PST Integration Guide of MTL (4840 series) HART
Contents
1. IS Application Layout Cu i E S lo Ethernet RS435 xw 1 Converter module MTLA 41 No t PC Running Yokogawa PRM Software for PST MT LAH B G ms tet R Es 1 i i ene i 1 Hj ESD AO OP c a fs za a I zt Cc o P o ESD DO O P 24V In this diagram the relevant Hardware components for a 4 Wire non IS Application are shown Figure 2 Key Item 1 Safety System DO Card Item 2 Safety System AO Card Item 3 MTL HMU16 AO HART Connection Unit and MTL4842 HART Interface Module and MTL4841 HART Communication Module Item 4 Westermo RS485 232 Converter Item 5 PRM Software PC Workstation The difference between the 2 Wire and 4 Wire applications is that the Valve is powered via an Analogue Output Card producing 4 20mA rather than a 24Vdc signal as in the 2 Wire Application Yokogawa Electric Corporation SBDB 080045 Some Analogue Output current sources can interfere with the HART Signal or the HART Signal can interfere with the Current Source Therefore a HART Filter is added in the loop to make sure this can t happen in the above drawing the HCU16A0O is used This allows connection to 16 Devices and as per the other applications the system can be built up to connect up to a total of 7936 Devices In this application the Logic Solver provides two separate signals one 4 20mA to the Valve and a 24Vdc signal for2. application This Note covers Non S applications only and the detailed hardware requirements for 2 or 4 wire applications are shown in section 5 The key elements of the MTL HART Multiplexer system for this application are the MTL4841 HART Communication Module and the MTL4842 HART Interface Module Both of these modules offer a compact plug in style thus providing quick and easy installation onto the HMU16 backplanes Between one and sixteen ESD Valves can be connected via the HMU16 backplane to the MTL4841 HART Communication Module Node A further 15 HMU s can also be daisy chained to the MTL4841 to give expansion of the system However due to the speed of HART communications and the number of variables that can be scanned from the positioner it is advisable to restrict the number of connections to less than 64 devices per MTL4841 With the HMU16 backplane the MTL4841 Communications Module and MTL4842 Interface Module provide the HART data interface between smart devices in the field and the HART Instrument Management Software Also required is a HART capable Control Valve or ESD Valve such as the Fisher DVC6000 Series These can be controlled by either a DCS Analogue Output Card or via a Logic Solver or ESD DO Module with a 24Vdc output A Line Conditioner may also be required in the circuit this is used to boost the impedance in the loop to facilitate HART Communications However this is not always necessary if a backplane with th
3. or signal format 13 Yokogawa Electric Corporation SBDB 080045 Terminations RS485 interfaces should ideally be provided with a matched termination to prevent reflections and ringing of the signal on the bus cabling The termination is usually a simple resistive terminator with an impedance that matches the characteristic of the cable this will normally be in the range of 100 2000 Biasing When no communication is taking place the bus is in an undefined floating state and consequently noise on the bus may be decoded as real characters Well written software should discard most of these characters but the system may be further protected by biasing the bus to a known state and thereby preventing the reception of false characters MTL4841 communication modules from MTL have no built in facility for terminating or biasing the network as this is often provided by the RS232 RS485 converter RS485 2 wire interconnection The MTL4840 system uses a 2 wire connection as shown below in Figure 4 Figure 4 This 2 wire bus uses the same pair of wires to transmit queries from the master and responses from the slave The MTL4841 communications module connects to the maintenance workstation via a 2 wire link accessible from the RS485 Port connections on the backplane Up to 31 MTL4841 modules slaves can be connected to a single Master maintenance workstation Connect the bus to the backplane as follows using a scre
4. Yokogawa Electric Corporation SBDB 080045 PRM Integration Guide with MTL 4840 Series HART Multiplexer This manual explains how to connect the MTL4840 Series HART Multiplexer and configure Yokogawa s Plant Resource Manager PRM software This document is based on MTL s Technical Support Note No 205 Notes Yokogawa This manual simply explains certain functional details of PRM and makes no claims as to its suitability for a particular purpose No part of this manual may be transferred or reproduced without prior written consent from Yokogawa Yokogawa assumes no responsibility for any direct or indirect loss or damage that arises from the use of this manual due to circumstances that cannot be predicted in advance Notes MTL This manual has been prepared for informational purposes only While MTL has made every effort to ensure the correctness and accuracy of this document s contents it provides neither warranties or guarantees express or implied regarding the MTL products described herein or their use MTL reserves the right to make modifications to the designs and specifications of the products described herein at any time and without advance notice Yokogawa Electric Corporation SBDB 080045 Contents M eetuie M 3 2 Overview of MTL4840 System eeeeseeeeeeeeeeeenee enne nennen nnns 4 3 Hardware and Software Requirements eene 5 3 1 FV aT W
5. a project under Local and select IOM type for MTL 4840 IOM Type NI FBUS Port No Figure 9 19 Yokogawa Electric Corporation SBDB 080045 Also configure MTL 4840 for master and slave configuration as per dip switch setting and select COM port where RS232 9 pin cable is connected Select Preamble 10 for HART device communication Create IOM Type COM Port No Master No Slave No Preamble Figure 10 Save the information on Device Path Configuration Tool and restart the field communication server Log on to PRM client and go to Network view Select HART network and go to Register gt Read Device Path When message window pop up informing that it may take long time please select Yes 20 Yokogawa Electric Corporation SBDB 080045 Plant Resource Manager Server Set LOCAL User ID ADMINISTRATOR DAR Fie Edt View GITE Option Window Help 8x SES E 3 Network prm des v De el History Device List g Diagnosis IA PLANT Rebuild Acquistion Schedule oli Device Tag Criticality Alarm Patrol Historian Device ID F Foi User Management C SIS OFF 513B d Mec Data d ON EH OFF 370420BC35 4e 0 DEMO 01 0101 MUX MTL4840 0 EJX110 Ol Ol OFF 3751000083 4 OQ ISA 04 9999 MODEM 0 Qex 110 Ol Ql OFF 3751000001 0 5 ISA 05 9999 MODEM 0 EPIC Oo o OFF 4D04000001 ka ISA 07 9999 MODEM 0 FT 101 High OFF Ol OFF 37041EF83E F 0 Other 0 Qe Lo
6. a solenoid valve 10 Yokogawa Electric Corporation SBDB 080045 6 Installation 6 1 HMU Backplanes The HMU range of connection units is designed for applications where only a small number of HART signals need to be connected Consult the Appendix for field and system connections to these backplanes An HMU16 backplane uses one MTL4841 module and one MTL4842 module The type of HART signals handled depends on the HMU model chosen as shown below HMU16 provides connection for up to 16 Al signals HMU16A0 provides connection for up to 16 AO signals HMUs are supplied on a DIN rail mounting carrier and may be mounted anywhere in the cabinet in any orientation 6 2 DC Power Connections Each HMU backplane has DC POWER terminals for the connection of a nominal 24V dc supply Power requirements Voltage 21 35V dc Current 72mA 24V dc Connect the dc power to the board as shown in Figure 3 Observe polarity HMU16 No MTL4842 module MTL4841 Figure 3 11 Yokogawa Electric Corporation SBDB 080045 6 3 Links to other HMU Backplanes HMU backplanes may be linked together to provide a total of sixteen MTL4842 modules under one MTL4841 communications module Consequently other HMUs do not need an MTL4841 module to be fitted 10 way connectors P1 and P2 see Figure 3 are used to link the additional HMU backplanes together See Section 6 6 for cabling recommendations and limits MTL can provide 10 wa
7. are as described in the PRM user s manual 7 1 MTL HART Multiplexer support on PRM MTL HART Multiplexer will provide RS485 serial communication link PRM Field Communication Server FCS computer will have RS232 COM port so RS485 to RS232 converter is used to convert the serial communication to RS232 Ethernet Field Communications Server 1 RS 232C RS 485 converter RS Communication FCS RS 485 HART Multiplexer commercially available 9909000000920 RIO bus lt Slave No 2 Adapter Slave No 1 board HART Devices 8 qe E te AAM11 95559999959995 AAM11 ve5soqosoocsose Master E 4 20 mA HART Digital Signals FOSE ai Figure Serial Port Connection via HART Multiplexer Parallel Connection and Two way Data Flow Figure 7 18 Yokogawa Electric Corporation SBDB 080045 PRM Field Communication Server will use a baud rate of 19200 for serial communication with the MTLHART multiplexer so the Com port setting on the computer as well as baud rate setting on multiplexer should be set at baud rate of 19200 Communications Port COM1 Properties Bits per second Data bits Parity Stop bits Flow control Restore Defaults Figure 8 After the com port setting is done on FCS computer you need to configure the device path for PRM Create
8. are E EE E A eed sunscesocnseassoussonsousssusstnossvasosesseadovassoessasssusousseasecssoasoes 5 3 2 OLE WADE 5e p trt soup suas cesscatsanacedaceuaesnas guns cbse E ENAT EEE 6 4 2 Wire non IS Application Layout eeeeeeeeeeeeeeeeeeennnnnn 7 5 4 Wire non IS Application Layout eeeeeeeeeeeeeeeeeeeeee 9 6 Jmnstallatlon o st t tet utet itta anii iE 11 6 1 HMUBackplares 5 5 rooster eret Certi eh vao eraat ep e epos tha Een ee e re e Do PvY Oe TOL V DR shes REN EUR UNS UR SERRE E Te TORTE 11 6 2 DC Power Co nn ctlons enetecseeess esae eese evvs tho stro t eve For ee bH dne eP Yee ed ob UNT REY e Ro UEREEE TEES NETTE TUR ESSENT Ge 11 6 3 Links to other HMU Backplanes 4 eres eres etes seen eene n eene tn seta setas eta sete seta stets ttes tne toaae 12 6 4 MTLAS4x modules fitting eere eee eee eese teens eene enean tn serans seines sesta sees sosta suse 12 6 5 RS485 communication connections eere sees ee esee ee ette eene en aetas etas tn seta seta sete stesse ess ene sta se 12 6 6 HMU Cable Connections eee eese esee seres seen seen sten stats tone toas ease osooso sorsot aoro 13 6 7 RS485 CONMECHON E 13 6 8 Module Configuration e eese eese e eere eee e sees seen setas tn tonto aetas etna ease ease ease te sete stesse seta seos 16 6 8 1 MTLA841 address
9. e necessary impedance is included Yokogawa Electric Corporation SBDB 080045 3 2 Software ESD Valves can be interfaced with a number of HART Asset Management Systems including Yokogawa PRM Software PRM offers the user not only Partial Stroke testing but many other sophisticated diagnostic options Yokogawa Electric Corporation SBDB 080045 4 2 Wire non IS Application Layout This solution can be used for connection to Positioners in a safe area HMU16 P250 MTL4841 can connect to 16 MTL4842 s thus giving you a total of 256 devices per Node MTL4842 can connect up to 16 positioners 24 VOLT DC POWER SOURCI Safety System DO Card L Pas as rer re Tr TRAVEL FEEDBACK poppe eee red ESD VALVE AND ACTUATOR Figure 1 Key Item 1 Safety System DO Card Item 2 MTL HMU16 P250 HART Connection Unit with 250 ohm parallel resistor and MTL4842 HART Interface Module and MTL4841 HART Communication Module Item 3 Westermo RS485 232 Converter Item 4 RS232 Cable Max 33ft approx 10metres Item 5 PRM Software PC Workstation Yokogawa Electric Corporation SBDB 080045 Note In this configuration the Emerson DVC6000 must be set to Multidrop mode Certain DO cards may generate a LFD pulse in these cases the configuration may need to be altered Contact MTL for further details Yokogawa Electric Corporation SBDB 080045 5 4 Wire non
10. ened cable for example Belden 8132 or 14 Yokogawa Electric Corporation SBDB 080045 9841 Connect the two cores of the RS485 cable to screw terminals A amp B of Port 1 on the HMU see Figure 5 ABC ABC Figure 5 Connect the cable screen to terminal C If multiple backplanes are to be connected use Port 2 to loop to Port 1 of the next backplane To avoid spending time in troubleshooting it is suggested that the same color convention is used for all connections to backplane terminals A and B e g red to A black to B Note No damage will occur if the signalling lines are connected with the wrong polarity The system will not operate in this case but all that has to be done is to reverse the two connections to make it operate correctly Data converters Many RS232 485 data converters are available but the one that has received the most extensive testing and which is recommended for use with the MTL4841 is the Westermo MA45 RS232 485 Follow the manufacturer s instructions for setting up the RS232 connection to the controlling PC The RS485 connection should be configured to suit the MTL4841 settings which are discussed in Section 5 7 of this Note If preferred a RS485 Ethernet converted can be utilized 15 Yokogawa Electric Corporation SBDB 080045 6 8 Module Configuration MTL4841 setting and configuration The baud rate for the RS485 interface is selected using switches A amp B top of the MTL4841 comm
11. not affect the general operation of the valve and thus there will be no disruption in production The Partial Stroke test can be initiated with a pushbutton remotely located from the valve or using a HART Communicator and appropriate software such as AMS ValveLink software Yokogawa Electric Corporation SBDB 080045 2 Overview of MTL4840 System The MTL4840 Hart maintenance system provides interconnection addressing and scanning of HART smart devices This allows the user to monitor calibrate and maintain an entire network from a single maintenance workstation or local area network independently of the main control system MTL s HART connection system allows you to implement HART capabilities in both intrinsic safety and general purpose applications by connecting up to 7936 HART instrument loops to a control system and a variety of process automation maintenance software This means better use of maintenance resources with reduced commissioning time and process downtime and consequently lower costs for commissioning and loop maintenance The MTL4841 HART Communications Module and MTL4842 HART Interface Module and several of the HART Connection units are SIL 3 BASEEFA Certified in accordance with IEC61508 Yokogawa Electric Corporation SBDB 080045 3 Hardware and Software Requirements 3 1 Hardware The hardware requirements will depend on a few factors is the application IS or non IS Is the application a 2 wire or 4 wire
12. s 6 9 Operation at power up The MTL4840 system is controlled by a host computer running instrument management software Although the software is needed to operate the system some checks can be made on the correct functioning of the hardware in isolation These checks are made by observing the operation of the LEDs on top of the MTL4841 and MTL4842 Self test checks When power is applied to the MTL4841 and MTL4842 the following events should happen The green PWR LED on these modules will light The red ACTIVE LED on the MTL4842 will light to show that itis being addressed by the MTL4841 LEDs A to D light in sequence as shown in Figure 6 as the MTL4842 scans once around all the loop addresses 1 to 16 The sequence is repeated with each MTL4842 loopaddress fo off O on J Note Address 16 is shown by all four LEDs being extinguished Figure 6 17 Yokogawa Electric Corporation SBDB 080045 7 Software Connectivity The MTL HART system provides access from a PC to the HART field devices for configuration diagnostics and the monitoring of device performance HART devices may be selected for regular status monitoring and an alert issued if the status changes For this application the MTL HART connection system communicates with Yokogawa PRM software to support Partial Stroke testing of Fisher DSC6000 ESD Valves Having connected the MTL4841 MTL4842 system as described in this TSN set up the softw
13. switch eese eene ener nnne nnn erre nentes nentes 16 6 8 2 MTLA842 setting and configuration essere nennen rennen inneren 17 6 9 Operation at DOWer UP P 17 7 Software Connectlivily a oeesieen e tucc acce tan ana nana in Iu duco eu aa a anao aun n aut ukd E 18 7 1 MTL HART Multiplexer support on PRM sesesessssssoesesesesoeroroesesesoroesesecocossoroesesecoesesosoeseeesoesesoe 18 8 References Acknowledgements ccccccesssssesseeceeeeeeeesseeeeeeeeeeeeeeees 24 Yokogawa Electric Corporation SBDB 080045 1 Introduction This note is intended to help the user with connection details for the use of the MTL4840 System for partial stroke testing of Emergency Shut Down ESD Valves Partial Stroke testing has been gaining in popularity over the past few years It enables users who have HART capabilities in their control valve or Emergency Shutdown Valves ESD Valves to perform partial stroke testing Valves such as the Fisher DVC6000 allow partial stroking to ensure the valves availability and thus avoiding any potential catastrophic situations Partial Stroke testing can significantly reduce costs for predictive maintenance and also improves reliability of the valves as a consequence productivity can be improved due to the improved performance of the valve Partial stroke tests check the valve movement with a small ramp this ramp does
14. tiplexer Info You will get COM port master and Salve Multiplexer information When FCS computer will start communication with HART Multiplexer the lights on the multiplexer will blink indicating that PRM FCS is communicating with multiplexer Select the Get Device List and all the HART devices connected to Slave Multiplexer will be registered with proper device tag This test will confirm that PRM FCS is communicating with HART Multiplexer system and HART devices 22 Yokogawa Electric Corporation SBDB 080045 Please refer to the MTL Document INM4840 for further details of the MTLA840 HART Maintenance System The contents of this document are presented for informational purposes only whilst MTL takes every care to ensure the content is correct they are neither warranties or guarantees express or implied regarding the products described herein or their use MTL reserve the right to modify or improve designs and specifications of the products herein at any time without notice NOTE If you have any queries please contact your local MTL representative or email us at systemsupport mtl inst com 23 Yokogawa Electric Corporation SBDB 080045 8 References Acknowledgements MTL Publications INM4840 Installation Manual for MTL4840 HART Multiplexer System TSN205 MTL4840 HART Multiplexer System with Fisher DVC6000 SIS 24
15. unications module Set the switches to one of the options given here 6 8 1 MTL4841 address switch Up to 31 MTL4841 communications modules can be workstation Each MTL4841 must be configured connected to a single maintenance with a unique address by using the five switches located on the top of the module See Table 1 for settings 2928 ZIXIZI 8 Q Q Olo O9 Oo o o mz ml Z Z O O Oo O9 O O 2 P4 o b ina e fe mm o Ri ojo zz E gt 8 ae 38 E m Q m m Ojo mim njn olo 33 Q o z e 74 z z z ON Ton Ton Lor Z ml Z Z Z Z ala Z o m m o m m m m olo e m gg z z e 2 us 2 m olololololololololololol olo Q 9 z o z o m o z m3 o T 999 o 999999 z z ziz zz o z o z z gagspao X Z 3 Z X g2sapes mAiz iz o olololo gepega o z ON ON ON ON o z z nN N E A N o nN o N jN o 16 Yokogawa Electric Corporation SBDB 080045 6 8 2 MTL4842 setting and configuration Up to 16 MTL4842 HART interface i O1 modules can be connected to a single ON MTL4841 communications module Each OFF ON ON MTL4842 must be configured with a unique OFF OFF address by using the four switches located E on the top of the module Table 2 shows the ON OFF ON OFF ON OFF ON OFF ON or OFF OFF OFF Switch settings for the individual addresse
16. w o o OFF 37510FB72A Ez MODBUS Q HART EIA Low a a OFF 3704 1FO89C PROFIBUS Q Pr iot Low le ON OFF 37510F45E5 OE other 0 QREALTEMP Low ON o OFF 37090F42E2 Q SAMSON Low ON a OFF 42EF5C742A Q See Low ON ON OFF 65CB6C8ASD 0 Testtag Low ON Ol OFF testtag TwPTAGOO Low ON ON OFF 3709899562 Q VALVE Low ON a OFF 4D04000E82 0 Qxv 207 Low ON ON OFF 65CB632BD3 a Plant amp Network amp Class Custom Ley gt Ready Rows 1 of 16 3 26 2008 s Start o inbox Microsoft TA Page Top Win Be C PRM IM335 Ul Document2 Micro Plant Resource Ma Adobe Acrobat Pro Ellal P 2 14PM Figure 11 After the project and Multiplexer is registered as device path under HART network view go to windows explorer and select PrmHartMuxMaintTool exe which is located at under folder PRM Tool MTL4841 supports two kinds of protocols which are Arcom protocol and ASTEC protocol Please order MTL4841 PRM of MTL4841 version to use with PRM If you ordered other MTL4841 version then select Arcom protocol using HART Multiplexer Maintenance Tool 21 Yokogawa Electric Corporation SBDB 080045 HART Multiplexer Maintenance Tool Field Communication Server Computer Name Get Multiplexer Info COM Pott Y Master Multiplexer Y Slave Multiplexer aet Device List Jv Rebuild Ch DewicelD DeviceTag Vendor Type Revisi HAR Soft Hard Figure 12 Type PRM FCS computer name and select Get Mul
17. x denotes lengths between 0 5 and 4 0 metres Note The ribbon cables connecting the HMUs are not suitable for running outside of the cabinet or under control room floors Generally this will not be necessary as to maintain integrity each group of cabinets would interface their HART signals via independent MTL4841 communication modules Each MTL4841 module is linked by standard communications cables suitable for RS485 data at 9 6 19 2 or 38 4 kbaud 6 7 RS485 connection The RS485 physical layer Most PCs running instrument maintenance software masters use RS232C for serial communication however this interface type does not allow the communications network to extend beyond 10 to 20 metres in length MTL have chosen to use an RS485 serial interface which includes tri state operation and allows network lengths of up to 1000 metres and operates with data rates between 1200 baud and 39 4 kbaud when used with the MTL4841 RS485 also allows the simple parallel connection of a number of units Note When an RS232 master is used a data converter must be inserted The RS485 serial interface standard For the purposes of this document RS485 can be regarded as a 2 wire half duplex differential multi drop 32 nodes communications standard The RS485 standard defines the characteristics of the drivers and receivers that can be connected to the bus It does not define the cabling or connectors used nor does it specify a particular data rate
18. y cables in a range of different lengths on request Up to 16 may be connected in this way but the sum of all the interconnecting cable lengths between the first and last unit must not exceed four 4 meters 6 4 MTL484x modules fitting Place the MTL4841 over its connector in the position marked on the HMU16 Ensure that the module is not tilted which could damage the connector pins then press it carefully to the HMU16 All safe area circuit and power connections are made through this connector Tighten the two captive mounting screws Repeat this procedure for the MTL4842 module but please note When fitting the MTL4842 module on the HMU16 and HMU16A0O backplanes DO NOT place the MTL4842 beside the MTL4841 see Figure 3 6 5 RS485 communication connections Two RS485 ports are provided on the board see Figure 3 These are used to connect the HMU backplane to the PC running the maintenance software and possibly to onward link to MTL4841 communications modules on other backplanes Full details of this communications link are provided in Section 6 7 12 Yokogawa Electric Corporation SBDB 080045 6 6 HMU Cable Connections The interface bus provides a connection between a single MTL4841 communications module and up to 16 MTL4842 HART interface modules backplanes This connection is made via a ten way ribbon cable Standard lengths of this 10 way cable are available from MTL using the part number HM64RIB10 x x where the x
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