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USER`S MANUAL Series 760D ValvePAC Digital

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1. Valve SA Actuator et Point 0 to 3 510 Spool 1 4 1 5 PSI Valve gt gt BO 4 Vavle Weld gt C Exhaust Buttons Mie gt Feedback Potentiometer 760D5b ds4 FIGURE 2 2 Setpoint Operation 2 3 PUSHBUTTONS The ValvePAC housing may contain three optional pushbutton switches and a local display These features permit reading and modification of the instrument operating parameters without a PC or HART hand held communicator The buttons perform generic functions Increase Decrease and Accept and facilitate movement through a conventional menu structure see section 4 0 Operations 2 4 FEEDBACK POTENTIOMETER Because of its mechanical linkage to the valve stem the feedback potentiometer position corresponds directly to the valve stem position The feedback potentiometer is mounted inside the ValvePAC housing Its function depends on the method of configuration AS a positioner or controller the feedback potentiometer provides feedback to the position control algorithm As a transducer EPC the feedback potentiometer signal can communicate valve position using the HART protocol October 1998 3 3 INSTALLATION UM760D 1 2 5 AUTOTUNE The AutoTune procedure automatically determines position control parameters such as P Padj I D and dead zone The AutoTune procedure in
2. Common Rail Series 760D Controller 4 20 mA Set Point 42 e A 250 Ohms Input B I 1 HH See Note 2 LI Process Control Room Non Hazardous Environment NOTES 1 Network resistance equals the sum of the barrier resistance and the current sense resistor Minimum value is 250 Ohms maximum value is 1100 Ohms 2 Connect the HART Communicator as shown The HART Communicator is a non polar device 61098 5 ds4 FIGURE 3 8 Single Loop PID Configuration with No Process Feedback to Control Room October 1998 3 21 INSTALLATION UM760D 1 The circuit shown below is an intrinsically safe configuration In this case the 1 5 Vdc process signal is developed in the MTL 788R barrier and returned to the ValvePAC as a voltage signal The 728 barrier supplies the 4 20 mA to the ValvePAC Note that the negative input to the ValvePAC and terminal B are at the same potential Current Source Process Signal Common Rail zc 4 20 mA Set Point Process Transmitter Series 760D Controller Barrier See Note 2 Control Room NOTES 250 Ohms Process Hazardous Environment 1 Network resistance equals the sum of the barrier
3. eei Ei 2 5 Configuration Without Process Feedback esee 2 5 Configuration With Process Feedback 2 5 Intrinsically Safe System eese nennen eene 2 5 BU NURSES Bd 3 1 MOUNTING ON THE ACTUATOR 0 00 8 3 1 Rotary Act atot 3 3 Rising Stem Acthator 2 2 2 5 dun deu dacadaaadeuadeuadenadeaumede nte 3 3 INPUTS OU TPU S nie EH vU uU IU RU UR RP RWV 3 6 Pneumatic C onnectiOns 5 5 8 n Recent shea co toe e pt c epe P E PEE PE 3 7 lvi i si 3 7 ValveRAG Connections 2 5 ng udi udeaadaausuauquduquauquaueuamne 3 8 ELECTRICAL CONNECTIONS EE 3 9 Non Hazardous 0 3 9 Hazardous Locations nennen nenne ennt 3 9 Sira Certification Service Special Conditions for safe use 3 10 TY PICALSINSTALATION 1G REUS RE 3 11 Valve Controler 7 5 5 5 5 ne ee dee n 3 11 Process Controller 22 3 14 OPERATION tedio ie Opel ee Gre ee i fee Go tad 4 1 PUSHBUTTONS DISPEAY 4 1 MENU STRUCTURE eco eoe eee eren etre eee e odi eoe des 4 4 Normal Operate Mode and Manual Mode
4. CONVERSION CURRENT i PNEUMATIC SPOOL TO POSITION Xx D A L gt INPUT SETPOINT RELAY VALVE ACTUATOR CONVERSION a TO ACTUAL VALVE POTENTIOMETER POSITION nan rrr VALVE actvlv DS4 FIGURE 2 1 Block Diagram of ValvePAC Unit Actuator and Valve 2 1 BIAS A good understanding of the ValvePAC requires a good understanding of bias The bias is the current signal that the ValvePAC s internal circuitry must send to the EPC the I P transducer in order to hold the spool valve in a steady state position where the actuator neither fills nor exhausts One of the most important steps in the calibration process is the adjustment of the bias spring There is a limit to how much the current signal to the EPC can vary The optional ValVue software displays this current as a value between 0 and 5500 This means that there is a limit to how much the EPC s output pressure can rise or fall When adjusting the spring the goal is to set the force such that the EPC s output can rise and fall enough to move the spool up and down properly during step changes With such a restriction on the range of the current signal to the EPC there must be a limit to how far the neutral current or bias can be allowed to vary A value between 2250 and 3500 will yield successful results October 1998 3 1 INSTALLATION UM760D 1 To maintain valve posit
5. yD Input Gear VE AA aji eee i o B p 76 684B ds4 FIGURE 5 2 Feedback Gear Feedback Mounting Bracket October 1998 5 7 TROUBLE SHOOTING UM760D 1 5 Reposition the potentiometer gear such that FAILSAFE is not displayed and the shaft s eventual motion will move the gear away from the FAILSAFE zone Re engage it with the main shaft gear NOTE When the actuator is on its stop engaging the second tooth from whichever end is appropriate given the direction of motion of the potentiometer s sectored gear will usually eliminate the FAILSAFE condition 6 Tighten the bracket s mounting screws The optional ValVue software reports values of zero and 32 767 at the extreme ends of potentiometer travel and provides a nPos response to message 141 Read Raw Data A properly positioned potentiometer never reaches these extremes because the ValvePAC declares the value Bad if not between 327 and 32 440 Garbage Display A display containing garbage e g indecipherable characters indicates that the ValvePAC microprocessor is not starting up properly due to a lack of power refer to Blank Display Check the electrical wiring or power Random text or numbers indicates a working but flawed microprocessor If checking power connections does not resolve the problem return the unit to the factory for servicing Reset Display The display shows the Reset set
6. The ValvePAC can be operated calibrated configured and interrogated either by using local pushbuttons display a handheld HART communicator or a remote PC running ValVue software 3 18 October 1998 UM760D 1 INSTALLATION Current Source 4 20 mA Barrier Process Process Transmitter Signal 2 4 3 4 Common Rail Series 7600 e Controller e F e d A Barrier B XJ Controller HE Process See Note 2 Control Room Hazardous Environment NOTES 1 Network resistance equals the sum of the barrier resistance and the current sense resistor Minimum value is 250 Ohms maximum value is 1100 Ohms 2 Connect the HART Communicator as shown The HART Communicator is a non polar device 61098 2 ds4 FIGURE 3 7 System Diagram Intrinsically Safe Installation October 1998 3 19 INSTALLATION UM760D 1 3 4 2 PROCESS CONTROLLER The ValvePAC can be purchased from the factory with an onboard single loop PID controller When this option is installed and turned on the secondary input terminals marked A and B become active The process variable feedback signal is measured across these terminals typically as 1
7. Lsic HI xt PA Na M PRESH lc E 4y N gt Y Bac Y Low gt EXAMINE gt CONFIG DOUBLE Y 22 gt gt LS SINGLE CONFG gt Ante x CTL OFF ON LATO X TY LINEAR ML ee TS OFF LINEAR x gt EQUAL 50 E Mane PL OFF c Hier A ay N M PU OFF D N Y P y z G a E CALIB SIGLO U L BECIP y R Y M SIG HI A TS OFF NNNM T L N V 2 i o _ TS ON T Saas N eae wae CLEAR PL P Y _ NONE d PY gt a yor Y _ PU gt gt gt O PER eor LENGLISH FRNCAIS L s gt MAN T ai v Y gt CNTL gt REMOTE LOCAL N T y LSETPNT ket ISETPNT amp y M CANCEL JY gt EXAMINE V SELECT pbchart DS4 FIGURE 4 2 Master Pushbutton Function Menu October 1998 4 3 OPERATION UM760D 1 4 2 MENU STRUCTURE The individual menu structures for operating the ValvePAC from the local pushbuttons and display are shown in Figure 4 3 to Figure 4 7 on the following pages 4 2 1 Normal Operate Mode and Manual Mode Menus When you leave Normal Operate mode to go to Manual mode the valve is placed in the last position it was in when it left Normal Operate When in Ma
8. TOTAL P 6 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR A 0 MODEL 275 UNIVERSAL HART COMMUNICATOR The Model 275 Universal HART Communicator is a handheld interface that provides a common communication link to Model 760D ValvePAC Valve Controllers and other HART compatible instruments Most of the functionality offered with the ValVue Software is also available with the HART Communicator with the exception of Process Trend and Diagnostic plotting This appendix describes HART Communicator connections liquid crystal display keypad and on line and off line menus It also provides short overviews of some of the Communicator s functions The Communicator is shown in Figure A 1 For information about the Communicator s battery pack Memory Module Data Pack and maintenance procedures refer to the manual supplied with the Communicator A 1 INTRODUCTION From a wiring termination point the HART Communicator interfaces with a ValvePAC Valve Controller or other HART device using a 4 20 mA loop provided a minimum load resistance of 250Q is present between the Communicator and the power supply The Communicator uses the Bell 202 frequency shift keying FSK technique of high frequency digital signals imposed on a standard instrument current loop of 4 20 mA Because no net energy is added to the loop HART communication does not disturb the 4 20 mA signal The Communicator can be used in hazardous and non hazardous locations WARNIN
9. 1 Location 7 Compare 2 Name 3 Data Type FIGURE A 4 Offline Menu Tree A 5 1 1 New Configuration This option is used to compile a custom set of device configuration data for downloading later to one or more HART compatible devices Downloading the same data to multiple devices ensures that they all store identical configuration data Use the following steps to compile off line new device configuration data 1 From the Main menu press 1 to access the Offline menu HART Communicator Offline ea 2 Press 1 to enter a new configuration The Manufacturer 1 gt New configuration menu appears 2 Saved configuration 3 Choose a manufacturer by scrolling to the manufacturer name with the DOWN arrow then pressing RIGHT ARROW SELECT The Model menu appears 4 From the Model menu choose a device by scrolling through the list then pressing RIGHT ARROW SELECT The Field Device Revision Fld dev rev menu appears The Field Device Revision menu contains the currently installed software revisions for the field device and device descriptions DD for the model selected from the Model menu April 1999 A 11 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 Select the software revision RIGHT ARROW SELECT or number to access the Blank Template menu at right To discover the software revision for a particular device connect the Communicator to the device and follow instructions given in the device man
10. 2 for hazardous or non hazardous locations The HART Communicator is a non polar device 5 Supply and return barriers shown Interconnect all cable shields and ground only at the barriers 6 For access to terminals remove enclosure cover AG00239a FIGURE A 7 Multi Drop Network April 1999 A 25 A PARTS LIST Process Automation Solutions PL760D 1 Rev 1 July 1999 MODEL 760D VALVEPAC See the next page for a list of kits and kit contents ITEM KIT Beacon Indicator Flat Indicataor Exhaust Vent 1 4 NPT Maintenance Parts Kit Gauge Kit Display Kit Adapter 3 4 NPT to M20 AG00300a Ref 16300 773 XV3051VDB PL760D 1 PART NUMBER CONTENTS QUANTITY 1 Beacon Indicator Kit 16300 488 Beacon Indicator Kit Instructions Beacon Indicator Extend O Shaft Indicator Indicator Cover 760 Beacon Lens Enclosure Cover Gasket Lens Gasket Lens Clamping Plate Retaining Ring 0 625 Shaft Label 760 Beacon Top Label 760 Beacon Bottom 8 32 x 0 50 Flat Head Screw 8 32 x 0 938 Fillister Head Screw 8 Flat Washer Washer Cup 0 255 x 0 50 Aha A nn A 2 Flat Indicator Kit Lever 16300 486 Instructions Flat Indicator Flat Indicator 760 Standoff 1 00 Long 6 32F Indicator Cover 760 Lens Flat Indicator Enclosure Cover Gasket Lens Gasket Lens Clamping Plate Label Electrostatic Hazard 6 32
11. 5 volts You can range this input The primary input signal measured across the and terminals is used as the controller setpoint and must be between 4 and 20 mA to power the unit In order to avoid loop errors the terminal of the primary signal and the B terminal of the secondary signal must operate within 0 2 volts of each other They should both be referenced to the common rail Various configuration schemes are illustrated in Figures 3 8 through 3 10 The circuit shown in Figure 3 8 is the simplest configuration for the controller It requires two two wire lines to the field The sense resistor is located across the A and B terminals of the ValvePAC unit There is no sensing of the controlled variable in the control room which is acceptable for applications such as a heat exchanger where the primary variable is temperature and the secondary is flow In such a case the ValvePAC is the flow controller and the control room temperature controller sets flow based on the requirements of the temperature loop with no need to monitor flow in the control room 3 20 October 1998 UM760D 1 INSTALLATION Current Source Process Transmitter 4 20 mA Process Signal
12. A 16 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR Configuration Menu Tag Setup Reverse Fail High Setpoint Controller Air to Close On Off Do NOT Change On Off No Change M Startup Local Startup Remote Startup Last Mode Local Only Descriptor Message 1 Final Assembly Number 34 Date Polling Address Position Error Band Time 1 Time 2 Pressure Time Instrument On Off On Off lt Cam Used L Options No Change Lower Limit On Off Pressure Units Language Buttons Lock 71 5 Linear Upper Limit On Off Psi English Level 3 m Equal 50 Tight Shutoff On Off Bar French Level 2 Valve Near Closed Equal 30 kPa Level 1 3 Quick Open Level 0 Custom gt 5 Setup 2 c s gt E LL Controller On Off Bumpless Transfer On Off Hardware Reverse On Off Startup Direct Action Reverse Action Primary Variable Units Gal min etc Remote Setpoint Units Gal min etc Ratio Control Yes No Initial Local Setpoint Control Rate FIGURE A 5A On Line Configuration Menu Tree Range From Manual Mode u Figure A 5 Signals Calibrate Calibration Menu Choice Range Signals Find Stop Limits Low Signal LHigh Signal L Supply Pressure L Low Primary Variable LHigh Primary Variable L Low Setpoint Value L High Setpoint Value These seven screens are selected serially Choice
13. A confirmation message appears Press Yes or No to complete the function Rename provides access to the configuration name editing menu After making name changes enter and save the data to return to the previous storage location menu Compare compares a selected device configuration from a stored location with other device configurations The HART Communicator can compare device types variables marked lists and other configuration parameters Messages appear indicating if the configurations compared are the same or different A 5 2 Online Menu The Online menu permits a ValvePAC Valve Controller to be tested and configured while it is operating Extensive options available through the Online menu are shown in Figures A 5 and A 5A through E The Online menu is displayed immediately if a device description for the connected device exists in the Communicator If not the Generic Online menu is displayed see Figure A 6 NOTE The ValvePAC Valve Controller stores fault messages in memory to record occurrences such as position errors or resets These usually occur if the unit has experienced a power interruption or an interruption in supply pressure The memory location is referred to as Status When a HART Communicator is connected to a ValvePAC Valve Controller that has information stored in Status the Communicator displays a diagnostic message stating that the Field device has Status available To stop this message from being disp
14. PID Coefficients Examine and Modify Run Auto Tune Set Bias D Pac Beta Damping Compensation Dead Zone Choice Primary Signal Secondary Signal Pressure View Signals Reset to Factory Settings FIGURE A 5B On Line Calibration Menu Tree April 1999 A 17 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 Controller Controller View lt gt 5 z2 Sg o 2 g Mode and Setpoint oOo 2 So 2 PID Settings Controller Parameters 1 Alarm View Continuously Shown Continuously Shown Manual Mode OR Local Mode OR Process Variable Process Variable Manual Setpoint Local Setpoint Valve Position Output Remote Setpoint Valve Position Remote Setpoint Choice Setpoint Value Setpoint Mode Choice No Change Remote Setpoint Local Setpoint Manual Contoller PID P D Kd Beta Controller Parameters Ratio Gain Ratio Bias Setpoint Lower Limit Setpoint Higher Limit Lower Alarm Limit Higher Alarm Limit Output Rate Limit Manual Reset Bias Controller Dead Zone Setpoint Tracking On Off Freeze Output On Off Derivative Mode On Off Alarm Type On Off Continuously Shows Alarm Type Process Varaible Setpoint Alarm FIGURE A 5C On Line Controller Menu Tree Continuously Shown Remote Mode Process Variable Remote Setpoint Output Valve Position A 18 April 1999 UM760D 1 APPENDIX A MODEL 275
15. S Vd 95 80 05 OWA JO suoisrAo1d oy SUIMOTIOJ Z Z800SNA PU 1 800 SUOISSIUTY C T800SNH OWH sjuoumoop SATCULIOU JO sprepuejs SULMOT OJ jIULojguoo SI seje oy STU YOM 0 K1019 uonemsiyuos Aue pue suondo po e1sur A107983 Aue yim I9uontsoq ALA 1097 POW jonpoJd eq yey Aj iqrsuodsai epos Ino Jopun 11 61 Vd esnoy Surds oxrq umojKouumg OD SPONpolg PLOSP 01 ALINYOANOD AO NOLLV3OIV IOWG NATIONAL ACCREDITATION Certification Service 2r GIAN Hime on GROUP 1 CERTIFICATE OF CONFORMITY Apparatus 2 Certificate Sira 98D2108 3 This Certificate is issued for the electrical apparatus Series 760D Valve Controller 4 Manufactured by Moore Products Company Spring House PA 19477 0900 USA 4b Submitted for certification by The Manufacturer 5 This electrica apparatus and any acceptable variation thereto is specified in the schedule to this Certificate and the documents therein referred to 6 Sira Certification Service being an Approved Certification Body in accordance with Article 14 of Directive 76 117 EEC of the Council of the European Communities of 18 December 1975 certifies that the apparatus has been found ta comply with the following harmonised European Standards EN 50 014 1977 amendments A1 t
16. TABLE A 2 Moore Device Descriptions MODEL FIELD DEVICE DESCRIPTION APPROXIMATE VINTAGE REVISION 340B Dev V1 DD V1 340 Transmitter Controllers 8 90 8 96 Model 5 340 pushbutton design 340A Dev V1 DD V1 340 Transmitter pushbutton design 8 90 8 94 Model s 340 A 344 Dev V1 DD V1 344 Transmitter Controller 8 90 8 94 Model s 344 Dev V2 DD V1 344 Transmitter Controller 8 90 Present Model 344 341 Type 5 Dev V1 DD V1 341 Transmitter 8 94 Present Model s 341 340A Type 6 Dev VI DD 340 Transmitter pushbutton design 8 94 8 96 Model 5 340 Dev V2 DD V1 340 Transmitter magnetic switch Present Model s 340 B design 340S Dev V1 DD V1 340 Steameter 3403 Dev V1 DD V1 343 TemperatureTransmitter 345 Dev V1 DD V1 345 Critical Transmitter 9 98 Present 760D Dev V2 DD V1 Series 760D ValvePAC Valve 9 98 Present Controller Note Always verify the Model and Field Device Revision for the device at hand using the Quick Access Key Status Model command of the Model 275 HART Communicator A 5 MAIN MENU When the Communicator is not connected toa device the HART Communicator first menu to appear after powering up and Self Test is the 1 Offline Main menu at right If the Communicator is turned on while 2 Online connected to a device access the Main menu by pressing the 3 Frequency Device LEFT ARROW PREVIOUS MENU key Depending o
17. Turn Tight Shutoff Off or On Hd i Displays TS value if turned ON Press to change ON OFF provides max seating force n status Displays value when changed from OFF to ON at 0 position TS ON Press or to enter new value Press to accept new value and move to next menu item Software Limit Stop Settings x HHH Displays PL value if turned ON Press to change ON OFF Value displayed if set to ON status Displays value when changed from OFF to ON If ON valve cannot go gt Press or to enter new value Press to accept new beyond limit value and move to next menu item 7 Software Limit Stop Settings m gt Displays PU value if turned ON Press to change ON OFF Value displayed if set to ON 7 status Displays value when changed from OFF to ON If ON valve cannot go gt PU OFF Press or to enter new value Press to accept new beyond limit value and move to next menu item x Select Display Langauge gt ENGLISH FRNCAIS 21 gt MAN To move to next option Press Returns to To accept and move to next POS MAN in X menu item Press Manual Menu CONFMENU ds4 FIGURE 4 4 CONFIGURATION Menu Structure October 1998 UM760D 1 OPERATION 4 2 3 Calibrate Menu If a change is made in the Air to Open Air to Close or Direct Reverse configuration options or if you move the ValvePAC to a different valve or make any change to the valve position linkage you m
18. a scribe by carefully pulling on and around the edge of a screen 3 Insert a new screen until it bottoms using an object such as the eraser end of a pencil that will not cause damage 6 2 SPARE AND REPLACEMENT PARTS Refer to the parts list at the back of this Instruction for a list of replacement parts and an exploded view Spare and replacement parts are available from any of the addresses in the warranty statement Refer to the parts list for recommended on hand spare parts 6 3 RETURN FOR REPAIR To Return for Repair Call the Service Department at 1 215 646 7400 ext 4762 weekdays between 8 00 a m and 4 45 p m Eastern Time to obtain an RMA Return Material Authorization number Mark the RMA number prominently on the outside of the shipment When calling for an RMA number provide the reason for the return If returning equipment for repair failure information e g error code failure symptom installation environment will be requested A purchase order number will also be needed Material Safety Data Sheet A Material Safety Data Sheet MSDS must be included with each item being returned that was stored or used where hazardous materials were present Packaging Package assembly in original shipping materials Otherwise package it for safe shipment or contact the factory for shipping recommendations a October 1998 6 1 UM760D 1 MODEL DESIGNATION 7 0 MODEL DESIGNATION Each ValvePAC has a nameplate iden
19. allow the TIC representative taking the call to use the central customer database to quickly identify the caller s location and past support needs e Product part number or model number and version e If there is a problem with product operation Whether or not the problem is intermittent The steps performed before the problem occurred Any error messages or LED indications displayed Installation environment Customers that have a service agreement ServiceSuite or Field Service Agreement are granted access to the secure area of our Web site www moore solutions com techservices This area contains a variety of product support information To log on you will be prompted to enter your username and password TIC CONTACT INFORMATION Tel 1 215 646 7400 extension 4842 TIC Fax 1 215 283 6343 E Mail TICGroupNA moore solutions com NORTH AMERICA Hours of Operation 8 a m to 6 p m eastern time Monday Friday except holidays Secure Web Site www moore solutions com techservices Tel 465 299 6051 TIC Fax 65 299 6053 E Mail TICGroupAPQ moore solutions com ASIA P Hours of Operation 9 a m to 6 p m Singapore time Monday Friday except holidays Secure Web Site www moore solutions com techservices October 1998 1 3 INTRODUCTION UM760D 1 TIC EUROPE Tel 44 1935 470172 Fax 44 1935 70696
20. confirm that the power is turned on 2 Use a test meter to evaluate system power Expect readings of 24 volts for incoming power and at least 9 to 11 5 volts across the ValvePAC TABLE 5 4 Blank Display Checklist IF THEN Voltage between the ValvePAC positive and Assume module failure and return it to the negative terminals falls between 9 and 11 5 factory for replacement volts and the display remains blank or shows a random set of segments NOTE Disconnecting and re connecting the current input may power up the module The module however remains marginal and requires replacement Return it to the factory 5 6 October 1998 UM760D 1 TROUBLE SHOOTING Fail Safe Display If the display indicates ValvePAC operation in Fail Safe mode restart the ValvePAC by shutting down and then re applying power The ValvePAC usually displays the Fail Safe mode because of incorrect installation of the position sensor potentiometer The ValvePAC employs a 140 degree potentiometer Valve rotation must not rotate the potentiometer beyond that 140 degrees its limit is several degrees from each end of the scale Improper installation e g forcing the zero value off the end of the potentiometer in either full open or full closed position causes the valve to go to fail safe mode The following procedure describes how to check and reset the potentiometer s position 1 Use the pushbuttons or HART handhe
21. each function key is pressed A 4 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR TABLE A 1 Function Keys with Their Labels and Actions Performed HELP ON OFF ABORT activate or deactivate a terminate current task bit enumerated binary variable DEL Access on line help RETRY ESC leave a value unchanged delete current character or Quick Access Key menu item SEND try to reestablish communication EXIT QUIT terminate session because of a communication error PGDN send configuration data to device leave the current menu YES PGUP move down one help screen NEXT move up one help screen PREV Answer to yes no question ALL Include current Quick Access Key item on Quick Access Key menu for all devices NEXT go to next message in a go to previous message list of messages in a list of messages SAVE HOME go the top menu in the device description BACK save information to Communicator MARK go to the next variable in off line edit FILTR go back to the menu from which HOME was pressed EDIT toggle marked variable in configuration to be sent to a field device XPAND Open customization menu to sort configurations opens detailed edit a variable value configuration information CMPRS ADD add current item to Quick Access Key menu closes detailed configuration information Acknowledge information on the
22. feedback signal is measured across these terminals typically as 1 5 volts You may choose to range this input The primary input signal measured across the and terminals is used as the controller setpoint and must be between 4 and 20 mA to power the unit NOTE The system does not isolate the process input from the control input Take suitable precautions to avoid ground loops 2 7 1 Configuration without Process Feedback Configuration without process feedback the simplest configuration for the controller requires two two wire lines to the field The sense resistor is located across the auxiliary terminals of the ValvePAC No sensing of the controlled variable exists in the control room In a heat exchanger with a primary variable of temperature and a secondary variable of flow for example the ValvePAC functions as the flow controller The operator can adjust flow based on the requirements of the temperature loop with no need to monitor flow from the control room For an example of this configuration refer to Figure 3 8 2 7 2 Configuration with Process Feedback Configuration with process feedback uses three two wire connections to the field The control room senses the controlled variable as a 1 5 volt signal For an example of this configuration refer to Figure 3 10 October 1998 3 5 INSTALLATION UM760D 1 2 7 3 Intrinsically Safe System An intrinsically safe configuration develops the 1 5 volt process signal in the MTL
23. from Normal Operate Mode or from Manual Mode When entered from Manual Mode the valve is locked in position When entered from Normal Operate Mode however the valve still responds to changes in setpoint input signal and the values displayed change in accordance with changes in input signal When you exit from the Examine menu you return to the menu from which you entered October 1998 4 15 OPERATION UM760D 1 4 7 1 How to Enter the EXAMINE Menu If in Normal Mode and the Normal Operate Mode Display is shown input signal actuator pressure valve position displayed in sequence then 1 Press any button 2 Press to move through the options until Examine is displayed 3 Press to go to the Examine menu CONFIG will appear on the display This leaves the valve in the Normal Mode If in Manual Mode then 1 Press repeatedly until EXAMINE is shown 2 Press to go to the Examine menu CONFIG will appear on the display 4 7 2 Using EXAMINE to View Configuration Parameters 1 After entering the Examine menu press when CONFIG is displayed 2 Press to move forward through the list of configuration values Press to move backwards 3 Press to return to CONFIG at any time 4 7 3 Using EXAMINE to View Calibration Parameters 1 After entering the Examine menu press when CONFIG is displayed 2 When CALIB is displayed press 3 Press to move forward through the list of calibration values P
24. non hazardous and hazardous locations 3 3 4 Non Hazardous Locations An installation in a non hazardous location should be in accordance with the current edition of the National Electrical Code NEC or Canadian Electrical Code CEC and all local electrical codes 3 3 2 Hazardous Locations IMPORTANT An installation in a hazardous location must be in accordance with the current edition of the National Electrical Code NEC or Canadian Electrical Code CEC and all Local Electrical Codes For installation in hazardous locations the Controller must display the following The NEC or CEC hazardous location s for which the equipment is approved The FM or CSA logo Hazardous location classifications appropriate to the installation Before installing a controller in a hazardous location the need for energy limiting barriers and consideration of the FM entity parameters must be reviewed October 1998 3 15 INSTALLATION UM760D 1 When electrically installing a Controller in a hazardous area adhere to the guidelines on the control drawing P N 15032 7607 available from Moore upon request see section 1 2 Product Support A typical system consists of a Controller installed in a hazardous area energy limiting barriers installed in a non hazardous location and interconnecting twisted pair wiring WARNING Modifications to the Controller or installation of non approved options will void the electrical approval CAUTION In an intrinsically s
25. or CUSTOM L RECIP linear reciprocating The custom curve must have been entered through the remote PC TS OFF or ON Display and set value of tight shutoff point Default is 0 096 PL OFF or ON Display and set value of the lower software position limit stop Default is 0 096 PU OFF or ON Display and set value of the upper software position limit stop Default is 100 0 ENGLISH or FRNCAIS Select language for displays English or French 4 10 October 1998 UM760D 1 OPERATION 4 4 1 Configuration Procedures using pushbuttons NOTE Supply air does not need to be connected at this time To configure the ValvePAC unit execute the following procedures Refer to the menu structures in Figure 4 2 through Figure 4 7 for assistance with the following procedures 1 If in NORMAL OPERATE mode press any button OPER will be displayed Press to get to the MAN menu item Press to move to MANUAL menu This locks the valve in position and places it in MANUAL Mode POS MAN is displayed Press twice to move to gt CONFIG option Press to put the ValvePAC in the configure mode and display the first item in the CONFIGURATION menu In Single or Double if option displayed is correct press to move to the next item If not press to select the alternate choice When OK press to move to next item In CTL ON OFF if option displayed is correct press to move to the next item If not
26. position correspond to the nominal travel rather than the full stroke The STOP OP option allows this correction If a correction is to be made press to move valve to the 10096 position Using the and buttons position the valve to the nominal full open position Press to accept this position as the new 100 position 7 The Bias is the signal sent to the EPC the internal I P that causes the actuator to neither fill nor exhaust There is a large tolerance on the bias but if not set inside that tolerance the EPC will not have an output range sufficient to drive the spool valve properly In addition the Auto Tune feature will not be successful unless the bias is within tolerance To maximize the chance for a successful initial calibration the pneumatics are adjusted at the factory so that this value is near the center of the tolerance 2750 If the pneumatics still need to be readjusted for any reason the BIAS option should be selected by pressing This will output a value of 2750 to the EPC The bias screw shown in Figure 4 8 should be adjusted until the valve is nearly stationary near mid travel Remember to loosen then tighten the locking plate at the top of the adjustment screw Press to move to the next menu item 8 The TUNE menu item allows the user to initiate the automatic position control tuning function which will select appropriate PID parameters for the position controller This procedure will be most successful if th
27. press to select the alternate choice When OK press to move to the next item CTL OFF Note The controller is a factory installed option In ATO if option displayed is correct press to move to the next item If not press to select the alternate choice When OK press to move to the next item In LINEAR or other curve if the option displayed is the one desired press to move to the next item If not press to select the other options When OK press to move to next item If custom is selected the custom curve must have been entered through the optional ValVue software program The curve itself cannot be entered from the local pushbuttons The tight shutoff TS option allows the user to configure the controller to apply full supply pressure or atmospheric pressure to the actuator whenever the signal directs the valve near the closed position If the tight shutoff option is on the value of the TS option determines the near value at which the valve is forced fully shut In TS OFF ON if status and value displayed are satisfactory press to move to next item If not press to change on off status and display value Then press or buttons to increase or decrease value displayed When status is changed from ON to OFF no value is displayed When value is OK press to accept value and move to next item October 1996 4 11 OPERATION UM760D 1 10 11 12 13 The Val
28. provides immediate access to up to 20 frequently performed tasks The Quick Access Key menu is accessible when the Communicator is powered and on line or when the Communicator is off by simply pressing the Quick Access Key For the Quick Access Key to be active the Communicator must be connected properly to a HART compatible device From the factory the Quick Access Key menu includes for the ValvePAC Valve Controller e Examine View such device information as identifiers configuration calibration diagnostic data and status e Change Position Allows an operator to change the position setpoint More options can be added to provide rapid access to frequently performed tasks User defined options can be deleted later but these two factory options are permanent To use the Quick Access Key 1 Connect the Communicator to a HART compatible device 2 Press the Quick Access Key upper right hand key in the Moore760D VP100 action keys group The Communicator will power up and Hot Key Menu display the Quick Access Key menu at right 1 EXAMINE 2 change pos lt gt Before any custom options have been installed the Quick Access Key menu displays only the two factory installed options To add options see below 3 Use the UP and DOWN arrows followed by the RIGHT ARROW SELECT key to choose an option or press the option s number on the keypad The menu for the chosen option displays HELP SAVE 4 When finished pr
29. the optional software for remote control of the ValvePAC runs on standard IBM compatible computers with 486 or Pentium processors Minimum requirements are 8 MB RAM Windows 95 one available serial port with a HART modem and a hard disk drive The basic functions performed by ValVue are e Display of valve position actuator pressure setpoint calibration parameters configuration parameters and status error indicators Calibration Configuration Operation Manual control of valve position Perform valve diagnostics and display results signature friction stroking speed cumulative travel cycles and operation in near closed position e Recall previous test results for comparison with current data These remote functions except for extended diagnostics can also be performed with a hand held unit 1 1 1 ValvePAC FEATURES AND FUNCTIONS Local operation calibration and configuration using optional pushbuttons and digital display e Remote operation calibration and configuration diagnostics using ValVue software or a hand held HART communicator with Device Descriptor DD e Two way data communication using industry standard HART protocol e Automatic setup of valve travel range can be user modified e User configurable tight shutoff adjustment e Optional PID controller with remote setpoint and process variable inputs e User adjustable response times e Direct or reverse acting operation Compatible with air to close or air to
30. to display the Data Type menu below right Data Type Standard refers to all user editable variables in a device configuration Data Type Partial refers to only the marked editable variables Data Type Full refers to a all device variables whether user editable or not In general it is best to save as Data Type Standard Saving as Data Type Full preserves a complete configuration for future reference When all changes have been made save the new configuration to either the Memory Module or the Data Pack and return to the Offline menu A 5 1 2 Saved Configuration The second option on the Offline menu is the Saved Configuration menu which permits access to previously stored configuration data 1 Press 2 from the Offline Menu to display the Saved Configuration menu at right Select either Module Contents or Data Pack Contents to open stored configurations Both storage locations list all saved configurations by assigned Tag See XPAND below for more configuration identification details Note The PC option shown on the menu is not operational with firmware release 2 2 Unnamed Save as ea 1 gt Location 2 Name 3 Data Type Standard Module HELP SAVE Unnamed Name UNNAMED MYNAME 1 HELP SAVE Unnamed Data Type Standard Standard Partial Full HELP ESC ENTER HART Communicator Saved Configuration 1 gt Module Contents 2 Data Pack Contents April 1999 A 13 AP
31. x 0 313 Pan Head Screw 8 32 x 0 50 Flat Head Screw 8 32 x 0 938 Fillister Head Screw 8 Flat Washer Washer Cup 0 255 x 0 50 AR AAA AH SA SBA Ss Ss sa sm os os 2 Flat Indicator Kit 1 4 Turn 16300 487 Instructions Flat Indicator Flat Indicator 760 Standoff 1 00 Lg 6 32F Indicator Cover 760 Lens Flat Indicator Enclosure Cover Gasket Lens Gasket Lens Clamping Plate Label Electrostatic Hazard 6 32 x 0 313 Pan Head Screw 8 32 x 0 50 Flat Head Screw 8 32 x 0 938 Fillister Head Screw 8 Flat Washer Washer Cup 0 255 x 0 50 AR AAR A HAH Aa SBA Ss Ss Ss os os 3 Exhaust Vent 1 4 NPT 16300 203 4 Maintenance Parts Kit 16300 762 Filter Screen 3 Lens Gasket 1 Diaphragm Neoprene Nylon 1 O Ring Neoprene 1 487 x 0 103 1 5 Gage Kit 16300 763 Gage 1 160 PSI 1 8 NPT 2 PL760D 1 6 Local Display with Push Buttons Kit 16300 820 7 Adapter 3 4 NPT to M20 X 1 5F Brass NOTES 1 Seven kits and their contents are shown in the above lists The exploded view drawing has callout numbers 1 7 to correlate parts assemblies to listed kits 2 Referto Model 760D User s Manual UM760D 1 for servicing information Display PCB Assembly 760D LCD Spacer 760D 2 x 0 313 Philips Pan Head Screw 4 x 0 313 Philips Pan Head Screw Po po
32. 03 Q Pod 1 117 2 28 37 1 404 85 66 M6 X 1 1 968 l I 50 00 EXHAUST N 31 DP BOLT CIRCLE SUPPLY ene VALVE 1 INPUT SHAFT BACK VIEW 1 4 NPT FOR ROTARY TYPICAL APPLICATIONS RONDUIT CONNECTION RIGHT VIEW Dimensions in inches Millimeters 3 818 ARCA 96 99 t LJ 7 482 PEN 190 04 BOTTOM VIEW 760Ddima ds4 FIGURE 3 1 Installation Dimensions 3 8 October 1998 UM760D 1 INSTALLATION 3 1 1 Rotary Actuator Couple the specified rotary input shaft to the actuator shaft Shaft centerlines must be in line to minimize friction and binding as shafts rotate 3 1 2 Rising Stem Actuator When the actuator is at mid stroke the feedback lever must be perpendicular to the actuator stem The connection between the actuator stem and the feedback lever is typically made using a slotted bracket and a feedback pin The bracket is attached to the stem and must be rigid so that motion is transferred to the pin without deflection There are two ways to transfer the motion through the pin The recommended method is illustrated in Details A and B of Figure 3 2 Here the pin is fixed in the slotted bracket and rides inside the feedback arm For optimal linearity the distance between the centerline of the ValvePAC s shaft and the centerline of the pin at mid stroke must equal 0 866 x the actuator stroke The alternate assembly method is to fix the pin in the feedback lever and have it ride freely inside t
33. 788R barrier user supplied and returns it to the ValvePAC as a voltage signal The 728 barrier supplies the ValvePAC with the 4 20 mA signal This configuration requires special certification approved by the local jurisdiction It connects two IS loops together in one instrument a configuration not generally allowed Note that in each configuration the negative input to the ValvePAC and the B input remain at the same potential except for wiring drops For an example of this configuration refer to Figure 3 9 3 6 October 1998 UM760D 1 INSTALLATION 3 0 INSTALLATION If the controller is to be stocked stored or shipped to another location prior to piping make sure that the factory installed plastic plugs remain in the pneumatic ports to prevent entry of moisture dirt or other contaminants Operating limits are stated in section 8 0 Specifications of this document The temperature in the selected location must not exceed the specified operating temperatures CAUTION Exceeding the specified operating temperature limits can adversely affect performance and safety and may cause damage to the Controller The Controller will need to be calibrated before being put into service 3 1 MOUNTING ON THE ACTUATOR Refer to Figure 3 1 for dimensions and mounting hole locations The ValvePAC can be mounted in any orientation but the mounting must be rigid for optimal performance 1 Determine the orientation of the unit If the Valve
34. 9 E Mail TICGroupEurope moore solutions com Hours of Operation 8 30 a m to 5 15 p m GMT BST Monday Friday except holidays Secure Web Site www moore solutions com techservices 1 3 RELATED LITERATURE When the ValvePAC is furnished with the optional software the following Software Guide should be available when configuring the ValvePAC e ValVue Configuration Software for the ValvePAC ValvePAC Digital Valve Controller SG15939 76 1 4 October 1998 UM760D 1 INSTALLATION 2 0 PRINCIPLES OF OPERATION When configured as an electro pneumatic valve controller the ValvePAC unit accepts a 4 20 mA setpoint signal from a controller or other device After adjusting for zero and span it compares this input signal to the actual valve position which it measures with the potentiometer that is connected to the feedback shaft The difference between the setpoint and the actual position is then amplified and a corrective current signal is sent to the electro pneumatic converter EPC The EPC converts the current signal to a pneumatic signal which is sent to the pneumatic relay and the spool valve The spool valve directs supply air to the actuator to move the valve until the potentiometer reading agrees with the setpoint m E ELECTRONICS MODULE MICROPROCESSOR ERROR DETECTED CORRECTIVE SIGNAL SENT
35. A USER S MANUAL Process Automation Solutions UM760D 1 Rev 1 October 1998 Series 760D ValvePAC Digital Valve Controller Intelligent Valve Control Our Positioners Control the Best Valves amp Actuators in the World UM760D 1 SECTION SR NAWNRwWNHS bihi hibo NNN t2 t3 09 2 C2 C2 C2 GA gt gt gt EES ie Ne A 4 2 1 4 2 2 4 2 3 4 2 4 4 3 4 4 4 4 1 4 5 4 5 1 4 6 4 7 4 7 1 4 7 2 October 1998 CONTENTS TABLE OF CONTENTS TITLE PAGE INTRODUCTION o enenatis 1 1 PRODUCT DESCRIPTION eaa a a esse ees 1 1 ValvePAC FEATURES AND 2 1 2 PRODUCT SUPPORT 4 Schieber ee See See ae eh 1 2 RELATED LITERATURE 2 1 4 PRINCIPLES OPERATION 222 2 1 BEAS e 2 1 22 2 2 PUSHBUTTON S 2 3 FEEDBACK POTENTIOMETER 00004000 eese 2 3 AUTOTUNE 2 4 PROCESS DESCRIPTION aeaee oeaio eae eiie e ee esie Sae a 2 4 PROCESS CONTROLLER OPTION
36. Air 5 2 October 1998 UM760D 1 TROUBLE SHOOTING The ValvePAC requires sufficient supply pressure to drive the actuator against its stops For best results the supply pressure should be about 5 psi higher than the pressure required to drive the actuator to its stops refer to the actuator data plate for the actuator pressure range For example if the actuator is nominally 3 to 15 psi set the supply pressure to approximately 20 psi The maximum pressure that can be applied to the ValvePAC is 100 psi Consult the factory if a higher pressure is required WARNING Never exceed maximum supply pressure Injury to personnel and damage to equipment may result Maximum allowable air supply pressure to the controller varies according to actuator valve size and valve type See pressure drop tables in valve catalog user supplied to determine correct controller supply pressure Plugging or applying pressure to the Exhaust port will damage the unit and may cause personal injury Pressure in excess of 100 psi in the V1 V2 or Supply ports may cause damage to the controller Supply pressure to the controller must not exceed actuator maximum pressure rating In addition the following conditions must be met 1 The exhaust port must vent to atmosphere e g no obstructions and not under water 2 The actuator port s V1 and or V2 must be connected to the actuator For best response times use tubing of 3 8 inch minimum size After disconnect
37. C should be supplied with instrument quality air Follow these guidelines for instrument quality air when making the pneumatic connections CAUTION Synthetic compressor lubricants in the air stream at the controller may cause it to fail There are many types of synthetic lubricants Some may not be compatible with the materials used in the construction of the ValvePAC Wetting of these materials by such an oil mist or vapor may cause them to deteriorate This can result in failure of the ValvePAC Requirements for a quality instrument air supply can be found in the Instrument Society of America s Quality Standard for Instrument Air ISA S7 3 Basically this standard calls for the following Particle Size The maximum particle size in the air stream at the instrument should be no larger than 3 microns Dew Point The dew point at line pressure should be at least 10 C 18 F below the minimum temperature to which any part of the instrument air system is exposed at any season of the year Under no circumstances should the dew point at line pressure exceed 2 C 35 6 F e Content The maximum total oil or hydrocarbon content exclusive of non condensables should not exceed 1 ppm under normal operating conditions 3 2 2 Piping Connect the controller to a source of clean oil free instrument air Instrument air requirements are given in the preceding section Failure to do so will increase the possibility of a malfuncti
38. ELP DEL ESC ENTER e g XYZ S2 3R followed by a dash followed by any single character e g 1 D M and ending with a 1 The tags A M1 B1 A N2 Z1 or A SF X1 would display whereas the tags BA53 PT101 or ATT48 would not display XPAND The XPAND function key allows a user to view the Tag Descriptor and Name for the configuration being edited or VP118 viewed Selecting Compress restores the previous compressed Saved Configuration display which shows only the current Tag Descriptor or 1 gt Edit Name 2 Copy to 3 Send 4 Print 5 Delete HELP 1 With the Module Contents or Data Pack Contents menu displayed press the RIGHT ARROW SELECT key to open the Saved Configuration menu for a device that was highlighted at right Edit displays the Edit menu providing the same functions as described under Edit individually in Section A 5 1 1 When editing off line only stored data may be edited Moreover data stored as a Partial configuration must be converted to a Standard configuration then saved prior to editing A 14 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR Copy To specifies the storage location for a copy of the configuration Copy To also provides a way to change the configuration name Send sends a saved configuration to a connected device Print not implemented with firmware release 2 2 Delete removes a saved configuration from memory
39. F and G Class III Division 1 Class I Division 2 Groups A B C and D Suitable for Class II Division 2 Groups F and G Class III Division 2 CSA Canadian Standards Intrinsically Safe Class I Division 1 Groups A B C and D Association Certification Class II Division 1 Groups E F and G Class III Division 1 Suitable for Class I Division 2 Groups A B C and D Class II Division 2 Groups E F and G Class III Division 1 CENELEC Certification Intrinsically Safe EEx ia 4 SCS Sira Certification Services N IIC T5 Suitable for Zone 2 Enclosure Rating Type 4X in accordance with NEMA Std 250 Type IP 65 in accordance with IEC Std 529 NOTE The ValvePAC unit is designed to meet the electrical safety specifications listed here Consult factory for current status of agency approvals 8 2 October 1998 WARRANTY The Company warrants all equipment manufactured by it and bearing its nameplate and all repairs made by it to be free from defects in material and workmanship under normal use and service If any part of the equipment herein described and sold by the Company proves to be defective in material or workmanship and if such part is within twelve months from date of shipment from the Company s factory returned to such factory transportation charges prepaid and if the same is found by the Company to be defective in material or workmanship it will be replaced or repaired free of charge f o
40. F key to turn the Communicator off A 4 3 Reviewing Installed Devices For the HART Communicator to recognize a HART compatible device it must have a description for that device installed The HART Communicator is supplied from the factory with a description for the Moore Series 760D ValvePAC Valve Controller and other HART compatible devices from leading manufacturers In addition it contains a generic device description which allows limited access to most HART devices when no device description for that specific device exists in the Communicator To review the currently installed devices on the Communicator use the following steps 1 Turn on the Communicator off line to display the Main Menu 2 From the Main menu press 4 on the keypad for quick access to the Utility Menu 3 From the Utility menu press 5 on the keypad to access the simulation mode The LCD shows the Manufacturer menu which contains a list of manufacturers whose device descriptions are installed in the Communicator 4 Press the DOWN arrow until Moore Products appears Press the RIGHT ARROW SELECT key to reveal the Model menu which lists the Moore Products Co devices currently installed in the Communicator see Table A 2 5 To end the review of devices press the LEFT ARROW PREVIOUS MENU key three times 6 Turn off the Communicator or proceed to the next section April 1999 A 9 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1
41. G Explosions can cause death or serious injury Before connecting the HART Communicator in an explosive atmosphere make sure that the instruments in the loop are installed in accordance with intrinsically safe or non incendive field wiring practices Refer to the Communicator nameplate and the manual supplied with the Communicator for certifications and approvals before connecting A 2 COMMUNICATOR CONNECTIONS The Communicator can interface with an instrument from the control room the instrument site or any wiring termination point in the loop Connections are made through loop connectors on the Communicator s connection panel Figure A 1 The connection panel also may have a jack for the optional NiCad recharger and it has a serial port for a future connection to a personal computer PC To interface with an instrument or other HART device connect the HART Communicator in parallel with the instrument or load resistor The connections are nonpolar For intrinsically safe FM and CSA wiring connections see the manual supplied with the Communicator WARNING Explosions can result in death or serious injury Before making connections to the serial port or NiCad recharger jack in an explosive atmosphere check the Communicator nameplate and the manual supplied with the Communicator for approvals April 1999 A 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 Figure A 2 illustrates typical wiring connections between th
42. HA x gt CNTL 41 HHA EXAMINE a HA gt OPER Examine Menu To the Normal Operate Mode Display Display Sequence NRMLMENU ds4 FIGURE 4 3 NORMAL OPERATE MODE SELECT and MANUAL Menu Structures 4 5 OPERATION UM760D 1 4 2 2 Configuration Menu Because calibration depends on certain configuration options you must perform Configuration before you perform Calibration when installing the ValvePAC the first time CONFIGURATION MENU From in Manual Menu Y Press to select option Select type of Actuator A Press or to accept and double not implemented SINGLE A move to next menu item at present DOUBLE Select Controller Option B Press to select option CTL OFF is always gt CTLOFF Press or to accept selected if no controller 4 CTLON move to next menu item is present even if no limit SW is used Press to select option Select Air to Close or Air gt ATO N Press or to accept and to Open very important ATC move to next menu item to set correctly Select Characterization gt LINEAR gt EQUAL 50 gt EQUAL 30 A 2 CUSTOM L RECIP QUICK
43. Items 5 MM DD YY 10 10 10 MOT P 6 XVrite Protect Yes i Previous Menu 1 0303450 FIGURE A 3 Communicator Display Icons A 4 2 Menu Structure The HART Communicator uses a hierarchical menu structure That is high level menus are accessed first and they provide access to lower level menus This structure groups related functions together and minimizes the number of options displayed at once To learn how the menu structure works perform the following actions 1 With the Communicator off line not attached to any devices press the ON OFF key to turn the Communicator on After running a self diagnostic it will display the Main menu with the cursor gt positioned at 1 Offline 2 Access the Utility menu by pressing the DOWN arrow key three times then pressing the RIGHT ARROW SELECT key The display changes to show the Utility menu 3 Access the Configure Communicator menu from the Utility menu by pressing the RIGHT ARROW SELECT key The display changes to show the Configure Communicator menu A 8 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR 4 Access the Contrast menu by pressing the DOWN arrow once then pressing the RIGHT ARROW SELECT key The display shows a message explaining how to adjust the LCD contrast 5 Press ESC F3 to return to the Configure Communicator menu 6 Press the LEFT ARROW PREVIOUS MENU key two times to return to the Main menu 7 Press the ON OF
44. LCD ENTER accept user entered data EXIT leave the current menu NO answer to yes no question ONE include Quick Access Key item for one device April 1999 A 5 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 A 3 3 Action Keys Directly beneath the LCD and software defined function keys are six blue white and black action keys Each has a specific function as described below automatically searches for a HART compatible device on the 4 20 mA loop If no device is 4 ON OFF KEY Use to power up the Communicator When Communicator is turned on it found the Communicator displays the Main menu HART Communicator 1 gt Offline 2 Online 3 Frequency device 4 Utility If a HART compatible device is found the Communicator displays the Online menu Moore760D VP100 MANUAL MODE a 1 gt valve pos 14 8 act press 0 1 psi change pos lt gt MANUAL MODE MENU CONTROLLER HELP SAVE UP ARROW KEY Use to move the cursor up through a menu or list of options or to scroll through lists of available characters when editing fields that accept both alpha and numeric data DOWN ARROW KEY Use to move the cursor through a menu or a list of options or to scroll through lists of available characters when editing fields that accept alpha and numeric data LEFT ARROW PREVIOUS MENU KEY Use to move the cursor to the left or back to the previous menu RIGHT ARROW SELECT KEY Use to m
45. Menus see 4 4 Configure o GEG EGE fou 4 6 Calibrate Menu aee ete e e de ee deridet eters 4 7 Examine Ment m cc 4 8 NORMAL OPERATION 2 2 2 1 00 4 10 CONBIUGRATION 2 2 22 22 082 4 2 2 20 etis teile dete dete bee ee ede eu 4 10 Configuration Procedures using pushbuttons eee 4 11 CAEIBRACHION ote le te cet ed Le d Ld Ed Leki teal LE Be tad 4 12 Calibration Procedures using pushbuttons eee 4 13 USING THE PUSHBUTTONS TO ADJUST POSITION 4 15 EXAMINE ote eeepc obe eere ode ext 4 15 How to Enter the Examine Menu eene eene nnne 4 16 Using Examine to View Configuration Parameters 2 211222 4 16 CONTENTS TABLE OF CONTENTS Continued SECTION TITLE 4 7 3 Using Examine to View Calibration Parameters 4 7 4 Using Examine to Display Clear Faults sess 4 8 FAULT MESSAGES 5 0 TROUBLESHOOTING 5 1 INTRODUCTION ele esee etes es es edes 5 1 1 Factory Service alist nes 5 2 FAIL SAFE DISPLAY 52 1 Fail Safe Considerations 2 000000 000000000 5 2 2 IE PTT 5 3 PROBLEMS AND SOLUTIONS errem 5 3 1 C
46. ONNECTIONS ee eoe Gesu cosh Gust cosh Gust ra ear enn 5 3 1 1 Pneumatic Connections 5 3 1 2 Electrical Connections 2 5 3 2 GROUNDING 0 5 3 3 5 3 4 HART CommuniCations e eoe etu ee o ae eu eee ree a o n eene 5 3 5 pias Adjustin nt 5 3 6 2 22 22 MJ ARSA 5 37 Position Instability ceo eee e ere sees 5 4 TROUBLESHOOTING CHECKLIST cttm 6 0 MAINTENANCE ssaubohsshbosbh s bb GG Sb 6 1 FILTER SCREENS 6 2 SPARE AND REPLACEMENT PARTS 6 3 RETURN FOR REPAIR so cccccscccccecocccocnsvcccovnvececcuavsedecavesedecavescoctes 7 0 MODELE DESIGNASEIQN 7 1 OPTIONS E SEG oe es BASE OAS SiS E REIP EE NES 8 0 SPECIFICATIONS WARRANTY DECLARATION OF CONFORMITY LIST OF ILLUSTRATIONS FIGURE TITLE 2 1 Block Diagram of ValvePAC Unit Actuator and Valve 2 2 Setpoint Operation deesse tote dendi eed 3 1 Installation Dimensi on 2 Re 3 2 Controller Mounting and Feedback Pin Connection 3 3 Retaining Clip Position nennen 3 4 Input Output Diagram 0 3 5 Internal Wiring Connections 3 6 Basic Valve Contro
47. PAC is to be mounted on a rotary actuator see section 3 1 1 Rotary Actuator If the ValvePAC is to be mounted on a rising stem actuator see section 3 1 2 Rising Stem Actuator 2 Position the ValvePAC on the actuator mounting bracket and secure in place with four M6 x 1 bolts 3 Install the pneumatic piping 4 Install the electronic connections October 1998 3 7 INSTALLATION UM760D 1 RISING STEM APPLICATION ROTARY APPLICATION 7 840 199 14 6 190 157 24 8 0 25 AS es pi t 6 1 E ipl2 s SO D INPUT SHAFT m FOR RECTILINEAR APPLICATIONS 2 050 12 7 SQUARE 8 FOR ROTARY D D APPLICATIONS 0 58 D 14 73 RIGHT VIEW FRONT VIEW COME ROTARY APPLICATION im mE oe 2 396 325 60 86 8 26 o lt 596 seal VALVE 2 perl a Mie ee oad 2 618 17 mm 69
48. PENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 The Module Contents menu which lists the configurations currently stored in the Memory Module is shown at right HART Communicator Data Pack Contents a The Data Pack menu is similar Both give the user several gt 101 options for handling and viewing configuration data as VP102 explained below VP103S VP104 FILTR The FILTR function key F1 opens a menu that provides FILTR XPAND both Sort and Filter options These options select only the chosen configurations from all those stored This is particularly valuable for the Data Pack which stores up to 100 configurations Sort allows unique device configurations to be grouped and displayed by Tag Descriptor or user assigned Name Filter allows configurations to be grouped and displayed according to certain characters within the chosen device identifier Tag Descriptor or Name It is useful for selecting all the tags from a certain area of the process or plant When setting up a Filter see display at right two wildcard characters the period and the asterisk are used The period replaces a single character of any value The asterisk replaces one or more alphanumeric characters of any value A 1 HART Communicator Tag Filter For example if A 1 is entered as the filter the configurations displayed will be all those with device tags starting with A followed by any combination of characters H
49. TROUBLESHOOTING 5 1 INTRODUCTION This chapter offers procedures and options to confirm setup and configuration and allows you to exhaust most service options before seeking assistance from a factory trained technician By first following these procedures you can save time prevent costly downtime and provide the service technician with more detailed information about the possible problem 5 1 1 Factory Service Trained service personnel perform high level ValvePAC troubleshooting and servicing Should the ValvePAC unit require replacement of internal parts the unit will be replaced with a new or rebuilt unit An extensive replacement inventory is available for immediate shipment If this service is needed contact your local salesperson or contact Moore at www mooreproducts com 5 2 FAIL SAFE DISPLAY 5 2 1 Fail Safe Considerations A reading of Fail Safe on the display indicates a fatal or non fatal error in the ValvePAC and acknowledges that the computer holds the output in a fail safe condition The misplacement of the position sensor potentiometer is just one of many problems that can create a Fail Safe error Refer to Using EXAMINE to Display Clear Faults for how to use the pushbuttons to view these errors NOTE Not all errors are fatal e g not all errors cause a fail safe condition 5 2 2 Latches Certain errors occur and self correct The ValvePAC clears the bit in the status when the error disappears and uses latches to sh
50. UNIVERSAL HART COMMUNICATOR Examine Read Identifier Positioner Configuration From either the Manual Mode Menu or Normal Mode Figure 5 Read Identifier Tag Descriptor Message Final Assembly Number Date Polling Address Manufacturer Model Moore 760D Device ID Universal Command Revision Transmit Command Revision Positioner Configuration Read Identifier Continued Software Revision Hardware Revision Physical Signal Code Device Flags Number Response Preams Setup Air to Close On Off Double Acting On Off Reverse Instrument On Off Setup e Fail High On Off Limit ie Controller On Off COS Level pues Limit Bumpless Transfer On Off am Hardware Reverse On Off Position Unit Tight Shutoff Pressure Unit psi Language English Positioner Calibration Positioner Calibration Diagnostic Data Read Status Clear Status Positioner PID Diagnostic Data Total Travel Time Closed Time Open Time Near Closed Number of Cycles Friction psi Lower Spring Range Upper Spring Range Lower Pressure Upper Pressure Stroke Time Open Stroke Time Closed Low Signal High Signal Low Pressure Value High Pressure Value Error Limits Error Limits Switches Position Controller Configuration 3 Controller Calibration Controller PID Controller Configuration Primary Variable Units Setpoint Units Controller Rate Initial Local Setpoint C
51. afe installation follow code practice when servicing the instrument in the field 3 3 2 1 Sira Certification Service Special Conditions for safe use denoted by X after certificate No 1 The following are the maximum input parameters A Field Connector Power Input B Field Connector A B C Controller Link U 30 4 U 30 Vdc 1 125mA C OuF P 09W L OmH C 2 2 nF L 96uH Perform the following steps to install the ValvePAC in a hazardous location Note that barriers may not be needed in an installation 1 Install Controller as detailed in the preceding sections 2 Install energy limiting barriers in the non hazardous area Refer to the barrier manufacturer s instructions and to the appropriate connection diagram in the control drawing P N 15032 7607 available from Moore upon request see section 1 2 Product Support 3 Install conduit for wiring to Controller Install pull boxes as needed and remove burrs and sharp edges from conduit tubing 4 Install wiring between Controller and barriers per the control drawing P N 15032 7607 available from Moore upon request see section 1 2 Product Support Ground the Controller A barrier must be grounded and the resistance to ground must not exceed 1 ohm 3 16 October 1998 UM760D 1 INSTALLATION 5 Install the wiring between barriers and output terminals of the Controller driving device 6 Check all signal and ground connections before applying po
52. al mode The valve does not perform the Review the following conditions open close command correctly 1 Confirm that the supply pressure is set properly and that it is connected to the ValvePAC 2 See Calibration Procedures using pushbuttons to check and adjust the bias 3 If the valve is stuck it may need to be cleaned 4 If FAILSAFE appears on the display review Fail Safe Display 4 The evaluation of a faulty EPC or faulty connection to the EPC is beyond the intent of this procedure and the ValvePAC unit must be returned to the factory for repair or replacement Set the STOPS as described in Calibration The procedure runs successfully Continue to step 8 FAILSAFE is displayed when the The position sensor potentiometer must be reset valve hits either one of its stops Refer to Fail Safe Display Perform the automatic TUNE operation as described in Calibration THEN The procedure runs successfully Continue to step 9 BIAS is displayed for over 5 minutes The bias needs to be adjusted Stop the Auto while the procedure continues to run Tune procedure and mechanically adjust the bias by changing the bias spring s compression Follow the procedure in Calibration Procedures using pushbuttons The procedure runs to completion but Refer to Damping Coefficient the Damping Coefficient is non zero While still in Manual mode use the pushbutto
53. alve Controllers may be connected together and powered on a single pair of wires Figure A 7 Each unit must be set to the Multi Drop function by positioning the jumper on the terminal board Each unit must be configured with a unique Polling Address number from 1 to 15 before being installed in the loop Each unit must be set to Manual Mode operation and controlled with HART commands April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR See Note 4 lt gt Non Hazardous Hazardous 250 Location Location See Note 2 R2 Network Primary Master See Note 1 System O Power Supply E2 Model 760D Model 760D Model 760D Valve Positioner 1 Valve Positioner 2 Valve Positioner 15 See Notes 3 amp 6 See Notes 3 amp 6 See Notes 3 amp 6 Notes 1 The System Power Supply is shown separate from the host input device In practice it may be part of the host input device The host input device can either be a HART or non HART signaling device a Primary Master or Secondary Master 2 Network resistance equals the sum of the barrier resistances and the current sense resistor Minimum value 250 Ohms maximum value 1100 Ohms 3 A maximum of 15 instruments may be connected All must be configured for digital mode 4 Connect the HART Communicator as shown in Figure A
54. ay It will appear momentarily when the unit is powered up If it continues return the unit to the factory HART PROBLEMS 2 Ifahand held HART communicator or the optional ValVue software is to be used connect it to the unit and attempt to establish communications THEN Continue to Sep 3 Communication is unsuccessful Verify that the 4 20 mA wires are not loose used Verify that the HART wires are clean and in good condition Verify that there is no other master device in service Check grounding per Grounding CONFIGURATION PROBLEMS 3 Confirm the accuracy of the configuration parameters Errors here are easy to fix yet they are often overlooked 4 Turn on the supply pressure 5 Place the ValvePAC in Manual mode using hand held commands the pushbuttons see Operation or the optional ValVue software STEP ACTION determine the cause Clear the error and restart Verify that the correct device descriptor is being October 1998 5 13 TROUBLE SHOOTING UM760D 1 TABLE 5 6 Trouble Shooting Checklist Continued 6 7 amp PERFORMANCE PROBLEMS With the unit still in Manual mode confirm that the valve is in the set position by moving it to the fully open and fully closed positions This step requires ValVue software Skip if it is unavailable IF THEN The valve correctly performs the Continue to step 7 open close command in manu
55. b Company s factory The Company assumes no liability for the consequence of its use or misuse by Purchaser his employees or others A defect in the meaning of this warranty in any part of said equipment shall not when such part is capable of being renewed repaired or replaced operate to condemn such equipment This warranty is expressly in lieu of all other warranties guaranties obligations or liabilities expressed or implied by the Company or its representatives All statutory or implied warranties other than title are hereby expressly negated and excluded Warranty repair or replacement requires the equipment to be returned to one of the following addresses Equipment manufactured or sold by MOORE PRODUCTS CO MOORE PRODUCTS CO Sumneytown Pike Spring House PA 19477 U S A Tel 1 215 646 7400 Fax 1 215 283 6340 Equipment manufactured or sold by MOORE PRODUCTS CO Canada Inc MOORE INSTRUMENT LTD LTEE P O Box 370 Brampton Ontario L6V 2L3 Canada Tel 41 905 457 9638 Fax 1 905 457 4182 Equipment manufactured or sold by MOORE PRODUCTS CO UK LTD MOORE PRODUCTS CO UK LTD Copse Road Lufton Industrial Estate Yeovil Somerset BA22 8RN England Tel 44 1935 706262 Fax 44 1935 706969 Warranty will be null and void if repair is attempted without authorization by a member of the Moore Products Co Service Department 1ueuido oAe pue yoreasay lodeueJA again Dd RA 4 gt 27 V
56. cludes three steps e Search for bias e Estimate control parameters e Refine control parameters In searching for the bias the ValvePAC locally displays values such as 2753 and 2761 that approach or converge on a real bias value Expect the valve to move back and forth slow down and remain still by the end of this step In estimating control parameters ValvePAC displays three types of values input step sizes such as 80 and 320 valve relative opening such as 1874 and 1756 and dead time such as 4 00 and 7 00 Expect the valve to move back and forth several times ValvePAC uses these tests to estimate the preliminary control parameters based on position control characteristics In refining the estimated control parameters ValvePAC displays several numbers such as 1211 and 6 Interpret the number 1211 as the rising time T98 is 12 x 0 05ms 0 6 ms and overshoot is 11 The code number 6 indicates a specific control parameter adjustment A successful AutoTune provides position step responses in both air fill and exhausting directions that meet the tuning criteria Overshoots range between 0 and 8 and rising times range from 0 5 second for a small actuator to 1 5 second for a large actuator A successful AutoTune updates the previous control parameters AutoTune usually results in fast position responses 0 to 8 overshoots If the user prefers a smooth response without overshoots reduce the P value by 10 to 2096 If the user
57. ctional areas is used to enter commands and display data A 3 1 Liquid Crystal Display The liquid crystal display LCD is an 8 line by 21 character display that provides communication between the user and a connected device When the HART Communicator is connected to a ValvePAC Valve Controller or other HART compatible device the top line of the Online menu displays the model name of the device and its tag A typical display is shown below Moore760D VP100 MANUAL MODE a 1 gt valve pos 14 8 act press 0 1 psi change pos lt gt MANUAL MODE MENU CONTROLLER HELP SAVE The bottom line of each menu is reserved for dynamic labels for the software defined function keys F1 F4 which are found directly below the display More information on software defined function keys is given in the next section A 3 2 Software Defined Function Keys The four software defined function keys softkeys located below the LCD and marked F1 through F4 are used to perform software functions as indicated by the dynamic labels Pressing the function key immediately beneath a label activates the displayed function The label appearing above a function key indicates the function of that key for the current menu For example in menus providing access to on line help the HELP label appears above the F1 key In menus providing access to the Online menu the HOME label appears above the F3 key Table A 1 lists these labels and describes what happens when
58. d Feedback Pin Connection 3 10 76 00 October 1998 UM760D 1 FEEDBACK LEVER FEEDBACK PIN UPWARD POSITION 1 UPWARD POSITION 2 A Upward Mounting Positions INSTALLATION RETAINING CLIP DOWNWARD POSITION 1 DOWNWARD POSITION 2 B Downward Mounting Positions 30 00 Cx S ___ Mid stroke Position Slide Area C Feedback Pin Slide Area FIGURE 3 3 Retaining Clip Position October 1998 3 11 INSTALLATION 3 2 INPUTS OUTPUTS UM760D 1 As shown in the block diagram below the ValvePAC has the following inputs and outputs e Setpoint signal for valve position when configured as a valve controller or for a PID controller when configured with a process controller e Actuator pressure e Valve position e Process variable SET POINT SIGNAL FOR VALVE POSITION OR PROCESS 4 20 mA CONTROLLER SET POINT INPUT Series 760D ValvePAC PROCESS VARIABLE WHEN CONFIGURED AS A PROCESS CONTROLLER 1 5 V AIR SUPPLY UP TO 100 PSI 0 100 PSI AIR PRESSURE TO FROM ACTUATOR 0 100 PSI IF DOUBLE ACTING MECHANICAL POSITION FEEDBACK FROM VALVE STEM NOTE ELECTRIC POWER IS SUPPLIED FROM A 3 LOCAL DIGITAL PUSHBUTTONS DISPLAY IODIAGA ds4 FIGURE 3 4 Input Output Diagram 3 12 October 1998 UM760D 1 INSTALLATION 3 2 1 Pneumatic Connections The ValvePA
59. d indicates the AutoTune result TABLE 5 5 Damping Coefficients DAMPING MESSAGE ACTION COEFFICIENT 33 The found Bias is not in the required Adjust the Bias range and self tuning is canceled 34 The found Bias is not in the required Adjust the Bias range and self tuning is canceled The found Bias is not in the required Adjust the Bias range and self tuning is canceled Self tuning for air exhausting direction Check the pneumatic block fails after 30 times tuning especially spool S A Self tuning for air fill direction fails after Check supply pressure 30 times trying check noise check the pneumatic block especially spool S A NOTE The Damping Coefficient adjustment range is 0 to 9 The out of range value is equivalent to 0 or no damping Unacceptable Response Characteristics Valve position responses depend on many factors including the condition of the valve actuator and process ambient temperature noise the ValvePAC itself supply pressure and the setup and step change size for the positioner control parameters NOTE A 5 step change requires a change in the 20 to 80 opening range With damping coefficient of zero no damping consider the following valve responses unacceptable Overshoot greater than 20 Rising time T98 greater than 1 5 seconds for small actuators and 2 5 seconds for large actuators Dead time greater than 0 5 seconds Limit cycling peak to peak measurement greater than 0 5 Position stead
60. dback Mounting Bracket and Input Gear eee 5 7 LIST OF TABLES TITLE PAGE TIC Contact Information ace eee A AAA ee e eere Ans 1 3 Pneumatic ConnectwOms oet eoo edi Ea 8 3 8 Local Configuration Options 4 10 dl eee v en on 4 17 Brror Eatches 2d bett e EE TEE Ae 5 2 Electrical Connection List e aie 5 4 Process Controller Ground Checklist 5 5 Blank Display Checklist eiseres cisci 2 11i ioi sees te oie teo dentes aist 5 6 Damping Coefficients simeik o oH HC HE E e ui oi ood 5 11 Tro bl Shootime Checklist eed eee 5 13 SIDIDINSERERRREERRRR TERI 7 2 Operating Limits Eee UU eu uu eue 8 1 Performance Specifications Controller Mode Only ee 8 1 Physical Specifications 2 8 2 Electrical Safety Design Specifications 8 2 a CONTENTS UM760D 1 Changes for September 1999 printing Cover and page dates were not changed at this time Section Change 1 2 Product support information updated Moore Products Co assumes no liability for errors or omissions in this document or for the appl
61. e as read only allows users to view but not change the parameter using the Quick Access Key Menu Marking it as read write permits the value to be changed from the Quick Access Key menu Finally Display value of variable on hotkey menu may be displayed Press YES F1 to display the current variable associated with the option next to the option on the Quick Access Key menu as shown at right for Damping and Tag Press NO F2 not to display the variable on the Quick Access Key menu When finished adding options press EXIT F4 to exit the Hotkey Configuration menu and return to the menu of the last option deleted A 6 2 Deleting Quick Access Key Options Moore760D VP100 Hotkey Configuration ADD tuning EXAMINE lt gt Change pos ADD EXIT Use the following steps to delete an option from the Quick Access Key menu 1 From any on line menu press any shift key release it then press the Quick Access Key The Hotkey Configuration menu displays at right Using the UP or DOWN arrow key move the menu bar to highlight the option to be deleted and press DEL F2 Factory provided options cannot be deleted When finished deleting options press EXIT F4 to exit the Hotkey Configuration menu and return to the menu of the last option deleted A 7 MULTI DROP NETWORK Moore760D VP100 Hotkey Configuration ADD Descriptor Examine lt gt Change pos tuning DEL ADD EXIT As many as 15 ValvePAC V
62. e Data Pack EEPROM A 5 4 3 Listen for PC Not implemented A 5 4 4 Storage Location From the Utility menu the Storage Location menu at right provides access to data concerning the Memory Module or the Data Pack Information available through this menu includes a label for the Memory Module or Data Pack a feature that displays the total storage used bytes and the storage remaining free bytes PC selection is not implemented A 5 4 5 Simulation Use Simulation mode to simulate an on line connection to a HART compatible device without connecting to the device Simulation mode is a training tool that allows users to become familiar with different devices before configuring them in a critical environment First select a manufacturer from the Manufacturer menu then select a device from the Model menu just as is done when on line After selecting a software revision the Online menu for the simulated device is displayed Functions are the same as those available when on line HART Communicator System Information 1 gt Motherboard 2 Module 3 Data Pack HELP DEL ESC ENTER HART Communicator Storage location 1 gt Module 2 Data Pack 3 PC HELP DEL ESC ENTER A 22 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR A 6 USING THE QUICK ACCESS KEY Pressing the Quick Access Key Hot Key while on line displays the Quick Access Key menu a user definable menu that
63. e HART Communicator and a loop with a ValvePAC Valve Controller or other HART compatible device on a loop The Communicator is quickly connected into an instrument loop Connection Panel Loop Connections Non Polar o Serial Port NiCad Recharger Jack Optional X03032S0 LCD Function Keys Software Defined ttt HART Communicator Action Keys Communicator Nameplate it On Back See nameplate Guick Access Kay 55 for certifications and approvals before connecting in a hazardous location Communicator Model Number and Serial Number On Back Previous Menu Back left arrow Down Arrow Select Forward right arrow lt Alphanumeric Keys Keypad number sequence may be different from that shown EE Shift Keys Use to select alphabetic and other characters above a number period or dash FIGURE A 1 Model 275 Universal HART Communicator A 2 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR Current Sense Circuit Resistor 250 to Junction 1100 See Note 3 AG00240a lt lt gt Non Hazardous Hazardous Location Location Y Controller or Other 4 20 mA Model 760D Device See Terminals 14 Note 2 2 Ground See Note 4 Notes 1 HART Communicator Connecti
64. e bias is in tolerance and the unit has been given the opportunity to fully stabilize after any recent step changes Press to initiate the AUTO TUNE function This procedure may take from 1 to 5 minutes During this time the valve will make a series of steps CAUTION This procedure should not be performed while the valve is controlling the process When the function is completed return to TUNE Press to advance to the next item 4 14 October 1998 UM760D 1 OPERATION 9 SIG LO displays the input signal that should correspond to the full closed or full open position of the valve depending upon whether the valve is air to open or air to close and whether the controller is direct or reverse In SIG LO if the displayed value is correct press to advance to the next item If not press to display value of SIG LO Use and buttons to change the value When OK press to return to menu and move to next item 10 SIG HI displays the input signal that should correspond to the full open or full closed position of the valve depending upon whether the valve is air to open or air to close and whether the controller is direct or reverse SIG HI must be larger than SIG LO by at least 5 mA In SIG HI if the displayed value is correct press to advance to the next item If not press to display value of SIG HI Use and buttons to change the value When OK press to return to menu and move to next item 11 The PRES HI menu item allo
65. eck Failure Valve position did not agree with ValvePAC output command within acceptable time The position sensor has failed or is not aligned properly The pressure sensor has failed The primary signal 4 20 sensor has failed The A D reference voltage is incorrect ValvePAC failed self check diagnostics FAULT MEANING PROBALE CAUSE MESSAGE The valve did not go to the requested position within the time configured in Position Error Time 1 e Valve lost air pressure e Valve movement is blocked e Setting of Position Error Time 1 is too low for the size of valve The bias the output to the EPC within the ValvePAC that controls the actuator fill exhaust is out of normal range Adjust the bias as needed This error indicates an improperly adjusted bias If the ValvePAC once functioned properly this error usually indicates an improperly working pneumatics section Failed or linkage aligned incorrectly The pressure sensor failed While the ValvePAC can function in normal operation with a failed pressure sensor other calibration functions depend upon the pressure sensor Failure Failure Failure 4 17 OPERATION UM760D 1 TABLE 4 2 Fault Messages continued DISPLAY FAULT MEANING PROBALE CAUSE CODE MESSAGE iii TEMP ERR Circuit Temperature WRT ERR Error EEProm Write Failed Watchdog Timer Timeout TIMER ERR CAL FAIL STOP ERR Calibration Failed Fi
66. es If Polling is Never Poll then the Communicator will not check for a connected device with a polling address other than 0 Polling addresses are used for devices used in a Multi drop application which will be discussed later The Contrast menu is used to change the LCD contrast Contrast returns to the default value when the Communicator is turned off HART Communicator Utility a 1 gt Configure Communic 2 System Information 3 Listen for PC 4 Storage Location 5 Simulation HART Communicator Configure Communica 1 gt Polling 2 Contrast 3 Off Time 4 Ignore diagnostics HELP April 1999 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 Off Time is used to set the Communicator to turn off automatically when not in use to conserve battery power The Communicator normally displays diagnostic messages from a connected device The Ignore Diagnostics option permits the user to specify the number of messages to ignore so that messages will not be displayed as often extending the time between displayed messages The message count defaults to a nominal count of 50 each time the Communicator is turned on It can be set to a maximum of 500 A 5 4 2 System Information From the Utility menu press 2 to access the System Information menu at right This menu can be used to provide information on the motherboard e g firmware revision number the module hardware and software characteristics and th
67. ess the Quick Access Key to return to the previous menu A 6 1 Adding Quick Access Key Options The Quick Access Key menu contains space for up to 20 on line options For example if device tags and configurations must be changed often simply add both to the menu The Communicator automatically saves them so they can be accessed quickly by pressing the Quick Access Key From one of the menus or submenus reached via the Online menu use the following steps to add customized options to the Quick Access Key Menu 1 Using the UP or DOWN arrow keys move the menu bar to highlight the option to be added to the Quick Access Key menu e g Tuning under the Calibrate Menu menu 2 Press any shift key release it then press the Quick Access Key The Hotkey Configuration menu displays below April 1999 A 23 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 The Hotkey Configuration menu displays the new topic being added to the list of current Quick Access Key options For example in the figure at right tuning is being added Press ADD F3 to add the option Pressing EXIT F4 terminates the procedure and displays the menu that was displayed when Shift Quick Access Key was pressed Next the question Mark as read only variable on Quick Access Key menu may appear Press YES F1 to mark the variable for this option as read only Press NO F4 to mark the variable as read write Marking a parameter for a devic
68. g unit by pressing 5 A 5 3 Frequency Device Menu From the Main menu press 3 to access the Frequency Device menu This menu displays the frequency output and corresponding pressure output for current to pressure devices For a ValvePAC Valve Controller the display frequency and pressure values are both none A 5 4 Utility Menu From the Main menu press 4 to access the Utility menu at right This menu provides functions that affect the operation of the Communicator not the connected devices A 5 4 1 Configure Communicator From the Utility Menu press 1 to access the Configure Communicator menu below right Use this menu to set the polling adjust the contrast of the LCD set the Communicator shutoff time or set how many diagnostics messages to ignore before a warning message is displayed All Hart devices have polling addresses that is originally set to 0 and can be reset to any value from 0 to 15 When a HART Communicator is connected to an instrument loop it initially checks for a device with a polling address of 0 If no device is found with this address the Communicator can poll the loop to find devices with other polling addresses The Communicator then finds every device in the loop and lists them by tag number The Communicator then finds every device in the loop and lists them by tag number Use the Polling option to direct the HART Communicator to search for additional connected devic
69. g only tight enough to prevent leakage Evaluate the valve packing by running the ValVue diagnostic program if available to determine if the friction is consistent with the type of valve If you determine that the spool valve creates limit cycling clean or replace the valve 10 While still in Manual mode use the pushbuttons or the hand held communicator to order the ValvePAC to move the valve to the 9596 position THEN The ValvePAC and valve systems are performing manual mode correctly properly The valve does not perform the Review the following conditions command in the manual mode 1 Check the power supply to determine correctly insufficient voltage 2 Check the air supply to determine if an insufficient pressure condition exists October 1998 5 15 UM760D 1 MAINTENANCE 6 0 MAINTENANCE The Controller requires no routine maintenance It is highly recommended that quality instrument air be used as described in Instrument Air Requirements The filter screens may require periodic cleaning The frequency of their cleaning is conditional depending on the quality of instrument air used It is also recommended that the end user perform periodic functionality tests in accordance with the critical nature of the application 6 1 FILTER SCREENS Filter screens are located in the V1 V2 and supply ports Refer to the Parts List at the back of this Instruction 1 Turn air supply off 2 Remove a screen with
70. he slotted bracket This is illustrated by Detail C In the case the distance between the centerline of the ValvePAC s shaft and the centerline of the pin must be 7 0 x the actuator stroke This arrangement will increase the linearity error to approximately 2 Retaining Clip Installation The retaining clip is used with rising stem actuators to hold the feedback pin securely against one side of the feedback lever s slot This prevents excessive play in the linkage and limits the amount of error introduced into the system through the linkage The clip may be installed in any one of the four orientations shown in Figure 3 3 IMPORTANT The clip must be positioned such that the pin sits in the innermost side of the clip s slide area when the actuator is at mid stroke It may be necessary to separate the pin from the feedback lever to facilitate installation October 1998 3 9 INSTALLATION ACTUATOR CONTROLLER UM760D 1 ACTUATOR y STEM SLOTTED et BRACKET 2 2 FEEDBACK PIN FEEDBACK LEVER A CONTROLLER MOUNTING AND PREFERRED METHOD OF CONNECTING FEEDBACK PIN EQUAL TO 0 866 x STROKE AT MID STROKE S B PREFERRED METHOD OF STROKE SETTING FOR FEEDBACK PIN CONNECTION FEEDBACK LEVER SHOWN AT MID STROKE FEEDBACK LEVER SLOTTED 7 EQUAL TO STROKE C METHOD OF CONNECTING FEEDBACK PIN AND STROKE SETTING FIGURE 3 2 Controller Mounting an
71. ication and use of information included in this document The information herein is subject to change without notice Procedures in this document have been reviewed for compliance with applicable approval agency requirements and are considered sound practice Neither Moore Products Co nor these agencies are responsible for repairs made by the user The Moore logo and ValvePAC are trademarks of Moore Products Co All other trademarks are the property of the respective owners Copyright 1998 Moore Products Co All rights reserved iv October 1998 UM760D 1 INTRODUCTION 1 0 INTRODUCTION This User s Manual for the Moore ValvePAC ValvePAC Valve Controller ValvePAC is divided into the following sections Introduction Contains product description product support and related literature Principles of Operation This section is for the first time user of ValvePAC Any user unfamiliar with the ValvePAC should read this section before attempting to install configure or operate the unit Installation Provides product dimensions general installation considerations and installation procedures Operation Defines the controls and signal displays Trouble Shooting Offers procedures and options to confirm setup and configuration Maintenance Furnishes preventive maintenance guidelines A Parts List is at the end of this section Model Designation Provides model designation Specifications Consists of mechanical elect
72. iguration parameters in sequence Press to return to CALIB at any time Press or to step through configuration parameters in sequence Press to return to CALIB at any time Press or to step through configuration parameters in sequence Press to return to CALIB at any time Displays CLEAR at end of sequence Press to clear faults and return to FAULTS in Examine Menu EXAMMENU ds4 FIGURE 4 6 EXAMINE Menu Structure October 1998 UM760D 1 OPERATION CONFIGURATION PARAMETERS CALIBRATION PARAMETERS FAULT MESSAGES From CONFIG in From CALIB in From FAULTS in EXAMINE Menu EXAMINE Menu EXAMINE Menu reu dem 4 00 SINGLE s SIG LO POS ERR _ Returns to 2 CALIB in 20 00 CTL OFF EXAMINE SIG HI lt _ CLEAR Menu Returns to FAULTS in OTHER FAULTS Menu OTHER FAULTS LINEAR 5 0 TS OFF Returns to 0 0 CONFIG in ii EXAMINE PLOFF Menu 054 100 0 PU OFF Ld FIGURE 4 7 EXAMINE Sub Menu Structure October 1998 4 0 OPERATION UM760D 1 4 3 NORMAL OPERATION In normal operation the ValvePAC un
73. inal NOTE The instruction manual indicates that the negative and B terminals are returned to the system common rail Improperly grounded units can cause a 1 2 to 1 drift and affect auto tuning performance 2 To identify a noisy control loop set the positioner to manual TABLE 5 3 Process Controller Ground Checklist IF THEN The position is stable The problem is noise in the control loop NOTE Follow accepted wiring and grounding practice to correct a noisy control loop October 1998 5 5 TROUBLE SHOOTING UM760D 1 5 3 3 Power On You can apply power to the ValvePAC after checking the connections and grounding Restoring power to the local ValvePAC creates one of five possible images on the local display A Normal B Blank C Fail Safe D Garbage E Reset Normal Display The normal display includes a numeric reading in the manual or normal mode on the ValvePAC display The ValvePAC also may cycle between the three modes until a button is pushed If you receive a normal display no further action is required Continue troubleshooting by going to the HART Communications section Blank Display A blank display screen after startup indicates a power problem This usually means unconnected electrical power wiring or insufficient power sent to the ValvePAC Use the following procedure to troubleshoot a blank display or suspected power problem 1 Check all wiring connections and
74. ing the electrical current to the ValvePAC confirm that the pressure in V2 registers zero psi and that the valve sits against a stop Figure 5 1 illustrates the proper configuration of air supply and output NOTE Air to open ATO requires a closed valve air to close ATC requires a open valve VALVE 2 rip SUPPLY EXHAUST nr 1 4 NPT TYPICAL 760D3b ds4 FIGURE 5 1 Exhaust Actuator and Air Supply October 1998 5 3 TROUBLE SHOOTING UM760D 1 5 3 1 2 Electrical Connections The ValvePAC requires an electrical input from a 4 20 mA current source The ValvePAC must be connected to an analog output of the control system Because the ValvePAC is polarity sensitive connect the positive terminal to the positive lead and the negative terminal to the negative lead Use the following one step procedure to verify the wiring 1 Connect a voltmeter across the ValvePAC terminals Result The voltage should read between 9 5 and 11 5 volts DC for any current input value between 3 8 and 22 mA NOTE Test points located adjacent to the terminal block facilitate this measurement These test points connect directly to the positive and negative terminals These test points can also be used to connect a HART Handheld Communicator if local electrical guidelines so permit TABLE 5 2 Electrical Connection Checklist IF THEN Polarity is rever
75. ion the ValvePAC constantly updates the bias as conditions e g temperature orientation warrant In consideration of this fact the factory sets the bias near 2750 Occasions may arise where further adjustment is necessary In such a case the bias spring should be adjusted so either more or less pressure is required by the EPC to balance the system 2 2 SETPOINT As a field connection applied at two screw terminals in the terminal compartment the setpoint provides an analog input of 4 to 20 mA in analog mode or 12 to 25 volts in multi drop digital mode The setpoint input establishes setpoints for the following e Valve when operating as a positioner e Control loop when operating as a single loop process controller The setpoint input also provides power to operate the instrument The control setpoint terminals in either analog or digital operating modes provide a HART protocol compliant communication signal In the analog mode the HART signal is superimposed on the 4 to 20 mA control signal The control setpoint terminals also support HART burst analog and multi drop non analog modes NOTE All electrical connections are isolated from the housing Figure 2 2 illustrates the setpoint operation and the relevant positions of the electronic module spool valve actuator valve and feedback potentiometer 3 2 October 1998 UM760D 1 INSTALLATION Supply Pressure 20 to 100 PSI Pressure gt Sensor
76. ion of the ValvePAC October 1998 3 17 INSTALLATION UM760D 1 Series 760D Controller Controller Ouput Actuator 4 20 mA Signal A Valve See Note 2 I NOTES 1 Network resistance equals the sum of the barrier resistance and the current sense resistor Minimum value is 250 Ohms maximum value is 1100 Ohms 2 Connect the HART Communicator as shown The HART Communicator is a non polar device 760D 11 ds4 FIGURE 3 6 Basic Valve Controller Setup A typical system setup is shown in Figure 3 7 In the diagram the ValvePAC is configured as a valve controller and is located in a hazardous area Valve position is determined by an internal feedback potentiometer mechanically linked to the valve stem The process controller or other source of input signal to the ValvePAC is located in a non hazardous location and an intrinsic safety barrier with ground can be placed between the process controller and the ValvePAC A handheld communicator can be connected as shown In a similar way a PC equipped with a HART modem can also be connected These communication links are not intrinsically safe and must be connected to the circuit on the non hazardous side of the intrinsic safety barrier if the valve is located in a hazardous area
77. ired to issue a particular command refer to the complete map in Figure 4 2 Details are included in Figure 4 3 to Figure 4 7 and in the sections that follow NOTE If the buttons are pushed after being locked by the ValVue software the message LOCKED will appear 4 2 October 1998 UM760D 1 OPERATION Normal Operate OPERATE Menu MANUAL Menu Mode Display K V Y 7 MAN 4 POS Press y y gt R gt CAL x gt STOPS lt INP SIG any f A Y button gt MAN v 3 STOPOP EE i RU _ E gt CNTL gt l LOCAL kK L BIAS X REMOTE eis AS LTUNE gt Auto Tunes IsETENT el R 1 e y Kin A SIG LO x CANCEL Toe E
78. it operates as a controller using a 4 20 mA input signal as setpoint The local digital display sequentially displays valve position input signal and actuator pressure on a 1 5 second interval Pressing any button moves you to the gt OPER option in the OPERATE MODE MENU as shown in Figure 4 2 The OPERATE MODE MENU has 3 options OPER return to display of current position pressure and signal MAN put valve in manual model and go to MANUAL Menu CNTL go to PID controller menu if so equipped EXAMINE go to EXAMINE Menu Use the pushbuttons to move from one option to the next Press the button to go to the item displayed in the menu To return to the Normal Operate Mode from any menu press or repeatedly until gt MAN or OPER is displayed If OPER appears press to return to Normal Operate Mode If MAN appears press to return to the Manual Mode menu Press repeatedly until OPER appears Press to return to Normal Operate Mode and normal operation 4 4 CONFIGURATION The configurable options and how they appear on the display are described in Table 4 1 NOTE Configuration can only be done in the Manual Mode Manual Mode can be accessed as described in section 4 4 Normal Operation TABLE 4 1 Local Configuration Options LINEAR EQUAL 50 Select desired valve characteristic curve linear rotary equal EQUAL 30 QUICK percentage 50 equal percentage 30 quick opening custom curve
79. lat Indicator Flat lens and indicator provide a rough visual indication of valve position Beacon lens and indicator provide a rough visual indication of valve position Indicator used only on rotary actuators 7 2 October 1998 UM760D 1 SPECIFICATIONS 8 0 SPECIFICATIONS TABLE 8 1 Operating Limits PARAMETER REFERENCE OPERATIVE STORAGE AND LIMITS TRANSPORT 210 180 C Bw aC Relative Humidity 10 to 55 5 to 100 0 to 100 NOTES 1 External surface temperature 2 May be condensing 3 Compatible with CE Mark requirements Applies to 4 20 mA input Physical protection is provided for other terminals Refer to EN50081 2 and EN 50082 2 TABLE 8 2 Performance Specifications Flow Capacity 8 5 scfm 60 psi Cv 0 26 Linear equal percentage 50 equal percentage 30 quick opening and customer defined October 1998 8 1 SPECIFICATIONS UM760D 1 TABLE 8 3 Physical Specifications TYPE DESCRIPTION Air Supply and Output 1 4 inch NPT internal Connections Electrical Connections 3 4 inch NPT conduit 65 Finish Trimite epoxy polyester powder coating Film thickness 2 to 5 mils cured Hardness Pencil to per ASTM 0 3363 74 Direct Reverse impact Up to 160 inch pounds ASTM D 2794 84 TABLE 8 4 Electrical Safety Design Specifications AGENCY SERVICE APPLICABLE CLASS FM Factory Mutual Approval Intrinsically Safe Class I Division 1 Groups A B C and D Class IL Division 1 Groups E
80. layed every few minutes it is necessary to move down through the menus to EXAMINE and CLEAR STATUS see Figures A 5 and A 5D Main Menu Moore 760D VP100 From the Main menu with a HART compatible device connected MANUAL MODE press 2 to access Online menu at right The Online menu l Valve pos 14 9 displays the name of the device at the top of the LCD if it is a 2 act pres 0 1 psi supported device If a device description for the connected device change lt gt is not present in the Communicator contact the manufacturer of the device 3 4 MANUAL MODE MENU 5 CONTROLLER HELP SAVE When no device description is found the Communicator provides a generic interface which enables users to perform functions common to all HART compatible devices ValvePAC Valve Controller specific menu options are described in detail later April 1999 A 15 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 Generic Menu The Generic Online menu at right is the first menu in the generic interface It displays critical up to date device information Configuration parameters for the connected device may be accessed using the Device setup option Figure A 6 shows the 1151 GENERIC v complete Generic Online menu tree Online 1 gt Device setup From the Online menu use the options below to change device 2 PV 50 0000 20 12 000 mA 4 LRV 0 0000 in H20 5 URV 100 0000 in H20 SAVE configuratio
81. ld communicator to enter the Manual mode and go to the Calibrate menu A bar graph on the local display indicates the true potentiometer position within the zero to 140 degree range 2 Confirm that the actual installation settings fall within the zero to 140 degree range by moving the actuator and observing the bar graph This step ensures that ValvePAC operates within proper limits of the potentiometer NOTE The Fail Safe message eliminates unrealistic and hard to determine results from improper potentiometer settings Reaching the potentiometer limits automatically produces a Fail Safe message 3 If the potentiometer s limits are being exceeded then it needs to be repositioned Move the actuator to one of its stops noting the direction that the feedback shaft will have to turn when the actuator moves away from that stop 4 Loosen the potentiometer bracket s mounting screws and disengage the potentiometer gear from the main shaft gear Feedback Gear Y s A Ib E oy a Feedback Gear i Mounting Bracket D AD D
82. ller Setup eee UM760D 1 October 1998 UM760D 1 FIGURE 1 a 55 N TABLE 1 1 o ken BH CA CA CA AA 95 October 1998 CONTENTS TABLE OF CONTENTS Continued TITLE PAGE System Diagram Intrinsically Safe Installation 3 13 Single Loop PID Configuration with No Process Feedback to Control Room 3 15 Intrinsically Safe Single Loop PID Configuration with No Feedback to Control 3 16 Single Loop PID Configuration with Process Feedback to Control Room 3 17 Local Display and Pushbuttons 4 2 Master Pushbutton Function 4 3 Normal Operate Mode Select and Manual Menu Structures 4 5 Configuration Menu Structures nennen 4 6 Calibrate Menu Structures 4 7 Examine Menu Structure 4 8 Examine Sub Menu Structure 2 4 9 Feedback Gear Feedback Gear Mounting Bracket Input Gear Bias Screw and Locking Screw 4 13 Exhaust Actuator and Air Supply 5 3 Feedback Gear Fee
83. main still by the end of this step 2 In estimating control parameters ValvePAC displays three types of values input step sizes such as 80 and 320 valve relative opening such as 1874 and 1756 and dead time such as 4 00 and 7 00 Expect the valve to move back and forth several times ValvePAC uses these tests to estimate the preliminary control parameters based on position control characteristics 3 In refining the estimated control parameters ValvePAC displays several numbers such as 1211 and 6 Interpret the number 1211 as the rising time T98 is 12 x 0 05ms 0 6 ms and overshoot is 11 The code number 6 indicates a specific control parameter adjustment Evaluating the Results A successful AutoTune provides position step responses in both air fill and exhausting directions that meet the tuning criteria Overshoots range between 0 and 8 and rising times range from 0 5 second for a small actuator to 1 5 second for a large actuator A successful AutoTune updates the previous control parameters AutoTune usually results in fast position responses 0 to 8 overshoots If you prefer a smooth response without overshoots reduce the P value by 10 to 2096 If you prefer a slow response set the damping coefficient at 1 to 9 e g zero equals no damping 9 equals maximum damping 5 10 October 1998 UM760D 1 TROUBLE SHOOTING Damping Coefficient The following table lists the damping coefficient which displays after AutoTune an
84. n 4 Utility which submenu of the on line series is displayed it may be necessary to press the LEFT ARROW PREVIOUS MENU key more than once Alternatively press HOME F3 to display the Online menu followed by the LEFT ARROW PREVIOUS MENU key to display the Main menu From the Main menu access additional menus by moving the cursor to them with the UP or DOWN arrow keys followed by pressing the RIGHT ARROW SELECT key or simply by pressing the appropriate number 1 4 on the alphanumeric keypad A 10 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR A 5 1 Offline Menu The Offline menu provides access to two other menus New Configuration and Saved Configuration These two configuration menus can be used without connecting to a HART compatible device but it is not possible to send saved data to a device if no device is connected From the Main menu press 1 on the keypad or the RIGHT ARROW SELECT key to access the Offline menu The complete menu tree for the Offline Menu is shown in Figure A 4 1 New Manufacturer Model Fld dev rev From Blank Template Configuration 1 Mark all 2 Unmark all 3 Edit individually 4Saveas Save 2 Saved EE al Module Contents Saved 1 Location Configuration Configuration Data Pack Contents 1 Edit Edit 2 Name PC 2 Copy to 1 Mark all 3 Data Type 3 Send 2 Unmark all 4 Print 3 Edit Individually 5 Delete 4 Save as Save As 6 Rename
85. n indicated on ValVue or in the push button display and the actual valve position This offset indicates the need for bias adjustment On start up after leaving the unit without power for an extended period of time an offset sometimes occurs between the signal and actual valve position On start up this offset begins moving slowly This offset exists because the present bias setting differs from the setting recorded when the unit last saved the bias October 1998 5 9 TROUBLE SHOOTING UM760D 1 NOTE The offset on startup resolves itself because the ValvePAC saves the bias value every hour which provides a more accurate signal valve position reading The optional ValVue software offers a live display of the bias value If you suspect that the bias may be set incorrectly and you do not have the software you can reset it by following the bias procedure already described in Calibration Procedures using pushbuttons NOTE If no amount of bias screw adjustment is sufficient to move the valve the unit likely contains a malfunctioning EPC and should be returned to the factory for replacement 5 3 6 AutoTune The AutoTune Procedure The AutoTune procedure includes three steps e Bias search e Estimate control parameters e Refine control parameters 1 In Bias Search the ValvePAC local displays values such as 2753 and 2761 that approach or converge on a real Bias value Expect the valve to move back and forth slow down and re
86. nd Stops Failed 4 18 ValvePAC has reset since last status clear Internal check failed to process data in time Internal ValvePAC temperature out of range Device failed to write to nonvolatile memory ValvePAC failed to send D A output within timeout Signal or pressure calibration The auto pos calibration failed A ValvePAC reset occurred because of a power loss or a command from ValVue Hardware failure The internal ValvePAC temperature is outside the normal operating temperature range in the ValvePAC specifications A write of data to the internal permanent memory of the ValvePAC failed If you detect this error issue a reset and check the configuration and calibration parameters An internal timer that checks proper ValvePAC operation has timed out indicating improper operation of the ValvePAC On watchdog timer time out the ValvePAC issues a self reset This error indicates that such a reset already occurred An attempt to recalibrate the primary or secondary signal or the pressure sensors failed The normal cause is sending the ValvePAC calibration values outside the allowed range or trying to calibrate two values too close together e g with insufficient range for accurate calibration The self position calibration routine failed The most likely causes are loss of air pressure or the pressure or position sensor not working properly October 1998 UM760D 1 TROUBLE SHOOTING 5 0
87. ne frequency noise Line frequency noise converts to low frequency noise when a noisy signal sampling occurs during a period not integrally related to the line frequency The resulting frequency e g alias measures more than 1 Hz a frequency too high for resolution by the process trend record A pulsating sound of escaping air at the exhaust port usually indicates line frequency noise In extreme cases the valve stem may appear to pulsate Correct a line frequency noise problem by proper grounding see Electrical Connections or by eliminating ripple noise from the current source HART compliance requires less than 4 WA of current ripple 5 12 October 1998 UM760D 1 TROUBLE SHOOTING 5 4 TROUBLESHOOTING CHECKLIST The following is a list of possible problems and solutions arranged in the order that they might be encountered during a typical installation TABLE 5 6 Trouble Shooting Checklist POWER UP PROBLEMS 1 Apply power to the ValvePAC Display is normal Continue to Step 2 Display is blank Check electrical connections and voltage per Blank Display FAILSAFE shown on display 1 Use the EXAMINE pushbutton menu to THEN 2 The potentiometer may be positioned incorrectly See Fail Safe Display for instructions Display is indecipherable Check electrical connections and voltage per Blank Display section If not a power problem return the unit to the factory RESET shown on displ
88. ns 3 AO Device setup provides access to the Device Setup menu Configurable device parameters common to all HART compatible devices can be accessed from this menu Primary Variable PV he dynamic primary variable and the related engineering unit When the primary variable contains too many characters to display on the Online menu access the PV menu to view the primary variable and related engineering units by pressing 1 Analog Output AO the dynamic output and the related engineering units The analog output is a signal on the 4 20 mA scale that corresponds to the primary variable When analog output contains too many characters to display on the Online menu access the PV AO Menu to view the analog output and related engineering unit by pressing 3 Manual Mode Start e Valve Position 96 Actuator Pressure psi Manual Setpoint Change Position 4 Setpoint Manual Mode Menu Full Open Controller Full Closed Examine Moore 760D Reset Manual Mode Menu Normal Mode Configuration Menu j Go to Figure A 5A Calibration Menu I Go to Figure A 5B Diagnostic Menu I Go to Figure A 5E Normal Mode Start e Valve Position 96 Actuator Pressure psi Input Signal mA To Manual Mode Controller bd Go to Figure A 5C Examine Go to Figure A 5D Moore 760D Reset FIGURE A 5 On Line Menu Selection Tree
89. ns or the hand held communicator to order the ValvePAC to move the valve to the 5096 position THEN The valve performs the command Continue with step 10 correctly 5 14 October 1998 UM760D 1 TROUBLE SHOOTING TABLE 5 6 Trouble Shooting Checklist Continued The valve does not perform the Review the following conditions command in the manual mode 1 Check for improper limit stops repeat the Set correctly Limit Stops commands and re test 2 Check the position sensor for misalignment or malfunction 3 The bias may be out of range If available use ValVue s Check 760D command to investigate Otherwise use the push buttons to reset the bias Calibration Procedures using pushbuttons 4 The spool valve may need to be cleaned The valve oscillates Review the following conditions 1 Check for improper tuning Then either perform another AutoTune or input manual values and re test 2 Check the grounding and eliminate noise due to improper grounding 3 Check the linkage between the position sensor and the valve for excessive play 4 Check for spool malfunction 5 Check for excessive friction in the valve packing Identifying Limit Cycling Tight valve stem packing an undersized actuator or foreign material in the spool valve can contribute to limit cycling Identify limit cycling conditions by a process of elimination e g not noise not oscillation Install valve packin
90. nual mode the device will not respond to the 4 20 mA signals However the ValvePAC unit can still respond to HART commands including HART commands to position the valve NOTE When you go to Examine from the Normal Operate Mode Menu the valve is still in Normal Operate mode and still responds to the 4 20 mA signal 4 4 October 1998 UM760D 1 NORMAL OPERATE MODE DISPLAY October 1998 In Operate mode the display sequences through VALVE POSITION INPUT SIGNAL AND ACTUATOR PRESSURE on a 1 second interval To Display Sequence THER POS Press Any Button THER INP SIG THEE PRES OPERATE MODE MENU VARE OPERATION gt gt OPER Y 2 To CONFIG in gt MAN EXAMINE MENU Valve is still in OPERATE mode t sea ew loe o To REMOTE in gt Controller Menu DN dp gt EXAMINE NT MANUAL MENU Press or to INCR DECR Valve Position Press to accept To STOPS in Calibrate Menu To Double or Single in Configuration Menu To REMOTE in Controller Menu To CONFIG in HH POS MAN Sp HA gt CAL 3 HA gt CONFIG 5
91. o A5 EN 50 020 1977 amendments to AS The assessment and test results are recorded in Sira Test Report 52 4841 7 The apparatus marking shal include the code EEx ia T4 T 40 C to 80 C 9 Dated 12 October 1998 M D Shearman Certification Manager File No 52AARAT index 12 This certificate and its schedules may only be reproduced in its entirely and without change rgelors Sira Certification Service South Hill Chislehurst Keni BR SEH England SCS BF 055 Tal 44 0 181 467 2636 Fax 44 0 181 295 1990 April 1908 Lrnall certificationf siracs prestel co uk NATIONAL D 2 ACCHEDITANION Certification Service Firg ttt Ni mer GROUP II CERTIFICATE OF CONFORMITY Sira Ex 9802108 Dated 12 October 1998 8 The manufacturer of thc clectrical apparatus referred to in this Certificate has the responsibility to ensure that the apparatus conforms to the specification laid down in the Schedule to this Certificate and has satisfied the routine verifications and tests referred to therein 9 This apparatus may be marked with the Distinctive Community Mark defined in Annex II of Commission Directive 84 47 of 16 January 1984 This mark is reproduced on cach page of Certificate it shall be affixed to the apparatus in such a way as to be visible legible and urable The use of this apparatus will normally be the subject of National Legislation and or Installation Codes This ce
92. om the Model menu Choose a software revision from the Fld dev rev menu Unnamed From Blank Template 1 gt Mark all 2 Unmark all 3 Edit individually 4 Save as HELP SAVE Unnamed Edit individually Tag kkkkkkkxk Not marked to send NEXT MARK EDIT EXIT Unnamed Tag kkkkkkkxk HELP DEL ESC ENTER A 12 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR The Communicator creates a configuration and displays the Blank Template menu Choose Save as to display the Save as menu at right With the Location highlighted press the SAVE F2 function key to save the configuration If the location highlighted is the Module but the configuration is to be stored in the Data Pack or vice versa press the RIGHT ARROW SELECT key to display the Location menu Choose either Module or Data Pack by pressing ENTER F4 This displays the Save as menu again Press SAVE F2 to save the configuration in the desired location The Save As menu also is used to enter or edit the configuration Name and Data Type To name a configuration simply choose option 2 then use the keypad with shift keys to enter the name as shown at right When the Save As menu is displayed one of the Data Type options Standard Partial or Full will be shown To change the option move the cursor to the Data Type line of the Save As menu and press the RIGHT ARROW SELECT key
93. on or deviation from specified performance All pneumatic connections e 1 4 NPT 1 8 for gauges User supplied materials e Scale free piping at least 1 8 ID for standard flow models and 1 4 ID for high flow models e 1 4 NPT pipe fitting is needed for each connection used Use care not to over torque the fitting when tightening 12 ft Ib maximum e 1 4 pipe plug to plug the unused port for single acting actuators October 1998 3 13 INSTALLATION UM760D 1 Piping recommendations Blow out all piping before connections are made to prevent dirt chips or debris from entering the controller e Use pipe sealant sparingly and only on male threads A non hardening sealant is strongly recommended NOTE Pipe sealing tape is not recommended 3 2 3 ValvePAC Connections Pneumatic connections are shown in Figure 3 1 and listed below V2 Output to actuator S Supply pressure to system V1 Output to actuator E Exhaust port Can be piped away from controller DO NOT PLUG Refer to the Table 3 1 to determine the required pneumatic connections between the ValvePAC and the actuator WARNING Never exceed maximum supply pressure Injury to personnel and damage to equipment may result Maximum allowable air supply pressure to the controller varies according to actuator valve size and valve type Plugging or applying pressure to the exhaust port will damage the unit and may cause personal injury Pressure in exces
94. ons Non hazardous location Connect as shown above Hazardous location Refer to Communicator nameplate and the Manual supplied with the Communicator for certifications and approvals before connecting The HART Communicator is a non polar device 2 The System Power Supply may be part of the host input device or a separate device 3 Network resistance equals the sum of the barrier resistances and the current sense resistor Minimum value 250 Ohms maximum value 1100 Ohms 4 Supply and return barriers shown Interconnect all cable shields and ground only at the barriers FIGURE A 2 HART Communicator Connections to a Transmitter Loop April 1999 A 3 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 A 40 1 m cable with a dual banana plug on one end and two mini grabber plugs on the other is provided The dual banana plug is inserted into the top of the Communicator the mini grabber clips are connected to lugs on the ValvePAC Valve Controller s terminal board or to the loop s current sense resistance usually at a receiving instrument see Note below NOTE The HART protocol requires a network loop resistance between 2500 and 11000 to support communications A 3 CONTROLS OVERVIEW As shown in Figure A 1 the front of the HART Communicator has five major functional areas liquid crystal display LCD function keys action keys alphanumeric keys and shift keys The next five sections describe how each of these fun
95. ontroller Action Controller Calibration Lower Primary Variable Value Upper Primary Variable Value Lower Setpoint Value Upper Setpoint Value Position Error Band Time 1 sec Time 2 sec Pressure Fault Limit Valve Near Closed Controller Parameters Controller Parameters Controller SP Mode Check 760D Controller SP Mode Setpoint Start Up Mode Local Control Current Mode Check 760D Temperature Bias Points Ratio Gain Ratio Bias Ratio Control Setpoint Lower Limit Setpoint Upper Limit Lower Alarm Limit Upper Alarm Limit Controller Output Manual Reset Bias Dead Zone Select Select Setpoint Tracking On Off Freeze Output On Off Derivative Mode On Off Alarm Type On Off FIGURE A 5D On Line Examine Menu Tree April 1999 A 19 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 From Manual Mode Menu Figure Diagnostic Menu Perform Standard Read Diagnostic Reset Continuous Choice Continuous Data Result of Standard Diagnostic Total Travel Time Closed Time Open Time Near Closed Number of Cycles FIGURE A 5E On Line Diagnostic Menu Tree Friction Lower Spring Range Upper Spring Range Lower Pressure Upper Pressure Stroking Time to Open Stroking Time to Close 1 Device setup 1 Process 1 Sensor 2 PV Variables 2 Al rnge 3 AO 3 AO1 4 LRV 5 URV 2 Diagnostics 1 Test device Does not function and Service 2 Loo
96. ontroller link U 30V dc Ci 04H This certificate and its schedules may only be reproduced in its entirety and without change mgeesr5s Sita Certification Service South Hill Chislehurst Kent SEH England 055 44 0 181 467 2636 Fax 44 0 181 295 1990 1998 aenifinatian araca proatel oc uls SCHEDULE CERTIFICATE OF CONFORMITY Sira Ex 98722108 DESCRIPTIVE DOCUMENTS Drawing No 15032 7605 15032 7605 15032 7605 15032 7605 15032 7605 15177 7609 Sheets lof S 2of5 3of5 4of5 Sof5 2 Rey aww Date 3 Ju 98 31 Jul 98 31 Jul 98 3 Jul 98 31 Ju 58 24 Sep 98 Dated 12 October 1998 Description CERTIFICATION DWG MODEL 760D CERTIFICATION DWG MODEL 760D CERTIFICATION DWG MODEL 7600 CERTIFICATION DWG MODEL 760D CERTIFICATION DWG MODEL 760D CERT DWG 76012 SCS EEx ia This certificate and its schedules may anly be reproduced in its entirety and without change 5 6 51 055 Apri 1908 Page 4 of 5 Sira Certification Service South Hill Chisishurst Kent BR7 SEH England Tol 4 44 0 181 467 2636 Fax 44 0 181 295 1990 Email certification siracs prestel co uk SCHEDULE CERTIFICATE OF CONFORMITY Sira 98D2108 Dated 12 October 1998 CONDITIONS OF CERTIFICATION 1 The use of the Sira Certification Service Mark is subject to the Regulations applicable to the holders of SCS certificates 2 Thi
97. open actuators e Span and zero configurable for split range operation Local operation functions include Calibrate valve stroke range tight shutoff point position limits Display and or set parameters for valve configuration Operate valve in manual mode or 4 20 mA mode Select characterization linear equal percentage 50 equal percentage 30 quick opening or custom Display clear fault codes Display valve position Display faults e Remote operation functions include all of the above plus the following when running the optional ValVue software on a PC Display total stem travel number of valve cycles and other data useful for predicting valve life Run valve diagnostics 1 2 October 1998 UM760D 1 INTRODUCTION 1 2 PRODUCT SUPPORT Product support can be obtained from a Technical Information Center TIC Each regional TIC is a customer service center that provides direct telephone support on technical issues related to the functionality application and integration of all products supplied by Moore Regional TIC contact information is provided in the following table Your regional TIC is the first place you should call when seeking product support information When calling it is helpful to have the following information ready e Caller ID number or name and company name When someone calls for support for the first time a personal caller number is assigned Having the number available when calling for support will
98. ove the cursor to the right or to select a menu option mI MN QUICK ACCESS KEY HOT KEY When the Communicator is on and connected to a HART compatible device pressing the Quick Access Key instantly displays the Quick Access Key menu of user defined options When the Communicator is off and the Quick Access Key is pressed the Communicator automatically powers up and displays the Quick Access Key menu Y See Section A 6 for more information on using the Quick Access Key A 6 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR IMPORTANT When performing certain operations the message OFF KEY DISABLED indicates that the Communicator cannot be turned off This feature helps prevent accidental shutoff of the Communicator while the output of a device is fixed or a device variable is being edited A 3 4 Alphanumeric and Shift Keys The alphanumeric keys perform two functions 1 rapid selection of menu options and 2 data entry The shift keys located below the alphanumeric keys on the keypad are used during data entry to select from among the characters available above each number A 3 4 1 Rapid Selection of Menu Options From any menu use the keypad to select available options in two ways First use the UP or DOWN arrow keys followed by the RIGHT ARROW SELECT key to access available options displayed on the LCD As an alternative use the rapid select feature Simply press the number on the alphan
99. ow you that an error occurred This means that the unit will continue to operate but you can still use the pushbutton procedure in Using EXAMINE to Display Clear Faults to see what errors occurred FAULTS in the EXAMINE menu For example if power is temporarily lost the RESET error will appear on the local display when the power returns The unit will start operating properly again and the RESET message will disappear but the error notification will remain latched in the unit s memory until it is manually cleared Errors that latch include RESET POSSEN PRESSEN REFERR and TEMPERR Table 5 1 lists the error latches and defines each term October 1998 5 1 TROUBLE SHOOTING UM760D 1 TABLE 5 1 Error Latches EE _ 2 HARTERR Continuous communication error Find Stops procedure failed A write to the EEPROM failed 5 3 PROBLEMS AND SOLUTIONS Below is a list of seven common problem areas followed by their solutions Connections pneumatic and electrical Grounding Power on HART communications Bias Auto Tune Position Instability 5 3 1 Connections The ValvePAC includes connections for air supply tubing and wiring grounding of the case and the 4 20 mA signal Proper fitting of these connections ensures optimum operation 5 3 1 1 Pneumatic Connections The ValvePAC requires a regulated air supply of clean dry oil free instrument air conforming to the requirements of ISA S 7 3 Quality Standard for Instrument
100. p Test Does not function 3 Calibration Does not function 4 D A Trim Does not function 3 Basic Setup 1 Tag 2 Unit 3 Range values 4 Device info 1 Date 5 Xfer functn Does not function 2 Descriptor 6 Damp 3 Message 4 Write protect 5 Meter type 4 Detailed setup 4 1 Sensors 5 Review 2 Signal condition 1 Process variables 2 Range values 3 Unit 4 Xfer Fnctn 5 Damp 1 Loop test 2 D A trim 3 Output condition 1 Process variables Scaled D A Trim 2 Analog output 3 AO Alrm typ 1 Poll Address 4 HART output 2 Number of Request Preambles 3 Burst mode 4 Burst option 4 Device 1 Field device info 1 Tag information 2 Sensor information 2 Date 3 Meter type 3 Descriptor 4 Self test 4 Message 5 Model 6 Write protect 7 Revision 5 8 Final asmbly num 9 Dev id 10 Distributor FIGURE A 6 Generic Online Menu Tree A 20 April 1999 UM760D 1 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR Lower Range Value LRV the current lower range value and the related engineering unit When the lower range value contains too many characters to display on the Online menu access the PV LRV Menu to view the lower range value and related engineering unit by pressing 4 Upper Range Value URV the current upper range value and the related engineering unit When the lower range value contains too many characters to display on the Online menu access the PV URV Menu to view the upper range value and related engineerin
101. polarity sensitive 1 Check the device description A hand held terminal must include the ValvePAC device description in order to perform diagnostic and calibration functions The HART 275 hand held terminal must report the primary and secondary variable tag message and other basic values 2 Verify that the wiring contacts are in good condition 3 Verify that there is no other HART master device in service such as the optional ValVue software The ValvePAC accepts only one master device at a time 5 3 5 Bias Adjustment As has been already discussed in the Calibration Procedures and Bias sections the bias is the signal sent to the EPC the I P transducer that holds the spool valve in a steady state condition and causes the actuator to neither fill nor exhaust If the bias spring is improperly adjusted the EPC will not have the output range necessary to adequately move the beam and spool valve in response to step changes Moore adjusts the bias at the factory in order to accommodate most environmental effects Situations do arise however when bias adjustment becomes necessary For example after replacing the spool valve or when the unit experiences extreme environmental conditions adjusting the bias can optimize positioner performance Bias adjustment becomes necessary in the following instances After calibrating the limit stops of the valve and setting the parameters an offset may occur between the ValvePAC positio
102. positioned supply air must be connected to the unit before calibration can begin Bias Screw Feedback Gear Locking Screw Feedback Gear Mounting Bracket Input Gear 76 684A ds4 FIGURE 4 8 Feedback Gear Feedback Gear Mounting Bracket Input Gear Bias Screw and Locking Screw Refer to the menu structures in Figure 4 2 through Figure 4 7 for assistance with the following procedures CAUTION Since some calibration functions stroke the valve over its full range the valve should be isolated from the process before starting calibration October 1998 4 13 OPERATION UM760D 1 To calibrate the ValvePAC unit using the local pushbuttons execute the following procedure 1 If in NORMAL mode press any button and OPER will be displayed Press to get to MAN menu item 2 Press to move to MANUAL MENU 3 Press to move to CAL option 4 Press to go to CALIBRATE menu 5 In STOPS press to initiate the operation which moves the valve to fully closed then fully open and then returns to the starting position This operation calibrates the end points for the position feedback potentiometer When the operation is complete press to move to the next item CAUTION This function strokes the valve over its full range Do not execute while valve is controlling the process 6 On some valves the full travel is larger than the nominal travel of the valve and it may be desirable to have the reported 10046
103. prefers a slow response set the damping coefficient at 1 to 9 e g zero equals no damping 9 equals maximum damping 2 6 PROCESS DESCRIPTION Cold Reset The following steps reflect the process of signal generation and the sequence of starting the ValvePAC NOTE This sequence resembles the steps in starting a PC for the first time and is considered a typical cold reset sequence 1 Sensors provide a signal to the A D converter which sends the signal to the microprocessor 2 The microprocessor supplies the display and pushbutton interface and outputs the signal to the D A converter and to the EPC 3 Air feeds into the EPC to the spool valve and then to the actuator 3 4 October 1998 UM760D 1 INSTALLATION 4 When power is applied to the ValvePAC the microprocessor searches stored memory and loads the appropriate configuration and startup information into the microprocessor This is the only time when the ValvePAC goes back and reads the stored memory 5 The ValvePAC displays the Reset message for a few seconds Hot Reset A hot reset results from performing a reset from the optional ValVue software The system does not re load all information in the stored memory into the microprocessor 2 7 PROCESS CONTROLLER OPTION The ValvePAC can be purchased with an onboard single loop PID controller When this option is installed and turned on the secondary input terminals marked A and B become active The process variable
104. resistance and the current sense resistor Minimum value is 250 Ohms maximum value is 1100 Ohms 2 Connect the HART Communicator as shown The HART Communicator is a non polar device 61098 6 ds4 FIGURE 3 9 Intrinsically Safe Single Loop PID Configuration with no Feedback to Control Room 3 22 October 1998 UM760D 1 INSTALLATION In the configuration shown below there are three 2 wire connections to the field In the circuit shown the controlled variable is sensed as a 1 5 V signal Current Source Process 4 20 mA Transmitter Process Signal Common Rail Series 760D Controller 4 20 mA Set Point e n Input 250 Ohms dB 9 gg Process Note 2 Monitor SOS Process Control Room Hazardous Environment NOTES 1 Network resistance equals the sum of the barrier resistance and the current sense resistor Minimum value is 250 Ohms maximum value is 1100 Ohms 2 Connect the HART Communicator as shown The HART Communicator is a non polar device 61098 7 ds4 FIGURE 3 10 Single Loop PID Configuration with Process Feedback to Control Room October 1998 3 23 UM760D 1 OPERATION 4 0 OPERATION This chapter disc
105. ress to move backwards 4 Press to return to CALIB at any time 4 7 4 Using EXAMINE to Display Clear Faults 1 After entering the EXAMINE menu press twice when CONFIG is displayed 2 When FAULTS is displayed press to display the list of status values 3 Press to move forward through the list of faults in sequence Press to move backwards The last item in the list is CLEAR When this message is displayed you can clear all faults by pressing This will also return you to FAULTS in the Examine menu If you do not want to clear all fault messages press or to move to another item in the list You can then press to return to FAULTS in the Examine menu without clearing fault messages This completes the Examine functions 4 16 October 1998 UM760D 1 4 8 FAULT MESSAGES OPERATION Table 4 2 lists the fault codes messages that may appear on the display The table also explains the meaning of each message the probable cause of the fault and recommended action you should take to correct the fault DISPLAY CODE POS ERR Note Setting Position Error Time 2 to a positive number may cause the device to fail safe on a POSERR BIAS ERR POS SEN PRES SEN SIG SEN REF ERR SW ERR October 1998 TABLE 4 2 Fault Messages Position Error I P Output at null point is out of range Position Sensor Error Pressure Sensor Error Current Sensor Error Reference Voltage Error Self Ch
106. rical and environmental specifications Parts List Provides parts drawing and parts list 1 1 PRODUCT DESCRIPTION This manual describes the procedures for configuring calibrating and operating the Moore ValvePAC ValvePAC Valve Controller An optional companion software product ValVue can be used to configure calibrate and perform valve diagnostics on the ValvePAC from a remote Windows 95 based Personal Computer The ValvePAC is a single or double acting valve controller that accepts a 4 20 mA input signal and converts it to a pneumatic output to position a control valve actuator The controllers can be used with either rectilinear or rotary single or double acting actuators Rectilinear action can range from 1 2 to 6 in valve stroke Rotary action can range from 45 to 110 degrees A spool valve is used to load the actuator for positioning in response to an input signal The ValvePAC can be configured calibrated and operated locally or remotely Local functions are controlled by means of local pushbuttons and digital display Remote operation requires the use of ValVue or a HART communicator As an option the ValvePAC can also be configured to include a process controller The process controller accepts standard inputs for process variable and setpoint and provides an output signal to the valve controller s function to achieve the value desired for the process variable October 1998 1 1 INTRODUCTION UM760D 1 ValVue
107. rtificate and its schedules may only be reproduced in its entirety and without change page2ors Sira Certification Service South Hill Chislehurst Kent England SORT Tel 44 0 181 457 2636 Fax 44 01181 295 1990 Anil 1998 Email cerlificalionsiracs prestel co uk SCHEDULE CERTIFICATE OF CONFORMITY Sira Ex 9802108 Dated 12 October 1998 APPARATUS The Series 76012 Valve Controller is designed to drive an actuator ta position a valve in proportion to an input signal The input signal can cither be pneumatic or electric 4 20mA The 760D can also receive feed back from a smart transmitter A valve position indicator can be viewed through a window in the enclosure The apparatus comprises a Masoncilan Dresser SVI Positioner and Controller a Jow power solenoid valve and a pressure transducer al of which are mounted a terminal board and are approved under Sira Certificate No 9702020 An LCD display may be mounted on top of the SVI Controller All of thesc component parts are housed within a meta enclosure which can be fitted with an optional transparent flat window or dome External electrical connections are made to terminal blocks via 4 threaded entry which accommodates conduit or cable A number of other threaded entries permit the pneumatic connections Electrica Parameters Field connector and Power input U 30V de Ji 125mA 0 9 2 2nF Li Gi 964H Field connector A B C C
108. s certificate relates only to the apparatus specified herein as executed in the samples supplied for evaluation 3 In affixing the Sira certificate number to the apparatus the manufacturer attests on its own responsibility that the apparatus conforms to the documents listed herein If the marked apparatus is found not to comply Sira Certification Service should be notified immediately at its office at South Jill Chislehurst Kent BR7 5EH England 4 The apparatus and that part of thc manufacturer s quality management system controlling the production of the apparatus covered by this certificate shall be subject to periodic surveillance by Sira in accordance with the Regulations applicable to the holders of SCS certificates 5 This certificate relies on the following previously certified products When they are used as part of the Series 760 Valve Controller they shall still be cavered by their original certificate Masoncilan Dresser SVI Positioner and Controller SCS Ex 97222020 Variation 1 Moore Products Series 760 Valve Controller SCS 97D2141X and Ex 97Y 4054X SPECIAL CONDITIONS FOR SAFE USE denoted by X after certificate No None This certificate and its schedules may only be reproduced in its entirety and without change Pagesos Sira Certification Service South Hill Chislehurst Kent BR7 SEH England 8 025 44 0 181 467 2638 Fax 44 0 181 295 1990 April 1997
109. s of 100 psi in the V1 V2 or supply ports may cause damage to the controller Supply pressure to the controller must not exceed actuator maximum pressure rating TABLE 3 1 Pneumatic Connections ACTUATOR TYPE CONTROLLER ACTION CONNECTIONS Single Acting Direct Acting output increases Connect V2 and plug V1 with increasing input signal Single Acting Reverse Acting output Connect V2 and plug V1 decreases with increasing input signal 3 14 October 1998 UM760D 1 INSTALLATION TABLE 3 1 Pneumatic Connections Continued Double Acting Direct Acting V2 increases Acting V2 increases Note the actuator position desired for the with increasing input signal minimum input signal to the ValvePAC Connect V2 to the actuator port that causes the actuator to move away from the position noted in the Step 1 Connect V1 to the remaining port Double Acting Reverse Acting V2 decreases Note the actuator position desired for the with increasing input signal minimum input signal to the ValvePAC Connect V1 to the actuator port that causes the actuator to move away from the position noted in the Step 1 Connect V2 to the remaining port Reverse action is accomplished with the pushbuttons by setting SIG LO the input current with the higher magnitude e g 20 mA and SIG HI the input current with the lower magnitude e g 4 mA 3 3 ELECTRICAL CONNECTIONS The following subsections provide information for installation in
110. sed Voltage usually exceeds 11 5 volts Voltage measures less than 9 5 Voltage compliance of the current source is volts and the polarity is correct inadequate to drive the ValvePAC and other series loads e g a safety barrier or milliamp meter in the loop Voltage measures above 11 5 volts Check the position of the jumper on the terminal and the polarity is correct board NOTE Use the mA jumper position for 4 to 20 mA applications and the V position for multi drop applications 5 3 2 Grounding In most cases a plant s normal grounding practices apply to the ValvePAC The ValvePAC does require the following grounding points A Case ground B Signal ground C Process controller ground 5 4 October 1998 UM760D 1 TROUBLE SHOOTING Case Ground Special screws on the inside and the outside of the case provide connections for the case ground Signal Ground Follow normal practice for your facility Most facilities reference the 4 20 mA signal ground to the ValvePAC to the rear of the barrier box or at the I O card You can reference any point in the loop to ground but you must not ground more than once NOTE Use only one ground reference in the loop Process Controller Ground Use the following procedure for a ground reference only when the ValvePAC is supplied as a process controller 1 Connect the auxiliary terminal B to the same ground reference as the negative current input term
111. shown in Figure 4 1 the upper line is a 7 digit numeric display and the lower line is a 7 digit alphanumeric display The upper line is used for displaying values such as input signal or valve position and the lower one is primarily used for messages and parameter identification October 1998 4 1 OPERATION LOCAL PUSHBUTTONS 7 DIGIT ALPHANUMERIC DISPLAY SELECT POS 56 8 UM760D 1 INCREASE VALUE OR MOVE DOWN NEXT IN MENU BUTTON DECREASE VALUE OR MOVE UP BACK IN MENU BUTTON SELECT OR ACCEPT BUTTON LOCLDISP ds4 FIGURE 4 1 Local Display and Pushbuttons The three pushbuttons perform the following functions e The lower button marked with permits you to select or accept the value or parameter option currently displayed e The middle button marked permits you to move back through the menu structure to the previous item in the menu or to decrement the value currently shown in the digital display When used to decrease a displayed value holding this button down causes the value to decrease at a faster rate e The upper button marked permits you to move down through the menu structure to the next item in the menu or to increment the value currently shown in the digital display When used to increase a displayed value holding this button down causes the value to increase at a faster rate To quickly identify the pushbutton sequence requ
112. tifying the model number bill of material and input range The following decodes the model number on the label located inside the cover Before installing or servicing a Controller review the model number information Basic Model No 760 Digital Valve Controller Device Type D1 Valve Controller Positioner D2 Valve Controller Positioner with optional process controller function Action 1 2 to 4 inch stroke lever 2 to 6 inch stroke lever 1 4 turn 1 2 inch square shaft 1 2 to 2 inch stroke lever 1 4 turn NAMUR style shaft end Enclosure with 3 4 inch NPT conduit connection Standard With 90 beacon indicator With 60 flat indicator rising stem applications With 90 flat indicator 1 4 turn rotary applications Flow Capacity A Standard capacity spool valve assembly Cv 0 3 Environmental Construction Options A Standard temperature 40 to 185 F Gauges G Gauges set of 2 included Type of Actuator 1 Single acting mechanical direct action 3 Double acting Display N Not required D With 2 line 7 digit alphanumeric display Reserved for Future Use N Ou Design Level A Electrical Certification refer to Specifications 7 FM CSA CENELEC SCS 760D1 5 A A A G3 N N A 7 Sample Model No October 1998 7 1 MODEL DESIGNATION UM760D 1 7 1 OPTIONS Options are installed either in the field by the user or at the factory The following options are available TABLE 7 1 Options TYPE DESCRIPTION F
113. ting when power reaches the unit This display stops when the ValvePAC resets itself If the Reset message repeats continuously without stopping assume an electronic fault and replace the unit 5 3 4 HART Communications This section contains information about computer and peripheral connections necessary to achieve proper communication so that ValvePAC can communicate with a hand held device or the optional ValVue software HART Compliance The ValvePAC requires a HART compliant communications loop The HART protocol specifies the noise level impedance requirements and configuration of the loop NOTES 1 When an intrinsically safe barrier separates the communicating device a HART compliant barrier must be used 2 Before calling for technical support with suspected HART compliance problems prepare a detailed description of the control loop including all devices on the loop and the type of wiring used 5 8 October 1998 UM760D 1 TROUBLE SHOOTING Conventional current output loops consisting of the following components usually meet requirements for HART compliance e Quality current source e g low noise high impedance e Loop impedance of 250 ohms more e Twisted pair cable meeting the requirements of the 4 20 mA standard Hand held Settings If the hand held communicator fails to communicate with the ValvePAC perform the following procedure NOTE The communication connection of a HART 275 hand held terminal is not
114. to a HART device such as the ValvePAC Valve Controller Use on line operation to download a configuration to a HART device upload a configuration edit HART device operating parameters and monitor process values April 1999 7 APPENDIX A MODEL 275 UNIVERSAL HART COMMUNICATOR UM760D 1 For off line operation the Communicator need not be connected to a HART device On line operation requires a connection to a HART device The menu that appears first when the Communicator is turned on depends on whether it is connected to a loop If the Communicator is powered up without being connected to a loop the first menu displayed is the Main menu If the Communicator is powered up while connected to a loop the first menu displayed is the Online menu To work off line when connected to the loop access the Main menu from the Online menu by pressing the LEFT ARROW PREVIOUS MENU key A 4 1 Display Icons Several symbols icons appear on the LCD to show the state of the Communicator and provide visible response to actions of the user Figure A 3 shows the display icons and how they relate to keypad functions HART Communication indicates connected device is configured in 4 the burst mode n HART Communicator K Device Info Low Battery 2 DevType T Dev ID Access Additional Tag 0 Menu
115. uage option When the desired language is displayed press to move to next item At MAN press to move to the top of the CONFIGURATION menu or to move back to the previous item To leave the CONFIGURATION menu press This returns you to the Manual Menu This completes the configuration procedure 4 5 CALIBRATION You can perform the following calibration functions with the ValvePAC 4 12 Minimum and maximum stops for valve position Rezeroing Automatic tuning Low and high values for input signal Supply pressure high value for actuator pressure output NOTE Calibration can only be performed in the manual mode October 1998 UM760D 1 OPERATION 4 5 1 Calibration Procedures using pushbuttons Because the final orientation of the unit cannot always be anticipated at the factory it may be necessary to reposition the potentiometer s feedback gear To check the gear s position manually move the actuator though its full range of travel and observe the display If at any time the word FAILSAFE appears then the gear must be repositioned Repositioning the feedback gear such that the limits of its rotation bring it no closer than about one tooth away from losing contact with the input gear should correct any problem The feedback gear can be repositioned by loosening the screws that secure the feedback gear s mounting bracket to the housing see Figure 4 8 NOTE After the potentiometer has been properly
116. ual With the Blank Template menu displayed choose from the options available as follows Mark All Flag all configurable variables before sending them to a HART compatible device Unmark All Remove the flags from all configurable variables in the configuration Unmarked configuration variables cannot be sent to a connected HART compatible device Edit Individually Open the Edit individually menu at right Example Use the Edit individually menu to change a configuration parameter For example to change the Tag press the EDIT function key F3 to display the Tag bottom right With the Tag menu displayed use the Shift Keys and Alphanumeric Keys to type in a new Tag then press the ENTER function key F4 Or to leave the Tag menu without making any changes press the ESC function key F3 to return to the Edit individually menu From the Edit individually menu use EXIT to go back to the Blank Template menu Save As Selecting the Save As option allows a new configuration to be saved to either the Memory Module or the Data Pack The Memory Module holds up to 10 typical configurations and contains the operating system software and device application software in non volatile memory The Data Pack stores up to 100 typical configurations in nonvolatile removable memory Example From the Offline menu choose 1 New configuration This displays the Manufacturer menu Choose a device then choose a model fr
117. umeric keypad that corresponds to the desired menu option For example to quickly access the Utility menu from the Main menu simply press 4 on the keypad A 3 4 2 Data Entry Some menus require data entry Use the alphanumeric and shift keys to enter all alphanumeric information into the HART Communicator Pressing an alphanumeric key alone while editing causes the large character in the center of the key number 0 9 decimal point or dash to be entered Pressing and releasing a shift key activates shift and causes the appropriate arrow icon to appear in the upper right hand corner of the LCD When shift is activated the indicated alpha characters or symbols are entered when the keypad is used Example To enter a number such as 7 simply press the number key To enter one of the small characters appearing above the large numeral i e a letter space or mathematical symbol first press and release the corresponding shift key at the bottom of the keypad then press the desired alphanumeric key To enter the letter E press and release the middle shift key then press the number 8 key To deactivate a shift key without entering a letter space or mathematical symbol simply press that shift key again A 4 GETTING TO KNOW THE COMMUNICATOR The HART Communicator operates in either of two modes on line or off line Use off line operation to create or edit a configuration that can then be downloaded
118. usses the fundamentals of operating the ValvePAC and the steps necessary to successfully configure and calibrate it Of key importance to the successful operation of the Series 760 ValvePAC is a good understanding of its command structure Whether the commands are issued by the optional pushbuttons a handheld communicator or the optional ValVue software the structure is the same Normal Mode Used during normal operation and for display of configuration and calibration parameters Manual Mode Used for configuration and calibration and to manually adjust the valve position Figure 4 2 illustrates the breakdown with the Normal Mode being on the left half of the chart and the Manual Mode being everything under the Manual menu 4 1 PUSHBUTTONS DISPLAY When the ValvePAC powers up it will be in Normal Mode The optional display shows the input signal the actuator pressure and the valve position The display sequences from one variable to the next every 1 5 seconds Using the pushbuttons you can exit from the Normal Operating Mode at any time and step through the menu structure to perform a wide range of manual operation calibration and configuration and monitoring functions all of which are described later in this chapter NOTES 1 If ValVue software is used pushbuttons must be placed in the unlocked mode in order to operate 2 If the ValvePAC is specified without local pushbuttons local operation is not available As
119. ust run the find STOPS calibration again CALIBRATE MENU A C AVITION This function strokes the valve over its full range Do not execute while the valve is controlling the process From CAL in Manual Menu Moves valve to Closed and Open Stops and Determines what valve returns to starting value Valve must be off process positions correspond to If button is pushed while running this task the task is Fully Open and Fully Closed STOPS interupted and the valve returns to starting positiong Displ lue of Open St HHH d isplays value of Open Stop hee es Press or to enter new value 5 2 Press to accept new value V c7 i To calibrate bias pressure on pneumatic block Sets the I P current to the normal bias value 2750 BIAS Press or to return to Calibrate Menu Use to detemine positioner Iniates the Autotune Function and returns to tuning parameters Partially TUNE when finished Pressing any button implemented now TUNE stops the tuning process Hd Displays value of SIG LO Press Ht Value of Input Signal for n or to enter new value Press Fully Closed or Fully Open SIG LO to accept new value and mo
120. ve to Lo Next menu item d ai HE UN Displays value of SIG HI Press Value of Input Signal for gt or to enter new value Press Fully Closed or Fully Open SIG HI 1 4 to accept new value and move to LE next menu item 2 Hd Displays value of SUPPLY PRESSURE m m Press or to enter new value Press Supply Pressure PRES HI m to accept new value and move to next menu item gt Returns to i POS MAN in t CALBMENU ds4 Manual Menu October 1998 FIGURE 4 5 CALIBRATE Menu Structures 4 7 OPERATION 4 2 4 Examine Menu UM760D 1 This menu and the sub menus shown in Figure 4 7 can be entered either from the Manual Mode Menu or from the Normal Operate Mode Menu The Examine menu allows the user to read the current configuration calibration and status information This information however cannot be changed from the Examine menu When you exit from the Examine menu you return to the menu from which you entered 4 8 EXAMINE MENU From gt EXAMINE in Manual Menu or from Operate Menu CONFIG gt CALIB lt FAULTS Returns to Normal Operade Mode Display or 2 OPER if in Manual Menu Depends on entry gt MAN or gt POS state Depends on entry state E Press or to step through conf
121. vePAC allows the user to configure a lower PL and upper PU software position limit stop When in operation with these limits on the valve will not move below the lower limit stop or above the upper limit stop CAUTION These are software limit stops If the ValvePAC fails for any reason including power failure or air failure the ValvePAC cannot enforce these limit stops and the valve will go to fail safe Furthermore the FULL OPEN AND FULL CLOSED buttons in ValVue bypass the limit stop controls If safety requires the use of limit stops mechanical limit stops should be used In PL OFF ON if status and value displayed are satisfactory press to move to next item If not press to change on off status and display value Then press or buttons to increase or decrease value displayed When status is changed from ON to OFF no value is displayed When value is OK press to accept value and move to next item In PU OFF ON if status and value displayed are satisfactory press to move to next item If not press to change on off status and display value Then press or buttons to increase or decrease value displayed When status is changed from ON to OFF no value is displayed When value is OK press to accept value and move to next item The ValvePAC local display may be configured to display English or French If the language displayed is correct press to move to next item If not press to display the other lang
122. wer BLACK VP Transducer Connection Jumpers to Select Voltage multi drop or Current Signal MULTIDROP stum 4 20mA Redundant gt 0 MODE Terminals A O Terminals for Connecting 4 20 mA Current Input Signal Process Variable For Process Input when a or 12 24 Vdc Multi Drop Voltage Signal Series 760D is used as a Digital Input Signal 250 Ohm Resistor PID Process Controller HART Protocol Required for Current Input Signal 16322 1 ds4 FIGURE 3 5 Internal Wiring Connections 3 4 TYPICAL INSTALLATIONS The following sections show the typical installations for the ValvePAC Section 3 4 1 covers the installation as a Valve Controller and section 3 4 2 covers the installation as a Process Controller Both sections have basic connection diagrams 3 4 1 Valve Controller The most basic setup for the ValvePAC is shown in Figure 3 6 The 4 20 mA signal is fed directly into the unit which then moves the valve until its position matches the setpoint This setup can provide a convenient way for a new user to learn and experiment with the ValvePAC NOTES 1 Use only shielded twisted pair wiring or place wiring in conduit for any auxiliary field wiring installation Do not expose the wiring to electromagnetic interference 2 Connections to any device that operates under an independent source of power e g a solenoid violates the intrinsic safety certificat
123. ws the user to enter the supply pressure This pressure is used for scaling of the pressure data in the ValvePAC In PRES HI if the displayed value is correct press to advance to the next item If not press to display value of SIG LO Use and buttons to change the value When OK press to return to menu and move to next item 12 Calibration as a controller is now complete At MAN press to return to the MANUAL mode 4 6 USING THE PUSHBUTTONS TO ADJUST POSITION After the unit has been configured and calibrated it will respond to either the current input signal or the pushbuttons To use the pushbuttons to move the valve perform the following 1 Starting with the Normal Mode Operating Display the repeating input signal actuator pressure valve position sequence on the display press any button 2 Press until MAN is displayed 3 Press to move into the Manual Mode POS MAN will be displayed 4 Press 5 Press or to move the valve as desired 6 Press when the valve is in position As long as the unit is in the Manual Mode the valve will remain in position If the unit is returned to the Normal Mode the current signal will take over as the setpoint 4 7 EXAMINE The Examine Menu permits you to display calibration parameters configuration parameters and to display and or clear fault status messages and codes Refer to Table 4 2 for explanations of fault messages You can enter the Examine menu either
124. y state error greater than 0 5 October 1998 5 11 TROUBLE SHOOTING UM760D 1 5 3 7 Position Instability The possible sources of position instability include Control loop measurement noise Process noise Oscillation Limit cycling Line frequency Control loop noise only appears in the Normal mode never the Manual mode For best control reduce control loop noise by re tuning the process controller in the ValvePAC or an external controller You may also dampen the ValvePAC response Process noise results from process pressure and flow changes that apply forces to the valve plug and cause changes in position Although the ValvePAC restores the plug position the response is not instantaneous Set the following values to identify PID oscillation P 20 0 0 0 D 0 Damping 0 Dead Zone 0 If the position remains stable then the problem is related to the positioner settings of the PID Re run AutoTune The characteristics of limit cycling include at least a 4 second period and a squared off as opposed to sinusoidal trend record Excessive friction in the valve actuator assembly or dirt in the spool valve assembly can cause limit cycling The ValvePAC diagnostic identifies excessive friction in the valve actuator assembly as a reported friction value greater than 30 of the actuator span Poor grounding of the signals and case or power supply ripple in the 4 20 mA control signal can introduce li

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