer. To successfully install and run ValveNavi, the computer system must meet minimum hardware and software requirements. The following lists the minimum hardware and software requirements:

•Windows 2000 service pack 4, XP service pack 2, or Vista service pack 1 operating system

•Pentium 166 MHz microprocessor or faster

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• CD-ROM drive

• National Instruments NI-FBUS interface card and server software

• 500 MB of free hard disk space to install and run ValveNavi

4.2 Installing ValveNavi

ValveNavi is distributed on a CD-ROM for Windows 2000, Windows XP, or Windows Vista.

1. Insert the ValveNavi installation CD-ROM into the CD-ROM drive.

2. Click Start > Run, then type x:setup (x is the letter of the CD-ROM drive.)

3. Follow the prompts on your screen to complete the installation process.

ValveNavi Administration and ValveNavi Help are also installed along with ValveNavi. After successful installation of ValveNavi software, the system administrator of ValveNavi should change the default logon and password and set up user accounts through the ValveNavi Administration program. Secure the ValveNavi CD-ROM in order to provide system security. Anyone with access to the setup disk could reload the software and thereby get access to YVP devices. For more details, see 4.6.

NOTE

In case of ValveNavi install folder (ex: C¥Program Files¥ValveNavi) is not writable, some functions can not be used.

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4.3 Trial Period

To start up ValveNavi, double-click the ValveNavi icon generated on the desktop.

This will open the Registration screen. Type your name and company name there. ValveNavi can be used for 60 days without entering the serial number after installation on a PC. If you are not a licensed user, leave the serial number box blank, then press OK. The evaluation or trial period for the software is up to 60 days from the first day it is used, and this time process will not be cleared even when uninstalling and reinstalling the software.

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Figure 4.1 Dialog box showing trial limits

Click OK and logon in the ValveNavi Logon dialog (Figure 4.2). See page 4-6 for setting up individual ValveNavi accounts and privileges.

Figure 4.2 Logon dialog

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4.4 Licensed User Process

Permanent use of this software requires a license for each computer on which it will be used. If you purchased a licensed copy of ValveNavi, you will have received a CD-ROM with a serial number. DO NOT LOSE THIS SERIAL NUMBER. KEEP IT IN A SECURE LOCATION.

To start using ValveNavi as a licensed user, in the required information in the Installation dialog (Figure 4.3), including the name of the person responsible for the registered software, the company name and the software serial number, and press OK.

4-3

Figure 4.3 Installation Dialog

Once licensed with proper registration information, this registration dialog will no longer open unless it is opened from the Help menu. Click Help/Installation Info to access the Registration dialog.

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4.5 Logging on with Registration

Once you complete the registration of the software, you will enter from the logon screen as shown in Figure 4.4.

4-4

Figure 4.4 Logon Screen

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4.6 Setting Up User Accounts

4.6.1 System Administration, Passwords, and Privilege Levels

In a plant with many users with various levels of training and responsibility, it is often desirable to restrict certain users access to a limited range of functions. Starting the ValveNavi program requires a valid account with a user name and a password for each user. The privilege level associated with a ValveNavi account determines which functions of the program the user is allowed to access.

The ValveNavi Administration program allows the administrator to perform all user account administrative functions to run ValveNavi and to control access to the functionality of the YVP positioner.

These administrative functions include:

• Adding new user accounts

• Deleting existing user accounts

• Changing existing user accounts

• Adjusting privilege levels

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4.6.2 Start the Administration Program

After installation of ValveNavi, the ValveNavi administrator should change the default passwords, set up the initial user accounts through the Admin program, and secure the setup disk. Anyone with access to the setup disk could reload the software and thereby get access to YVP devices.

To start ValveNavi Admininistration, select Start->Program->ValveNavi->ValveNavi Admininistration. The administrative program prompts you for a logon name and password. Log in for the first time with an administrator account. Enter the default logon name (“Admin”) and leave password blank. (Note: The system is case sensitive, and you must type the default names in correct case.) Then, clicking OK to open the VFAdmin dialog (Figure 4.5).

Figure 4.5 Add Users in VFAdmin dialog

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The program already contains two accounts.

• The first account is the administrator account, which you are using, with the logon name “Admin” (note that this is case sensitive with a capital A) and the initial password is blank (no password). Immediately use the administration program to install a password for administration to make the system secure from unauthorized use.

• The second account enables use of the YVP process controller simulator with the logon name of “training” (lower case) and password of “training” (lower case). The process control simulator will simulate, in software, a process with a dead time of one second and a lag of five seconds. The process controller simulator is useful for training users on the many functions and features of the YVP positioner and its PID function block.

WARNING

Do not logon with a “training” account to use ValveNavi with a valve that is not isolated from the operating process. Control links will be destroyed by using the simulate function.

CAUTION

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It is important that the administrator change the default logon names and passwords for the administrator account and the training account. Continued use of the default logon account names and passwords makes the system less secure.

4.6.3 Privilege Levels

Each user is assigned an account. For each account, there is an associated privilege level. Privilege levels range from 0 to 9, with level 0 the lowest and 9 the highest. The following defines several privilege levels, which control access to specific functions of the ValveNavi program. Services which are not accessible to a particular level are “grayed” out.

Level 0

Allows the user to logon to ValveNavi only if the connected YVP is in Auto. The user can send commands that will reply with configuration, calibration, and status information, but the user cannot change any information. Level 0 users cannot go to Out Of Service or Manual.

Level 1

Allows the user access Auto, Manual or Out Of Service states. The user can transfer from one mode or state to another (i.e. the user can take the YVP out of Auto and put it in Manual). The user can then set valve position. However, the user cannot change the calibration or configuration. The level 1 user cannot access the PID dialog.

Level 2

This level is not defined.

Level 3

Allows the user to change the configuration or calibration values, but does not allow the user to perform calibration and tuning operations that stroke the valve (Find Stops, Autotune or diagnostics).

The user may open the PID dialog and use it to change PID modes and to move the valve in manual or change process variable setpoint. The user can enter tuning parameters for the process variable PID control.

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Level 4

Allows the user to perform all operations except Download Configuration to YVP.

Level 5

This level is not defined.

Level 6

This level is not defined.

Level 7

This level is not defined.

Level 8

This level is intended for training and should be used cautiously. It grants all of the privileges of level 4 plus allows access to the Simulation State of the process controller. (The simulation of the PID Block allows the user to run the process controller without connecting a process variable input to the YVP and is useful for learning how to operate the process controller).

WARNING

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The simulation state must not be used if the valve is connected in a control loop or the if the valve is controlling process flow.

The simulation state will permanently remove important control loop configuration information from the YVP valve positioner. The soft-wired connection between the PID functions block and its input function block must be restored after simulation is used.

Reconfigure function block links after using simulate. The Clear Device command must be used when downloading restored configuration.

Level 9

Allows access to all YVP functions. In addition, it is the only level allowed to logon to the administration program.

The administrator has an account of privilege level 9. There must be at least one user of privilege level 9 in order to get access to the administration program.

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4.7 Finish ValveNavi

To finish ValveNavi, select Exit from File Menu. Clicking Yes to the Confirmation message will finish ValveNavi.

4-8

Figure 4.6 To Finish ValveNavi

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5. FOUNDATION FIELDBUS OVERVIEW

This chapter will introduce concepts that are used in most parts of the manual. It will briefly introduce Foundation Fieldbus blocks, and some of the essential block concepts. Throughout the manual we will reference a simple process example. The example is a simple heat exchanger with two control valves, and three measurement devices. The controls are configured in a cascade arrangement to illustrate concepts of transfer between modes and states of the various levels of control.

5.1 Reference Model Process Used in This User’s Manual

The heat exchanger model is shown in Figure 5.1. It is not a practical process, but incorporates elements that illustrate important features of ValveNavi. Note that each of the devices has a device tag that will be used to identify devices in ValveNavi. The process consists of a vessel with a product vapor inflow, which is condensed, and flows out as a liquid outflow. The tank level is controlled by an outflow control valve, LV 201. The tank contents are chilled by coolant water. The temperature is controlled by a temperature controller cascaded to a flow controller. The coolant flow is controlled by control valve FV

101.

5-1

Figure 5.1 Heat exchanger

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5.1.1 P & I D

Figure 5.2 Piping and Instrumentation Diagram

5-2

The piping and instrument diagram (Figure 5.2) shows, in schematic form, the physical devices and indicates the measurement and control functions that reside in each device. The coolant flow transmitter, FT 102, has only a transmitter function, but the coolant flow control valve, FV 101, has a PID control, two limit switches (DI blocks) and an AO block all located in the YVP valve positioner. The flow of control information between devices is indicated by dashed lines. The DI blocks, ZSL 101 and ZSH 101, serve as low and high stem position limit switches, respectively.

Liquid level is controlled by a remote controller LC201 (to demonstrate Remote Cascade operation). The controller receives the process measurement from level transmitter LT 202. The PID control regulates the valve LV201 (an YVP positioner with an Analog Output Block, and 2 DI function blocks. The DI blocks, ZSL 201 and ZSH 201, serve as low and high stem position limit switches, respectively.

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5.1.2 Function block links

Each of the control functions is represented in the Control configuration as Foundation fieldbus Function Blocks. All the blocks in the temperature cascade are shown in Figure

5.3. They are grouped according to the physical device containing them, and they are shown with the links between the blocks (“soft wiring” connections) for data flow.

Similarly, the level loop function blocks are shown in Figure 5.4.

5-3

Figure 5.3 Temperature Cascade Block Diagram

Figure 5.4 Level loop block diagram

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Finally, to complete the model, ValveNavi is shown, in Figure 5.5, temporarily connected to the heat exchanger’s Foundation fieldbus wiring at an intermediate point. The Heat Exchanger Reference Model segment consists of a Heat Exchanger Host in a control center with a Foundation fieldbus trunk running to two junction boxes. One junction box has spurs to the flow and temperature control devices and the other connects to the devices controlling tank level. A power supply with isolation electronics and two terminators are also shown. The interface cards (NI-FBUS ) used with the ValveNavi computer must be configured so that it will not interfere with the Heat Exchanger Host.

5-4

Figure 5.5 ValveNavi connected as a visitor device

WARNING

Do not connect a ValveNavi PC to an operating segment.

WARNING

Do not cause a short circuit in a working segment while connecting any device.

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5.2 Device Operational States and Block Modes

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Figure 5.6 Device Operation State in Pop-up Menu

The Operation State can be accessed several ways. From the Device Selection frame, right click the desired device to pop up a menu list and select Device Operation State. In the tool bar click the Device Operation State icon. Or choose Tools>Device operation State from the Menu bar.

The Device operation State dialog will then appear offering choice of Out Of Service, Manual and Normal states.

Figure 5.7 Device Operation State Dialog

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ValveNavi manages the operational states of the positioner and its embedded PID controller by controlling the target modes for each of the function blocks. The actual mode of each block may be different from the target mode. The actual mode is controlled by the block itself in accordance with mode rules based on the quality of the data and modes of the linked blocks. A brief summary of modes follows, but a thorough discussion of modes is beyond the scope of this instruction. The interested reader is referred to the Fieldbus Foundation that specifies the formal rules for mode changing.

Three operational states are set by ValveNavi (Figure 5.6 and Figure 5.7). The Out Of Service (OOS) state forces all of the blocks to Out Of Service Mode. The outputs remain at the values prior to the state change. All output calculation is suspended. Back calculation values are passed to other linked blocks to enable initialization. Note that the PID will remain in OOS after configuration changes unless it is put into one of its allowed modes from the PID dialog. The PID dialog can be started from the Device Operation Dialog.

Tab le 5.1 Allowed Block Modes For Three Operational States

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Operational state

Out of Service (OOS)

Manual operating state

Normal Operating state

Note: Italics indicate a permitted actual mode but a dis-allowed target mode.

Bold type indicates a target mode.

PID

OOS

IMan

Man

Auto

CAS

RCAS

OOS

Iman

RCas

IMan

Man

Auto

Cas

Function Block and Block Modes

1 or more block is in OOS

OOS

Man

Auto

CAS

RCas

Man Auto Auto

Each block must be one of the modes below

Auto

Cas

RCas

TB(Auto)

OOS

Auto

Auto Auto

RB(Auto)

OOS

Auto

T0501.EPS

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5.3 Block Modes

All blocks (function/transducer/resource) have operating modes. There are eight modes defined in the Foundation fieldbus specification. Not all modes are supported by every block. For example, the Discrete Input (DI) block supports just Auto, Man, and OOS. The action of the modes are described in the following paragraphs. Transfers between modes are managed by the function blocks in response to manual commands, in response to changes in the modes of linked blocks, and in response to changes in the quality of the parameters that are transmitted. Control and status options can be set to manage mode changing behavior.

(1) Remote-Output (Rout)

The block output is being set by a Control Application running on an interface Device through the remote-output-in parameter. The algorithm is bypassed and the remote block controls its output directly. The algorithm must initialize so no bump is experienced when the mode switches to auto. A remote-output-out parameter is maintained by the block to support initialization of the control application when the block mode is not remote-output. The setpoint may be maintained or, optionally, be initialized to the process variable value.

(2) Remote-Cascade (RCas)

The block setpoint is being set by a Control Application running on an interface device through the remote-cascade in parameter. Based on this setpoint, the normal block algorithm determines the primary output value. A remote-cascade out parameter is maintained by the block to support initialization of the control application when the block mode is not remote-cascade.

5-7

(3) Cascade (Cas)

A setpoint value supplied by another function block through the Cascade input parameter is used by the normal block algorithm in determining the primary output value. This connection between function blocks is defined by a link object.

(4) Automatic (Auto)

A local setpoint value is used by the normal block algorithm in determining the primary output value. The local setpoint value may be written by an operator through an interface device.

(5) Manual (Man)

The block output is not being calculated, although it may be limited. It is directly set by the operator through an interface device. The algorithm must initialize so no bump is experienced when the mode switches. The setpoint may be maintained or, optionally, be initialized to the process variable parameter value or to the setpoint value associated with the previous (retained) target mode.

(6) Local Override (LO)

Applies to control and output blocks that support a track input parameter. In the local override mode, the block output is being set to track the value of the track input parameter. The algorithm must initialize so no bump is experienced when the mode switches from LO back to the target mode. The setpoint may be maintained or, optionally, be initialized to the process variable parameter value.

(7) Initialization Manual (IMan)

The block output is being set in response to the back-calculation input parameter status. When the status indicates there is no path to the final output element, then the control blocks must initialize to provide for bumpless transfer when the condition clears. A backcalculation out parameter is supported by all output and control class function blocks. The setpoint may be maintained or, optionally, initialized to the process variable parameter value.

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(8) Out of Service (OOS)

The block is not being evaluated. The output and setpoint are maintained at last value.

(9) Multiple Modes and States

The AO block must go to CAS mode to connect to a PID function block in cascade. To stop the setpoint signal from the AO to the transducer block, the AO block must go into OOS mode.

The following, Table 5.2, shows examples of mode operation (not showing all cases).

Tab le 5.2 Mode operation

5-8

Operation

Configure the transducer block (Auto tuning, travel calibration, diagnostics, etc.)

Configure transducer block

(Changing position control parameters, etc.)

Manual valve positioning from ValveNavi or other human interface.

Manual valve positioning from a PID controller human interface

PID single loop control

PID cascade loop control

(AI) AO TB

Auto

PID

Manual

Auto

primary :Auto

secondary :CAS

OOS

Man

CAS

Cas

OOS

Auto

T0502.EPS

When a block is in OOS mode, its output status will be “bad,” so that any connected blocks will know and automatically change their modes. For example, when a PID block sees bad status in its BKCAL IN, it will go to IMAN mode for initialization to the downstream block while awaiting the status to return to “good cascade. ”

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5.4 Examples of IVI Operational States

Examples of operational states that are combinations of block modes are shown in the following figures.

A new device or a newly configured device may start up in the out of service (OOS) state shown in Figure 5.8.

5-9

Figure 5.8 Out of service at startup

To transfer to the manual state which allows ValveNavi to adjust the valve position, click the Operating State icon and select Manual. Enter a setpoint in the Set Point text box (Figure

5.9) then click OK, or drag the Set Point slider to the desire value. If the positioner is configured with a non-linear (such as =%) characteristic, the Target Position will be computed from the setpoint but may differ in value. The configuration options of Tight Shutoff Below, Full Open Above, as well as high and low position limits will be applied to the Set Point to arrive at the correct Target Position.

Figure 5.9 Manual State

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When the positioner has been placed in normal, it waits for the PID block to begin to send it a setpoint. It will remain in auto mode at the current valve position. When this condition exists, it is necessary to place the PID block in its normal mode.

5-10

Figure 5.10 Normal State Waiting For internal Controller block

When the process control PID is located within the positioner and when the PID receives its setpoint from a Foundation fieldbus function block, the normal state will be as shown in Figure 5.11. Both the PID and AO blocks are in Cas mode.

Figure 5.11 IVI Showing Cascade Normal State

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When the positioner is receiving its position setpoint from a remote computer system such as a DCS then the normal state for the positioner will be as shown in Figure 5.12. In this example the level control valve LV201 is receiving its signal from a DCS. The AO block is shown in RCas mode.

Figure 5.12 Remote Cascade Normal State

5-11

If an internal PID is used in a cascade where the PID receives a setpoint from a remote computer system, then the normal state will have the PID in RCas mode and the AO will be in Cas mode (not shown).

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5.5 Changing Operational States

The Foundation fieldbus Application process specifies the mode handling for interoperable function blocks. It also specifies which mode a block must be in when each parameter is written. ValveNavi provides an intelligent, optimized process for managing configuration and calibration changes. For efficiency, it does not place blocks into Out Of Service mode unless the parameter requires OOS. It analyzes the requested changes and then sets the correct mode for each affected function block. The actual block modes are displayed in the IVI.

The Foundation fieldbus specifies a mechanism for transferring between function block modes. The user declares a target for the block mode, but the actual mode is set by the block in accordance with rules. The rules allow modes based on the quality of input data and quality of the connection to the process. YVP function blocks comply with the FF rules. ValveNavi sets target modes for individual function blocks as required by configuration, calibration, diagnostics and other services. It sets target modes for group of function blocks to achieve three operational states of the positioner: Out of Service, Manual, and Normal.

(1) Changing Target Operational State

When a configuration or other process requires any of the affected function blocks to go into OOS mode, ValveNavi opens a Warning dialog as shown in Figure 5.13

5-12

Figure 5.13 Out Of Service State Change Warning

(2) Changing to Auto from OOS

In OOS, the YVP can be switched to Auto in order to return the device to the previous Auto state by clicking on Auto. In the event the user has selected “bumpless transfer” the device will execute the bumpless transfer routine.

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6. QUICK TOUR OF ValveNavi

In the quick tour we will briefly introduce each of the tools provided by ValveNavi. The chapters that describe the tools in details follow the quick tour.

6.1 Introduction

ValveNavi uses an integrated valve interface, IVI, to display all valve and positioner variables and to provide access to services, such as configuration and calibration tools. The information and controls for services are arranged in frames within IVI. From the IVI the user has single click access to the PID Controller interface. IVI displays and updates real time values for valve position, valve setpoint and actuator pressure numerically and graphically.

Data objects are grouped in “frames” within the IVI display as described below.

6-1

Figure 6.1 Integrated Valve Interface (IVI)

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6.2 Fieldbus Device Tree

All of the devices on the bus segment live list are shown as icons in the Device Selection box.

Figure 6.2 Device Tree

Click on the YVP device to open a communications session with the positioner. The fieldbus segment live list is continuously scanned and devices are shown when present. Devices that have communications failure are shown with a red X. The selected device is shown with a red check-mark.

6-2

When a device is selected, a warning dialog informs that an attempt is made to connect to a new device. Then the Read configuration dialog displays progress uploading device data.

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6.3 Menu Bar and Tool Bar

The IVI offers tools and wizards using standard Windows conventions, offering multiple paths to functions to suit a user’s preferences. Use the menu bar, the tool bar icons, or popup menus in the Device Selection frame. When the cursor is moved over an icon a Tool Tip appears to identify the icon’s purpose.

6.3.1 Menu items

Pull down menus are listed below and shown in Figure 6.3.

Figure 6.3 Menu and tool bars

• File

• Setup

•View

•Tools

6-3

• Help

Help use Web Browser technology to provide flexible access to help for all ValveNavi windows. It is good practice to open help.

6.3.2 Toolbar icons

Toolbar services are listed in Table 6.1. An icon may be “grayed out” to indicate that its function is disabled.

Tab le 6.1 Toolbar Icons

Open configuration file

Save Configuration file

Download configuration

Generate a report file

Diagnostics

Change device operation state

Query device

View Trend

Setup Wizard

Configuration management

Calibration management

PID Process controller

Rescan the field bus segment

About ValveNavi version

T6.1.EPS

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6.4 Control Valve Faceplate

The control valve faceplate frame encloses displays and controls for working with the positioner.

6-4

Figure 6.4 IVI Positioner Faceplate Frame

Figure 6.4 shows an example of the control valve faceplate frame in the IVI. The positioner’s tag is shown in the PD-Tag field. The current operating state of the positioner is shown in the Operation control button displaying, in this example, “NORMAL STATE.” Individual block modes are displayed for each of the positioners internal function blocks. The valve position Set Point is displayed by the graphical position of a slider control and numerically to two decimal places. Below the setpoint display, the target position and actual position are shown as a slider and bar respectively, with values shown to two decimal places.

The Target Position is derived from the Set Point signal based on the parameters defined in Configuration Services, on the valve characterization and on the configuration of air-toopen or air-to-close. It is further modified by any limits that may be configured.

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6.5 Companion Device Display Frame

This Companion Device frame displays and updates real time values for transducer block mode, target position, and valve position. It is used to observe summary information from a second positioner connected in the same segment as the selected device.

Figure 6.5 IVI Companion Device Frame

6-5

6.6 Status Frame

Below the position bar display, the Status Frame displays Analog Output (AO) block and PID block Scheduling status. In addition, the transducer block error (XD ERROR) is displayed. The communication error text box accumulates error messages that can be copied to a text file for analysis.

To clear the error text box, click View>Clear Comm Error Display.

Figure 6.6 Status frame

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6.7 Accessing Services in ValveNavi

Services in ValveNavi are accessed by three methods that are standard Windows techniques.

• By the Tools menu, after a device has been selected and opened, or

6-6

• By the toolbar icon, after a device has been selected and opened, or

•From the Device tree with a popup menu, by right clicking on the desired device.

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6.8 Setup Wizard

This setup wizard provides, in a single tool, all the services for setting up a basic positioner. It includes a sequence for basic configuration and basic tuning. It is most useful for first time setup of the positioner. Follow the step-by-step instructions to quickly complete the basic setup and start running the valve.

6-7

Figure 6.7 Setup wizard

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6.8.1 Actuator Wizard

This is the setup page in the setup wizard to configure the valve actuator information contained in Transducer (TB) block. For a description of the parameters, refer to Actuator in the Configuration window.

6-8

Figure 6.8 Actuator Wizard

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6.8.2 Tuning Wizard

This tuning step in wizard allows the user to execute the combination of Search Stops and Auto Tune described in Tuning in Calibration.

WARNING

Tuning will stroke the valve over its entire travel. Isolate the valve from the process prior to the calibration.

6-9

Figure 6.9 Tuning Wizard

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6.8.3 Travel Calibration Wizard

This travel calibration page in the setup wizard allows the user to calibrate the 0%, 50%, or 100% position points, when necessary. For a description of all the parameters and controls, refer to Travel calibration.

6-10

Figure 6.10 Travel Calibration Wizard

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6.8.4 Position Control Limits - Wizard

This position control limits page in the setup wizard allows the user to change the position limit setting for the valve position configuration parameters in TB block. For a description of all the parameters, refer to Position in Configuration window.

6-11

Figure 6.11 Position Control Limits Wizard

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6.8.5 Finish - Setup Wizard

This is the final screen of the Setup Wizard that indicates that the basic setup is valid and that provides a choice of Device Operation State before completing this setup. The Wizard is not completed until the Finish button is pressed.

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Figure 6.12 Setup Wizard Finished

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6.9 Configuration Services

This page of the general configuration of the device includes Device Info, Block Tag Info, and device installation options.

Figure 6.13 Configuration - General

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6.10 Calibration Services

The calibration page has a tab for adjusting the positioner to the actual stroke (range) of the valve, and for autotuning the position control algorithm. It also has a travel calibration service that provides for making further adjustments to the valve stroke. The advanced tab provides access to non-linear factors used to optimize dynamic performance.

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Figure 6.14 Calibration with Range, Tuning, Travel, and Advanced Tabs

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6.11 Diagnostic Services

The diagnostic page provides controls to perform the actuator and positioner signature test procedures. It also displays the continuous diagnostic data that is an accumulation of valve service.

6-15

Figure 6.15 General Tab of Diagnostics

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6.12 Operation State

The Operation State Dialog controls switching between the block modes. Three types of the state of operation are offered, and modes of each function block are set according to the selected state.

6-16

Figure 6.16 Operation State

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6.13 Device Query

The General page in Query Device provides access to device data in predefined categories. Simply select the category name from the drop down list box, then press Read to get all the parameter values in the category. For each device, there is a query window available and it is possible to open multiple query windows for multiple positioner devices at the same time. The query window can be run while accessing other windows.

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Figure 6.17 Query Device

The two tabs in the Device Query offer quick access to read parameters stored in the YVP. The general tab accesses general data while the Block Parameters present all parameters in each function plock.

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6.14 PID Control Dialog

The PID Process Controller dialog contains the tools for managing the PID function block. It is composed of frames that group controls and displays. The PID State frame displays and controls the PID states (block modes), the setpoint and process variable, and the Device tagname. In Manual State (M), drag the PID output slider to move the valve. In Local State (L), drag the Setpoint Slider (or enter a value in the Setpoint text box) to change the process variable setpoint. In Cascade (C), and in Remote cascade (R), the setpoint is controlled by a function block or remote application.

6-18

Figure 6.18 PID Process Controller Dialog

Figure 6.19 Change Tuning Parameters Dialog

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6.15 Rescan

Clicking Rescan button or selecting Tools >Re-scan Devices will refresh connections to all working devices on the fieldbus segment. It will close the opened device you will lose control until you have reselected a device. You will be prompted to confirm that a rescan is acceptable.

Figure 6.20 Rescan Dialog

6.16 About

Clicking the About icon or selecting Help>About ValveNavi will display the version of ValveNavi and the copyright notice.

6-19

Figure 6.21 About ValveNavi

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6.17 Online Help

ValveNavi uses Web based technology for its online help. Click on Help>Help Topics to start your normal browser (Internet Explorer or Netscape navigator).

6-20

Figure 6.22 Online Help

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7. INTEGRATED VALVE INTERFACE (IVI)

The main application screen of ValveNavi is the Integrated Valve Interface (IVI) that is displayed after a successful logon (ValveNavi Logon). It monitors the operation state and status of the valve. It provides access to all other services.

7-1

Figure 7.1 IVI

ValveNavi operation begins with the Integrated Valve Interface, IVI. The IVI is a window with a menu bar, a toolbar, a status bar, and frames containing displays and controls for fieldbus data objects. Each of the data objects relates to Foundation fieldbus parameters. The menu and tool bars provide access to services to work with files, devices and blocks. The status bar shows status of the fieldbus segment. The frames are used to group the device list tree, positioner data, Analog Output (AO) Block, and PID scheduling status, and block modes, as well as device tag.

IVI displays all valve and positioner variables and provides access to services such as Setup Wizard, Configuration, Calibration, and Diagnostics tools. The information and controls for services are logically arranged in frames within IVI. From the IVI the user has single click access to the PID Controller interface. IVI displays and updates real time values for valve position, valve setpoint, and actuator pressure, etc.

The IVI offers tools and wizards using standard Windows conventions, offering multiple paths to functions to suit a user’s preferences. When the cursor is moved over an icon, a Tool Tip appears to identify the icon’s purpose.

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Menu items

Menu bar contains File, Setup, View, Tools, and Help menus.

Toolbar icons

Toolbar services are listed below, in the order of the icons shown on the Toolbar. While a function is disabled its icon is “grayed out.”

Tab le 7.1 Toolbar Icons

7-2

Open configuration file

Save Configuration file

Download configuration

Generate a report file

Setup Wizard

Configuration management

Calibration management

Diagnostics

Change device operation state

Query device

View Trend

PID Process controller

Rescan the field bus segment

About ValveNavi version

T0701.EPS

The positioner’s tag is shown in the PD Tag field. The current operating state of the positioner is shown the text box. Individual block modes are displaye for each of the positioners internal function blocks. The valve position Set Point is displayed by the graphical position of a slider and numerically to two decimal places. Below the setpoint display, the target position and actual position are shown as a slider and bar respectively, with values shown to two decimal places.

The Target Position is derived from the Set Point signal based on the parameters defined in Configuration Services, as well as the characterization and the configuration of air-to-open or air-to-close. If linear characteristics and air-to-open are configured, without limits, the position setpoint is equal to input signal expressed in percentage. When the configuration is nonlinear with limits, the incoming setpoint and the target position differ because the Analog Output (AO) Block and Transducer (TB) Block re-compute the target to conform.

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7.1 Device Selection

All of the devices on the bus segment live list are shown as icons in the Device Selection box. Click on any device to open a communications session with the positioner. The fieldbus segment live list is continuously scanned, and devices are shown when present. Devices that have communications failure are shown with a red X. The selected device is shown with a red checkmark.

When a device is selected, a warning dialog informs that an attempt is made to connect to a new device. Then the Read configuration dialog displays progress uploading device data.

7-3

Figure 7.2 Device Selection

If the device has Link Master capability, the device will shown with the letter ‘LM’. When the device is set as a basic device, the letter LM will shown in red. When the device is set as a Link Master device, the letter LM will shown in Blue.

NOTE

If the AO block is not scheduled, the confirmation dialog is displayed when the IVI display is started to ask whether or not to automatically schedule it with the Offset time to 0 second. Click Yes to automatically schedule it.

Figure 7.3 AO Block Scheduling Dialog

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7.1.1 The Pop-Up Menu In Device Selection

The pop-up menu in device selection offers quick access to services.

7-4

Figure 7.4 Device Tree Popup

CAUTION

Do not change Device Tag or Node Address while NI Configurator or other host software with automatic address assigning function is running. All function block linkages will be cleared. These network parameters should be changed only when configuring a positioner independently.

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7.1.2 Setting Device as LM or Basic Device

This feature is available only when the opened device has the Link Master(LM) capability.

WARNING

The procedures will reboot the device. Check that the device is isolated from the operating process.

7-5

Figure 7.5 Change to Basic Device

Clicking Yes will set device as Link Master or Basic device. This procedure will set the NMIB parameter BootOperatFunctionalClass to LM or Basic first, then restart the device processor.

After the operation successes, the color of the letter ‘LM’ on the device icon on the device list will change.

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7.2 Control Valve Faceplate

7.2.1 Selected Device

The Selected Device Frame provides a dedicated view for the selected device which includes device tag and operation state, blocks actual mode, valve position and setpoint, other status, and other parameters bar graph. It encloses displays and controls for working with the positioner and control valve.

7-6

Figure 7.6 Control Valve Faceplate with =% Characteristic

Figure 7.6 shows an example of the control valve faceplate frame in the IVI. The positioner’s tag is shown in the PD-Tag field. The current operating state of the positioner is shown in the Operation control button displaying. Individual block modes are displayed for each of the positioners internal function blocks. The valve position Set Point is displayed by the graphical position of a slider control and numerically to two decimal places. Below the setpoint display, the target position and actual position are shown as a pointer and bar respectively, with values shown to two decimal places.

The Target Position is derived from the Set Point signal based on the calibration parameters defined in Calibrate, on the valve characterization and on the configuration of air-to-open or air-to-close as defined in Configure. It is further modified by any limits that may be configured.

Each of the parameters displayed in the control faceplate dialog has a function block and parameter name (shown in the form of BLOCK.PARAMETER). These are listed in Table

7.1.

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Tab le 7.1 IVI Faceplate Parameters

7-7

Display parameter

PD-Tag

Operational State

Setpoint Signal

Target Position

Valve Position

Temperature

Pressure

I/P

Block modes

Display type

Active control

Slider and XX.XX%

Bar and XX.XX%

Bar and XX deg

Bar and XX.XX Psi

Bar and XX.XX%

Color coded Individual boxes

Parameter name

[PD.TAG]

Device Operation State may be one of the following: NORMAL (Automatic) MANUAL Out Of Service If no physical device is selected, it displays OFFLINE as the operation state.

[AO.OUT]

TB.FINAL_VALUE

TB.FINAL_POSITION_VALUE

TB.ELECT_TEMP

TB.OUT_PRESSURE

TB.SERVO_OUTPUT_SIGNAL

Block.MODE BLK Block = RB, TB, AO, DI, or PID

Remarks

This indicates the YVP’s tag.

A right clicking on this display can change the operation status.

Desired valve position before application of characterization and limits

Desired valve position as derived by the FF input value into the YVP.

This indicates valve stem or shaft position in percent of ranged travel.

Device environmental temperature [-40, 85] Deg C or [-40, 185] Deg F Color: Yellow

YVP output pressure for a Single Acting actuator or output pressure of out1 for a Double Acting actuator. Blue color. Scale = TB.SUPPLY_PRESSURE

Yellow: [0 to 20] % Green: [20 to 80] % Red: [80 to 100] %

AUTO,CAS: Black MAN: Yellow OOS: Red

T0701.EPS

7.2.2 Block Actual Mode

The following table lists the supported modes of the valve positioner for each block.

Tab le 7.2 Block Modes

Block Supported Modes

Resource Auto, O/S

Tr ansducer Auto, O/S

AO RCas, Cas, Auto, Man, (LO), (IMAN), O/S

DI Auto, Man, O/S

OS Cas, Auto, (IMan), O/S

PID ROut, RCas, Cas, Auto, Man, (LO), (IMAN), O/S

7.2.3 Position

This frame displays the valve position setpoint with the slider and a bargraph. The corresponding target position is displayed with a slider. The actual position is displayed with a bargraph.

7.2.4 Other Status

It displays Analog Output (AO) and PID block schedule status, transducer (XD) Error description, and communication error.

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7.2.5 Temperature, Pressure, and I/P Graphs

Internal temperature, output pressure (optional code/BP) and servo output to I/P module are displayed as bargraphs.

Click View > (Bar Name) to toggle the bar on or off.

7.3 Companion Device

The Companion Device frame provides a view of a device which is a companion to the selected device, such as a valve related to the selected valve. To select a companion device, there must be a focus device selected and viewed in the Selected Device frame. Pull down the View menu or right click a non-selected device to access the Select/Deselect as Companion dialog. Currently, the companion device is limited to the YVP.

7-8

Figure 7.7 Companion Device

● Tag

The physical device tag of the selected companion device.

● TB Mode

The actual mode of TB Block of the selected companion device.

● Target Position

The target valve position of the selected companion device.

● Actual Position

The actual valve position of the selected companion device.

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8. SETUP WIZARD

To install and configure a YVP positioner the Setup Wizard is recommended. It combines basic calibration and tuning functions in a single sequence.

8.1 Introduction to Setup Wizard

8-1

Figure 8.1 Setup Wizard

This setup wizard provides, in a single tool, all the services for setting up a basic valve positioner. It includes a sequence of wizards for basic configuration and basic tuning. It is most useful for first-time setup of the positioner. Follow the step-by-step instructions in five dialogs to complete the basic setup and to start running the valve.

Click Next to begin the setup with the Acuator Wizard.

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8.2 Actuator Wizard

8-2

Figure 8.2 Actuator Wizard

In the actuator setup menu select the valve action, actuator type, relay type, and valve type.

Then, click Next to begin calibration and tuning.

NOTE

If “linear” is incorrectly selected (when the valve is rotary), there will be large angle span error message. To correct this, you must use the Configuration Services- Actuator dialog followed by the Calibration Services- Tuning dialog.

NOTE

Supply pressure must not exceed the Actuator pressure rating marked on the actuator. Positioner supply pressure should be at least 35 kPa higher than the upper spring range of the valve.

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8.3 Tuning Wizard

The positioner will automatically search for the mechanical valve travel limits and tune the valve position PID control algorithm. Click Go to begin. This will take several minutes to complete and will stroke the valve.

If this is not a first time setup of the valve, you may skip this step by clicking the Skip button.

WARNING

Before beginning the Auto or Manual range calibration, confirm that the valve is isolated from the process. This procedure exhausts and then fills the valve actuator to supply pressure and therefore strokes the valve over its full range.

8-3

Figure 8.3 Tuning Wizard

The air supply to the valve must be on and set to the correct pressure.

WARNING

Isolate the valve from the process and keep clear of moving parts before using Limit Searching or Autotune.”

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If Limit Searching and Auto Tuning is performed successfully, a tuning result dialog will be shown for user’s confirmation.

If Accept is clicked, the new servo parameters will apply to the system. Otherwise, the original servo parameters will be restored to the device.

Double acting specific parameters are applicable only for double acting actuator type.

Figure 8.4 Tuning Result

When the mechanical limits have been found and the tuning is complete, the result is displayed (Figure 8.5).

8-4

Figure 8.5 Tuning Wizard Succeeded or Failed

If the self calibration and autotuning procedures are unsuccessful, there will be messages shown as in Figure 8.6

Figure 8.6 Tuning Wizard Error/Warning Messages

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8.4 Travel Calibration Wizard

The mechanical stops on some actuators may allow the valve to move beyond its rated travel. The next wizard allows adjustment of the valve travel to correspond to the travel indicator on the actuator. In the example shown the valve has been moved to 100% travel mark on the actuator by trial and error. The YVP positioner indicates that the position corresponding to 100% rated travel is 93.5% of the measured mechanical travel. If this is correct, select the span calibration and click Apply Calibration. Click yes to the confirmation dialog “Are you sure you want to apply travel calibration?” The same method can also be used to adjust the 0% position to correspond to the valve’s actual closed position. It may also be used to correct non-linear travel by adjusting the position at which the valve is 50% open.

8-5

Figure 8.7 Travel Calibration Wizard

NOTE

Before running the Travel Calibration Wizard, check that the Tight shut Off and Full Open Features, and the Position Limits are disabled. Click next to see the Position Control limits Wizard (Figure 8.7), then click Back to return to Travel Calibration. If it is necessary to make changes, click next to Finish the Wizard and install the changes. Then, restart the Setup Wizard.

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8.5 Position Control limits Wizard

Click next to move to the Position Control Limits Wizard. If it is decided to limit the travel, set the appropriate values here. These values will alter the valve performance. Use them with caution.

The values shown in Figure 8.8 are the initial values to use if there are no special requirements. The parameters are defined below.

8-6

Figure 8.8 Position Control Limits Wizard

● Position Limit

Tight Shutoff Below

If the valve position setpoint is less than this value, the valve is forced to fully close. A value of -10 removes this function from the normal travel range. Set this between 1 and 3 to minimize seat leakage. There is a dead band.

NOTE

When Tight Shutoff below is configured to a positive value, small flows will not be controllable.

Full Open Above

If the valve position setpoint is more than this value, the valve is forced to fully open. A value of 110 removes this function from the normal travel range.

Position Lower Limit

The valve position setpoint may not be less than this value. This will prevent the valve from closing. Use only when required by the control strategy. A value of -10 removes this function from the normal travel range.

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Position Upper Limit

The valve position setpoint may not exceed this value. This will prevent the valve from closing. A value of 110 removes this function from the normal travel range.

“Near Closed” Value

The threshold below which the valve is considered “near closed.” “Near Close” term is useful for estimating when to change the valve trim. This value does not affect valve travel, and it is used only for reporting the time that valve is near the seat.

Set this between Position Lower Limit and Position Upper Limit.

● Limit Switch Threshold

The Limit switch thresholds apply to the DI block setpoints.

Threshold Low

The threshold for the low limit switch that communicated by the DI block.

Threshold High

The threshold for the high limit switch that communicated by the DI block.

● Fault Control

8-7

Error Band

The position deviation limit to start deviation timer of Time 1 and Time 2.

Time 1

The position deviation time limit to show the block alarm. A negative value turns off this function.

Time 2

The position deviation time limit to trigger the failsafe action. Enter “-1” to disable this function. A negative value turns off this function. Use of the Time 2 failsafe may result in unwanted process shutdowns.

● Servo Alarms (I/P Module Operating Point Fault Control)

This function is applicable only to the device revision 4 or higher (or the device revision 2 or higher when the software download functions are available).

Figure 8.9 Servo Alarms Setting

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Servo Warning High

If the operating point of the I/P module is more than this value, the timer that measures the time after the I/P module operating point error starts.

Servo Warning Low

If the operating point of the I/P module is less than this value, the timer that measures the time after the I/P module operating point error starts. Input a value that is less than that for Servo Warning High.

Servo Time (duration)

If the duration in which the I/P module operating point is out of the range from Servo Warning Low to Servo Warning High reaches this set time, block alarm “Servo output drift warning” is generated. If the duration in which the I/P module operating point is less than 10% or more than 90% of the range reaches this set value, block alarm “Severe servo output drift” is generated. A negative value turns off these I/P module operating point warning detection functions.

Servo Warning Count

Number of times of generation of block alarm “Servo output drift warning.”

To reset servo warning count to zero can be performed from General tab of Diagnostics.

8-8

8.6 Finish-Setup Wizard

Figure 8.10 Setup Wizard Finished

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9. CONFIGURATION SERVICES

Configuration services provide the tools to read and/or set parameters required for successful communications and control. Each set of tools is grouped in a page with a tab.

CAUTION

Do not turn off power for 60 seconds after writing configuration data. Data may not be saved. See positioner instruction manual.

9.1 Configuration - General

This page of the general configuration of the device includes Device Info, Block Tag Info and device installation options.

9-1

Figure9.1 Configure General

WARNING

Do not change Device Tag or Node Address while NI Configurator or other host software is running. These network parameters should be changed only when configuring a positioner connected to a segment that is not controlling a process.

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9.1.1 Device Info

● Tag

The physical device tag (PD-Tag). The device tag is defined in Foundation fieldbus as a string of maximum 32 characters. Make sure the tag is unique in the entire control network. When a device is selected, this field is grayed out for read only. Therefore, the access to the device tag change is handled in Main Screen (IVI) by selecting the Setup menu or by right clicking the device icon in Device Selection.

● Node Address

The node address is the address of the physical device on the fieldbus segment. The device address is defined in Foundation Fieldbus as a value between 1 and 255. Make sure the address is unique in the segment. When a device is selected, this field is grayed out for read only. Therefore, the access to the device address change is handled in Main Screen (IVI) by selecting the Tools menu or by right clicking the device icon in Device Selection.

● Device ID

The device ID number consists of manufacturer id number, device number, and device model related number. It is unique in all the devices among manufacturers and read only.

9-2

● Manufacturer ID

The 6 digits number of the device manufacturer ID is assigned by the Fieldbus Foundation and is read-only.

● Device Type

The type of the device is read only.

● Device Rev.

The revision of the device is read only.

● D. D. Rev.

The revision of the Device Description is read only.

● Model

The model of the device is read only.

● Descriptor

User may use this field for a description of the device or for memo.

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9.1.2 Block Tag Info

Each block is assigned a default tag-name that should be renamed by the user.

● RB

The tag of the resource block.

● TB

The tag of the transducer block.

● AO

The tag of the analog output block.

● DI1

The tag of the discrete input 1 block.

● DI2

The tag of the discrete input 2 block.

9-3

● PID

The tag of the PID block.

● SPLT

The tag of the output splitter block.

9.1.3 Others Installed

● PID Block

Checked when the device PID block is activated. Read only.

● Pressure Sensor

Checked when the device pressure sensor is installed. Read only.

● Link Master

Checked when the device link master function is equipped. Read only.

● Signature

Checked when the device signature option (/BP) is installed. Read only.

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9.2 Configuration - Position

This is the setup page for the valve position configuration parameters in Transducer (TB) block.

9.2.1 Servo Parameters

The servo parameters are normally set by autotuning in Tuning of Calibration. They determine dynamic response of the valve position control.

9-4

Figure 9.2 Configure Position

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9.2.2 Position Limit

The Position Limits frame provides parameters that allow you to limit the valve, to force the valve to close tightly or open fully at specified positions, to set the trip points of the limit switches (DI Block). You can also activate a warning when a deviation lasts longer than the Time 1 or to force the valve to its failsafe position if the deviation lasts longer that time 2.

Since there is a dead zone of 1%, Tight Shut Off is disabled if the valve position setpoint is 1% more than this value.

WARNING

Position Limit parameters are powerful tools to alter the valve performance to be non-linear. Use them with caution and only when the process requires special performance

● Tight Shutoff Below

If the valve target position is less than this value, the valve is forced to fully close. A value of

-10 removes this function from the normal travel range, unless the calibration of valve travel has been adjusted. Set this between 1 and 3 to minimize seat leakage. There is a dead band.

Since there is a dead zone of 1%, Full Open Above is disabled if the valve position setpoint is 1% less than this value.

9-5

CAUTION

When Tight Shutoff below is configured to a positive value, small flows will not be controllable.

● Full Open Above

If the valve target position is more than this value, the valve is forced to fully open. A value of 110 removes this function from the normal travel range.

WARNING

Use of Full Open Above at values less than 110 may result in rapid increase in flow rate if input reaches this value. Use with extreme caution.

● Position Lower Limit

The valve target position may not be less than this value. This will prevent the valve from closing. Use only when required by the control strategy. A value of -10 removes this function from the normal travel range.

● Position Upper Limit

The valve target position may not exceed this value. This will prevent the valve from closing. A value of 110 removes this function from the normal travel range.

● “Near Closed” Value

The threshold below which the valve is considered “near closed.” “Near Close” term is useful for estimating when to change the valve trim. This value does not affect valve travel. It is used only for reporting the time that valve is near the seat.

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9.2.3 Limit Switch Threshold

The Limit switch thresholds apply to the Discrete Input (DI) block setpoints.

● Threshold Low

The threshold for the low limit switch that communicated by the DI block.

● Threshold High

The threshold for the high limit switch that communicated by the DI block.

9.2.4 Fault Control

● Error Band

The position deviation limit to start deviation timer of Time 1 and Time 2.

Set this value to a value that is exceeded only in abnormal performance.

● Time 1

9-6

The position deviation time limit to show the block alarm. A negative value turns off this function. Set this value greater than the stroking time.

● Time 2

WARNING

Use the Time 2 failsafe only for a critical process that must be forced into its failsafe position if the valve is unable to respond to its position setpoint after a reasonable time delay. Do not set the error band to a value that is too small. If Time 2 is used, it must be longer than the valve stroking time. A Time 2 value that is too small will result in nuisance failsafe behavior.

9.2.5 Servo Alarms (I/P Module Operating Point Fault Control)

This function is applicable only to the device revision 4 or higher (or the device revision 2 or higher when the software download functions are available).

● Servo Warning High

If the operating point of the I/P module is more than this value, the timer that measures the time after the I/P module operating point error starts.

● Servo Warning Low

If the operating point of the I/P module is less than this value, the timer that measures the time after the I/P module operating point error starts. Input a value that is the same as or less than that for Servo Warning High.

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● Servo Time (duration)

If the duration in which the I/P module operating point is out of the range from Servo Warning Low to Servo Warning High reaches this set time, block alarm “Servo output drift warning” is generated. If the duration in which the I/P module operating point is less than 10% or more than 90% reaches this set value, block alarm “Severe servo output drift” is generated. A negative value turns off these I/P module operating point warning detection functions.

● Servo Warning Count

Number of times of generation of block alarm “Servo output drift warning.”

To reset servo warning count to zero can be performed from General tab of Diagnostics.

9.2.6 Advanced

Refer to Advanced Position.

9.2.7 Configuration - Advanced Position

This is the page for advanced position control parameters configuration contained in Tr ansducer (TB) block. It is intended for technician use only. It lists here as read only. To modify the value of any parameter, go to Calibrate Advanced Position.

9-7

Figure 9.3 Advanced Servo Tuning Parameters

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9.3 Configuration - Actuator

This is the setup page related to the valve actuator and diagnostics limit information contained in Transducer(TB) block.

9-8

Figure 9.4 Configuration - Actuators

9.3.1 Valve Action

This is the ACT_FAIL ACTION parameter.

● Air To Open

It specifies the final failure position of the actuator as air-to-open.

● Air To Close

It specifies the actuator as air-to-close.

9.3.2 Actuator Type

This is the ACTUATOR TYPE parameter.

● Single Acting

It specifies the actuator as single acting type.

● Double Acting

It specifies the actuator as double acting type.

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9.3.3 Relay Type

This is the RELAY TYPE parameter.

● Normal (Direct Acting Instrument)

It specifies the control relay as normal type.

● (Hardware) Reverse

It specifies the control relay as reverse type. This parameter is currently not available.

9.3.4 Valve Type

This is the VALVE TYPE parameter.

● Linear (Reciprocating)

It specifies the valve as linear (reciprocating) type.

● Rotary

9-9

It specifies the valve as rotary type.

9.3.5 Continuous Data Limit

The following diagnostic parameters may be set to values useful to notify if service may be needed. The maximum (default) value for each of the continuous data limits is 2^32 (4294967295). Enter realistic values that represent useful maintenance life values.

● Travel Limit (strokes)

The total travel limit to show the block alarm.

● Cycle Count Limit (times)

The total cycle count limit to show the block alarm.

● Open Time Limit (hours)

The total valve open time limit to show the block alarm.

● Close Time Limit (hours)

The total valve close time limit to show the block alarm.

● Near Close Time Limit (hours)

The total valve near close time limit to show the block alarm.

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9.3.6 Model And Serial Number of Valve

The items in this section can be set and modified by users as a record of the information related with the valve.

● Valve Manufacture

The valve manufacturer’s identification number as defined by the Fieldbus Foundation.

● Valve Model

The valve model number.

● Valve S/N

The valve serial number.

● Act. Manufacture

The actuator manufacturer’s identification number as defined by the Fieldbus Foundation.

● Actuator Model

9-10

The actuator model number.

● Actuator S/N

The actuator serial number.

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9.4 Configuration - AO Block

This is the setup page related to the setpoint that is received from another function block or a remote application. And I/O option contained in Analog Output (AO) Block.

9-11

Figure 9.5 Configuration - AO Block

9.4.1 Limits

● Setpoint High Limit (%)

Use this to limit the setpoint from another function block or remote application.

● Setpoint Low Limit (%)

Use this to limit the setpoint from another function block or remote application.

● Setpoint Rate High Limit (%/s)

The setpoint from another function block or remote application may also be limited to change at a configurable ramp rate. The ramp rate up and the ramp rate down may be individually configured. The default value is 1.#INF (infinity) which eliminates ramp rate limiting.

● Setpoint Rate Low Limit (%/s)

See Set Point Up Rate Limit (%/s)

NOTE

The AO Block setpoint limits are different from the Position limits configured in the Configure Position tab. The Position Limits apply to Target Position.

IM 21B04C50-01E

9.4.2 Configuration - AO Block Options

This setup page consists of both I/O Options and Status Options for the AO block. For each parameter, it is enabled/disabled if it is checked/unchecked. IO_OPTS and STATUS_OPTS are parameters that control options about the AO block’s signal processing and mode transitions.

● SP Tracks PV if Man

Permits the setpoint to track the process variable when the target mode of the block is Man.

● SP Tracks PV if LO

Permits the setpoint to track the process variable when the actual mode of the block is LO.

● SP Tracks RCas or Cas if LO or Man (SP Track retained target)

In LO mode, SP is set to RCAS IN if target mode is Rcas. SP is set to CAS IN if target mode is Cas.

● Increase to close

Indicates whether the output value should be inverted before it is communicated to the I/O channel of the TB. Inverts the SP signal before passing it to OUT.

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● Fault State type

The output action to take when a fault occurs. (uncheck to freeze, check to go to a preset value). The initial preset value is 0. To change this parameter, use a configurator to change FSTATE _VALUE in the AO block. Zero (0) is recommended for an air-to-open actuator and 100 is recommended for an air to close actuator.

● Fault State restart

At a restart uses the same value that is preset for fault state type .

● Target to Man (if Fault State activated)

Set the target mode to Man, thus losing the original target, if Fault State is activated. This latches an output block into the manual mode. Sets the target mode to Man upon activation of the fault state.

● (Use) PV for BKCAL OUT

The BKCAL OUT value is normally the working SP. This option changes it to the PV. Sets the value of PV in BKCAL OUT and RCAS OUT.

AO Status Options

● Propagate Fail Bkwd (Fault Backward)

Controls the handling of the value, data status and related alarm of BKCAL OUT and RCAS OUT.

When this option is selected, then the quality of the status of BKCAL OUT is set to Bad and its sub-status is set to sensor failure. The BKCAL OUT value is not affected. The AO block does not alarm (but enables an upstream block to alarm).

When this option is not selected, then the quality of BKCAL OUT is set to Bad and its substatus is set to non-specific. A block alarm is generated by the AO block.

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9.5 Configuration - PID Block

This is the setup page for the PID process controller configuration parameters mainly in PID block.

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Figure 9.6 Configure PID block

9.5.1 PID Parameters

● Proportional Gain

Dimensionless value used by PID block algorithm in calculating the block output.

● Integral Time

The integral time constant, in second per repeat.

● Derivative Time

The derivative time constant, in second.

● FF Gain

The gain that is applied to an optional feed-forward input before it is added to the calculated control output.

● FF Value (Manual Reset Bias)

The optional feed-forward value.

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9.5.2 Limits

● Set Point High Limit

The highest value that is allowed for the PID set point.

● Set Point Low Limit

The lowest value that is allowed for the PID set point.

● Output High Limit

The limit for the maximum PID output value.

● Output Low Limit

The limit for the minimum PID output value.

● Deviation Alarm High Limit

This is the parameter in PID block called DV_HI_LIM. It is the setting of the high deviation alarm limit.

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● Deviation Alarm Low Limit

This is the parameter in PID block called DV_LO_LIM. It is the setting of the low deviation alarm limit.

● High Alarm Limit

This is the parameter in PID block called HI_LIM. It is the setting of the high alarm.

● Low Alarm Limit

This is the parameter in PID block called LO_LIM. It is the setting of the low alarm.

● High/High Alarm

This is the parameter in PID block called HI_HI_LIM. It is the setting of the high high alarm.

● Low/Low Alarm

This is the parameter in PID block called LO_LO_LIM. It is the setting of the low low alarm.

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9.5.3 PV Scale

● Units

The engineering units code used for PID process variable.

● Upper Range (EU100)

Upper limit value

● Lower Range (EU0)

Lower limit value

9.5.4 Configuration - PID Options

This setup page consists of both Control Options and Status Options for PID block. For each parameter, it is enabled/disabled if it is checked/unchecked.

9-15

Figure 9.7 PID Control and Status Options

● PID Control and Status Options

Bypass Enable

The normal control algorithm may be bypassed through the BYPASS parameter. When bypass is set, the setpoint value (in percent) will be directly transferred to the output. To prevent a bump on transfer to/from bypass, the setpoint will automatically be initialized to the output value or process variable, respectively, and the path broken flag will be set for one execution. BYPASS is not permitted unless the BYPASS ENABLED option is set.

SP-PV Track in Man

Permits the setpoint to track the process variable when the target mode of the block is Man.

SP-PV Track in ROut

Permits the setpoint to track the process variable when the actual mode of the block is ROut.

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SP-PV Track in LO or IMan

Permits the setpoint to track the process variable when the actual mode of the block is LO or IMan.

SP Track retained target

Permits the setpoint to track the RCas or Cas parameter based on the retained target mode when the actual mode of the block is IMan, LO, Man, or ROut. When SP-PV track options are enabled, then SP Track retained target will have precedence in the selection of the value to track when the actual mode is Man, IMan, Rout, and LO.

Direct Acting

Defines the relationship between a change in PV and corresponding change in output. When Direct is selected, an increase in PV results in an increase in the output.

Track Enable

This enables the external tracking function. If true, the value in TRK_VAL will replace the value of OUT if TRK_IN_D becomes true and the target mode is not Man.

Track in Manual

This enables TRK_VAL to replace the value of OUT when the target mode is Man and TRK _IN_D is true. The actual mode will then be LO.

Use PV for BKCAL OUT

9-16

The BKCAL OUT and RCAS OUT values are normally the working SP. If this option is enabled, then the PV value will be used after the cascade is closed.

Restrict (Obey) SP limits if Cas or RCas

Normally the setpoint will not be restricted to the setpoint limits except when entered by a human interface device. However, if this option is selected, the setpoint will be restricted to the setpoint absolute limits in the Cas and RCas modes.

No OUT limits in Manual

Do not apply OUT_HI_LIM or OUT_LO_LIM when target and actual modes are Man. Trust the operator to do the right thing.

● PID Status Options

IFS if BAD IN

Set Initiate Fault State status in the OUT parameter if the status of the IN parameter is BAD.

IFS if BAD CAS IN

Set Initiate Fault State status in the OUT parameter if the status of the CAS _IN parameter is BAD.

Use Uncertain as Good

If the status of the IN parameter is Uncertain, treat it as Good. Otherwise, treat it as BAD.

Target to Manual if BAD IN

Set the target mode to Man if the status of the IN parameter is BAD. This latches a PID block into the Man state if the input ever goes bad.

No Select if not auto (Target to next permitted mode if BAD CAS IN)

Sets the target mode to next permitted mode if the target mode is CAS and the status of CAS_IN falls to BAD.

IM 21B04C50-01E

9.6 Configuration - Options

This is the setup page for other configuration settings including characterization, pressure range and units, bumpless transfer, display language, and temperature units.

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Figure 9.8 Configuration - Options

9.6.1 Characterization Frame

The positioner is supplied with a choice of characteristics that modify the characteristic built into the plug and actuator. Choose a characteristic that works with the control valve’s inherent characteristic to provide a desired overall installed characteristic. Avoid the common mistake of choosing an Equal Percent characteristic in the positioner if the valve has an Equal Percent characteristic built into the plug.

Possible choices are: linear, equal percent (50:1), equal percent (30:1), quick open, camflex percentage or (custom) define.

● Linear

The valve position is proportional to the input to YVP positioner.

● Equal Percent (50)

Equal percentage with rangeability of 50 to 1. For equal increments of the input, the valve position has equal percentage changes of current valve position.

● Equal Percent (30)

Equal percentage with rangeability of 30 to 1. For equal increments of the input, the valve position has equal percentage changes of current valve position.

● Quick Opening

The quick opening characterization is the inverse to the Equal Percentage (50) characterization curve.

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● Camflex Percentage

This function is used to equalize the flow rate characteristic with the Equal Percent characterization feature that is provided by mechanical positioners from Masoneilan.

● Define

A custom characterization defines the relationship between the input signal and the output position of the valve. Selecting this option will display an additional window where you can configure a characterization curve with 10 adjustable segments to fit your needs. The curve can have up to 9 adjustable points and points in between are linearly interpolated.

9-18

Figure 9.9 Custom Characterization Dialog

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● Custom Characterization Dialog

The Characterization Dialog lets the user define his own characterization. There are 9 definable points for the valve position at 10% increments of position setpoint. Use the mouse to drag the points on the curve or enter numerical values in the table to define the characterization.

To configure a custom characteristic curve, enter the values in the edit boxes at the bottom of the screen and press the Tab key. The graph is updated when the value is entered.

Alternatively, change the shape of the curve by clicking a point, holding the left mouse button down, and dragging the cursor to a new position before releasing the mouse button.

Figure 9.10 Display mismatch for non-linear characteristic

9-19

After configuring the curve, click the OK button to accept the value and exit the Characterization dialog, and click the OK button of Configure dialog, or click the Cancel button to exit without changing the values. To prevent a user from entering unreasonable points, ValveNavi will check the curve based on established rules and pop up a warning message when the curve does not meet the rules. The characteristic points are saved in YVP with a resolution of five digits.

The unfinished curve in Figure 9.9 illustrates that the curve must be monotonic. (Each point must be greater than the previous point.) To smoothly blend a point between its adjacent points, right click the point. For all non-linear characteristics the set point will differ from the target position.

Click OK to accept the custom characteristic.

NOTE

When the characteristic is linear, the displays of position setpoint and target valve position will all match. For all other (non-linear) characteristics the valve target position will differ from the setpoint. See Figure 9.10

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● Custom Linearization Dialog

Select the Custom Linearization menu item in the Characterization Dialog to display the Custom Linearization dialog (Figure 9.11).

9-20

Figure 9.11 Custom Linearization Dialog

A custom linearization method built into ValveNavi can be used to correct non-linearity. The method automatically generates a custom characterization that matches the specific linkage used. Custom characterization must be the selected configuration option to use the generated curve. This option is selected automatically when the user clicks OK to accept the displayed curve.

A custom linearization cannot be used in combination with the equal percentage or quick opening characteristics. If a non-linearity correction and equal percentage or quick opening characteristics are both required, use the non-linearity correction in Calibration>Travel Calibration dialog and adjust the 50% point.

To configure custom linearization, click the Custom Linearization button. The Custom Linearization window will appear.

Tw o types of linkages are modeled: simple and compound. Most linkages use the compound linkage system.

NOTE

Custom Linearization uses the same data as Custom Characterization. Therefore, only one of these configuration options may be used at any one time. Any custom characterization data will be discarded when Custom Linearization is used.

Simple Lever

The simple lever has the pivot point (the position sensor in the YVP) mounted a fixed distance (L1) from the valve stem pickup point. In order to compute the proper correction curve, the stroke length, the distance from the pivot to the valve stem pickup point and the valve position at horizontal must be entered.

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Compound Lever

The compound linkage has Lever1 attached at one end to the pivot (the position sensor in the YVP) and at the other end to Link L2. In order to compute the proper correction curve, the user must enter the stroke length, first lever segment length (L1), second lever segment length (L2), the distance from the pivot to the valve stem pickup (L3), and the valve position at horizontal. Most linkages use a linkage with L3 equal to L1, i.e. the second lever arm is vertical when the first lever arm is horizontal. The correction computation will correctly compute the correction curve when L3 is not equal to L1. However, L3 must be greater than 0, which requires that the valve stem pickup not be lined up with the pivot and that the pickup be on the same side of the pivot as the link between the first and second lever.

Click OK to compute the correction and display the curve. A Dialog will appear to show the angle the linkage will move.

Figure 9.12 Rotation Angle Message

9-21

The (custom) define characterization must be the selected configuration option to use the generated curve. Click OK to accept the displayed curve.

9.6.2 Pressure Frame

● Pressure Units

This is the unit code in TB_SPRING_RANGE parameter which affects output pressure unit code as well. However, it has no effect in controlling function.

● Pressure Upper Range (EU100)

This is EU100 of SPRING_RANGE of TB parameter for upper end engineering unit value.

● Pressure Lower Range (EU0)

This is EU0 of SPRING_RANGE of TB parameter for lower end engineering unit value.

● Supply Pressure

This is the supply pressure in engineering units specified in SPRING_RANGE parameter. It is for information only and has no effect on control.

9.6.3 Others Frame

● Bumpless Transfer

When this option is selected, returning from manual to normal operation state is deferred until the current valve position and the position setpoint match. This is to assure the smooth valve position transition when switching the operation state to avoid a process disturbance.

For most Foundation fieldbus installations, the initialization function built into the function blocks will handle bumpless transfer. Leave the box unchecked unless there is a special requirement.

● Display Language

It is currently unused.

● Temperature Units

This is the temperature unit used in the device which has choice of either degC or degF.

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10. CALIBRATION SERVICES

Calibration Services provide tools to set valve stroke, and to tune the dynamic parameters for control of position. Each set of tools is grouped in a tab.

10.1 Calibration - Range

To calibrate the position sensor to match the actual valve travel, use the Auto Stop Limits or the Manual Stop Limits function to search for the mechanical stop limits of the valve.

To check if the calibration is done properly, move the valve to the stops in the Main Screen (IVI) in manual operating state.

10-1

Figure 10.1 Range Calibration

WARNING

Range Calibration strokes the valve over its entire travel. Isolate the valve from the process prior to using the calibration procedure.

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10.1.1 Find Range Result

Display the result of the calibration execution after GO button is pressed.

10.1.2 GO

Start button to execute the selected calibration.

Figure 10.2 Warning

10.1.3 Auto Stop Limits

When Auto Stop Limits is selected, press GO button to execute the automatic position calibration process. The actuator will be fully exhausted, then fully filled. The position at each stop will be measured and saved. In some cases when the actuator size is extremely large, the process may time out and the Manual Stop Limits can be used instead.

10-2

For further information about error messages, see YVP User’s manual (IM 21B04C01-01E).

Figure 10.3 Stop Progress

IM 21B04C50-01E

Yokogawa YVP20S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. INTRODUCTION

1.1 About This Manual

1.2 Software License Agreement

1.3 About This Software

1.4 Important Safety Warnings

1.5 Trademarks, Copyrights, and Patents

2. INTRODUCTION TO ValveNavi

2.1 What is ValveNavi?

2.2 ValveNavi Specifications

2.3 Combination of ValveNavi & YVP

2.4 What is FOUNDATION® Fieldbus?

2.4.1 Guide to a successful Foundation fieldbus installation

3. INSTALLATION OF HARDWARE AND SOFTWARE

3.1 What you need to get started with ValveNavi

3.2 Reference Model Process

3.2.1 Wiring requirements

3.3 Installing NI-FBUS

3.3.1 Configure the NI-FBUS interface card safely for different tasks

3.3.2 Installing the Device Descripfions (DD) with NI-FBUS Interface Configuration Utility

3.3.3 Location of DD files and .DCT file

4. ValveNavi ADMINISTRATION

4.1 Hardware and Software Requirements

4.2 Installing ValveNavi

4.3 Trial Period

4.4 Licensed User Process

4.5 Logging on with Registration

4.6 Setting Up User Accounts

4.6.1 System Administration, Passwords, and Privilege Levels

4.6.2 Start the Administration Program

4.6.3 Privilege Levels

4.7 Finish ValveNavi

5. FOUNDATION FIELDBUS OVERVIEW

5.1 Reference Model Process Used in This User’s Manual

5.1.1 P & I D

5.1.2 Function block links

5.2 Device Operational States and Block Modes

5.3 Block Modes

5.4 Examples of IVI Operational States

5.5 Changing Operational States

6. QUICK TOUR OF ValveNavi

6.1 Introduction

6.2 Fieldbus Device Tree

6.3 Menu Bar and Tool Bar

6.3.1 Menu items

6.3.2 Toolbar icons

6.4 Control Valve Faceplate

6.5 Companion Device Display Frame

6.6 Status Frame

6.7 Accessing Services in ValveNavi

6.8 Setup Wizard

6.8.1 Actuator Wizard

6.8.2 Tuning Wizard

6.8.3 Travel Calibration Wizard

6.8.4 Position Control Limits - Wizard

6.8.5 Finish - Setup Wizard

6.9 Configuration Services

6.10 Calibration Services

6.11 Diagnostic Services

6.12 Operation State

6.13 Device Query

6.14 PID Control Dialog

6.15 Rescan

6.16 About

6.17 Online Help

7. INTEGRATED VALVE INTERFACE (IVI)

7.1 Device Selection

7.1.1 The Pop-Up Menu In Device Selection

7.1.2 Setting Device as LM or Basic Device

7.2 Control Valve Faceplate

7.2.1 Selected Device

7.2.2 Block Actual Mode

7.2.3 Position

7.2.4 Other Status

7.2.5 Temperature, Pressure, and I/P Graphs

7.3 Companion Device

8. SETUP WIZARD