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User Instructions - Flowserve Corporation

1. 2 Register Number Attribute Description Notes 42126 RW Floating point table pointer 12 Flowserve use only 350 to 1248 42127 RW Floating point table pointer 13 Flowserve use only 350 to 1248 42128 RW Floating point table pointer 14 Flowserve use only 350 to 1248 42129 RW Floating point table pointer 15 Flowserve use only 350 to 1248 42130 RW Floating point table pointer 16 Flowserve use only 350 to 1248 42131 RW Floating point table pointer 17 Flowserve use only 350 to 1248 42132 RW Floating point table pointer 18 Flowserve use only 350 to 1248 42133 RW Floating point table pointer 19 Flowserve use only 350 to 1248 42134 RW Floating point table pointer 20 Flowserve use only 350 to 1248 42135 RW Floating point table pointer 21 Flowserve use only 350 to 1248 42136 RW Floating point table pointer 22 Flowserve use only 350 to 1248 42137 RW Floating point table pointer 23 Flowserve use only 350 to 1248 42138 RW Floating point table pointer 24 Flowserve use only 350 to 1248 42139 RW Floating point table pointer 25 Flowserve use only 350 to 1248 42140 RW Floating point table pointer 26 Flowserve use only 350 to 1248 42141 RW Floating point table pointer 27 Flowserve use only 350 to 1248 42142 RW Floating point table pointer 28 Flowserve use only 350 to 1248 42143 RW Floating point table pointer 29 Flowserve use only 350 to 1248 42144 RW Floating point table pointer 30
2. 2 Modbus Register Type Range Description 42110 RW Oto 199 Integer table pointer number 60 42111 RW Oto 199 Integer table pointer number 61 42112 RW Oto 199 Integer table pointer number 62 42113 RW Oto 199 Integer table pointer number 63 42114 RW Oto 199 Integer table pointer number 64 42147 RW 200 to 598 Floating point table pointer number 33 42148 RW 200 to 598 Floating point table pointer number 34 42149 RW 200 to 598 Floating point table pointer number 35 42150 RW 200 to 598 Floating point table pointer number 36 42151 RW 200 to 598 Floating point table pointer number 37 42152 RW 200 to 598 Floating point table pointer number 38 42153 RW 200 to 598 Floating point table pointer number 39 42154 RW 200 to 598 Floating point table pointer number 40 42155 RW 200 to 598 Floating point table pointer number 41 42156 RW 200 to 598 Floating point table pointer number 42 42157 RW 200 to 598 Floating point table pointer number 43 42158 RW 200 to 598 Floating point table pointer number 44 42159 RW 200 to 598 Floating point table pointer number 45 42160 RW 200 to 598 Floating point table pointer number 46 42161 RW 200 to 598 Floating point table pointer number 47 42162 RW 200 to 598 Floating point table pointer number 48 42163 RW 200 to 598 Floating point table pointer number 49 42164 RW 200 to 598 Floating point table pointer number 50 42165 RW 200 to 598 Floating point table pointer number 51 42166
3. Figure 10 Manual Calibration Act Str uat oke Actuator This option calibrates the actuator pressure sensors in the unit The process requires that the valve stroke from full open to full closed Because the valve will change position during this process you must confirm that you want to proceed You will then be prompted for the instrument air supply pressure to the unit If the air supply varies by more than 1 psi during the calibration the test may abort Hence a regulator may be required if the air supply is not stable The unit will then complete the calibration process by stroking the valve open and closed over 30 to 60 seconds Upon successful completion the display will momentarily flash the message Calibration Successful Stroke This option calibrates the position feedback sensor in the unit The process reguires that the valve stroke from full open to full closed Because the valve will change position during this process you must confirm that you want to proceed You will then be prompted for the valve type linear or rotary You will then be prompted to do a Jog Calibration or an Auto Calibration Jog A jog calibration should be performed if there is no physical stop in the valve or actuator that prevents the valve from over stroking and causing damage to the actuator When Jog is selected a prompt will appear to move the valve to the 100 open position This can be done by using the F1 and F2 keys to move the valve up
4. Process 40645 40647 Sets the normalized range for process temperature in Deg F these must be set Temperature set to 30 set to 300 using Valtek StarTalk user interface because they are floating point registers Valve fixed at fixed at The position is fixed range where 0 12 5 and 9999 112 5 Position 12 5 112 5 Re calculate 40078 N A Register 40078 must be set to 1 in order to signal the system to recalculate the Flag setto 1 scalar range after they have been changed This only needs to be written one time after each change in scaling 67 68 rer FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Integer Registers for Monitoring Process Register Description 30020 Reads the normalized valve position in current percent open Position percent open counts 125 1000 12 5 30013 Reads the normalized gaseous flow in currently selected engineering units Flow lb hr counts 5000 0 10000 0 30017 Reads the normalized process temperature in currently selected engineering units Temperature Deg F counts 300 30 10000 30 30014 Reads the normalized upstream process pressure in currently selected engineering units Pressure in psi counts 600 100 10000 100 m FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 we Appendix H StarPac 3 NS No Sensors Setup This guide is a setup tool for conf
5. Save Installed Configuration Save configuration on device and on computer Make backup copy and archive or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wes Appendix B Detailed StarPac 3 Register Menu This reference will aid you in understanding the configuration of the StarPac 3 register table Registers are described and notes are provided that give the range and more detailed information The StarPac 3 register table consists of three different types of information integers IEEE floating point numbers and strings These types can have a read only RO access attribute or a read write RW access attribute You can only read RO registers Writing to a RO register will generate an exception error You can both read and write to RW registers The register numbering is as follows a 30000 base indicates RO integers a 40000 base indicates RW integers a 70000 base indicates floating point numbers anda 50000 base indicates strings For example a register number of 30003 indicates a RO integer Two contiguous integer registers make up a floating point register You will get an exception response if you try to access into the middle ofa floating point register Registers making up bit fields follow the MSB LSB Most Significant Byte Least Significant Byte format Internally Flowserve calculates the StarPac 3 variable numbers by taking the module of the register number and 10 000 and subtracting 1 For exa
6. 42251 Floating point variable 5 Flowserve use only 42253 h Floating point variable 6 Flowserve use only 42255 Floating point variable 7 Flowserve use only 42257 Floating point variable 8 Flowserve use only 42259 Floating point variable 49 Flowserve use only 42261 z Floating point variable 10 Flowserve use only ig 42263 Floating point variable 411 Flowserve use only 42265 is Floating point variable 12 Flowserve use only hi 42267 Floating point variable 13 Flowserve use only 42269 7 Floating point variable 14 Flowserve use only ig 42271 Floating point variable 15 Flowserve use only 42273 Floating point variable 16 Flowserve use only 42275 ig Floating point variable 417 Flowserve use only igi 42277 Floating point variable 18 Flowserve use only 42279 Floating point variable 19 Flowserve use only FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Register Number Attribute Description Notes 42281 Floating point variable 20 Flowserve use only 42283 Floating point variable 421 Flowserve use only 42285 Floating point variable 422 Flowserve use only 42287 Floating point variable 23 Flowserve use only 42289 Floating point variable 24 Flowserve use only 42291 ig Floating point variable 25 Flowserve use
7. Con tus brat fig Disp Err Trp Next Set Alrm Alrt Alrm Trip Alrt Next i Set Set Set Sys View Trip Alrt Info Reg View View Alrm Sen Dev Alrm View sor ice Rset Row1 Row2 Var Var Each option may have other menus or options to choose from Disp Set Displays a menu to select the information that will be displayed on row 1 or row 2 of the display during normal operation Each selection has the same list of options except where noted Mode Status Lists the operating mode and any current alarm or trip conditions This option is only available on Row One Scanning Display Rotates automatically through a list that is configured through PC software This option is only available on Row Two Valve Position Current valve position in percent open Designated as Posn in the display Valve Command Current valve command in percent open Designated as Comnd in the display or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 we Liquid Flow Current liquid flow rate in user defined units Designated as FlowQ in the display Gas Flow Current gas flow rate in user defined units Designated as FlowW in the display ISA Up Stream Press Current compensated upstream line pressure in user defined units Defined as two pipe diameters upstream of the valve designated as P1isa in the display ISA Dn Stream Pres
8. Reset Totalizer Selecting this option resets the time and amountin the flow totalizer to zero 8 Calibration Menu The CALIBRATE menu is used to calibrate the analog inputs and outputs process pressure and temperature sensors as well as the actuator position and pressure sensors Before entering the CALIBRATE menu the display will indicate that the system will be taken off line and will ask the user to accept the condition WARNING Taking the StarPac 3 unit offline may cause the valve to stroke unexpectedly Notify personnel working nearby that the valve may stroke While the CALIBRATE menu is open the system is in Test mode and will not respond to control signals To put the unit back on line you must press the LAST OPTION key until the display prompts you and then press ACCEPT While you are in the CALIBRATE menu the letter T will flash on the right side of the display indicating that the unit is in Test mode The unit may also change the valve position during some of the calibration processes that could affect the process if it is not properly isolated The CALIBRATE menu is arranged as shown in Figure 9 below or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 we Figure 9 Calibration Menu Tree Sta Tune __Cal tus iii Anlg Anlg Next Out1 In1 Anlg Quik Man T In2 Cal Cal P1 amp P1__P2__Next P2 IE ie aas cple Tune Analog Out No 1 This option is used to calibr
9. reverse 1 direct 40041 40042 RW RW Command source analog digital remote Air to open close 0 analog 4 20mA input 1 digital 2 remote 0 Air to open 1 Air to close 40043 RW 4 20mA feedback output source variable 0 Position 1 Liquid flow 2 Upstream P1 pressure 3 Downstream P2 pressure 4 Delta pressure 5 Temperature 6 Gas flow 7 Auxiliary 4 20mA input 8 Positioner Output 9 Register Number 27 28 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 40044 RW Flow totalizer source liquid gas 0 liquid 1 gas 40045 RW Positioner source bypass normal 0 bypass 1 normal 40046 RW Analog command signal state 0 normal 4mA 0 1 inverted 20mA 0 40047 RW Time to hold SP on loss of command sec 0 to 9999 40048 RW Pbot ADC value corresponding to 0 psig 32768 to 32767 40049 RW Pbot ADC value corresponding to MAX_PRESS 32768 to 32767 40050 RW Ptop ADC value corresponding to 0 psig 32768 to 32767 40051 RW Ptop ADC value corresponding to MAX_PRESS 32768 to 32767 40052 RW Cmd ADC value corresponding to 4mA 0 to 16384 40053 RW Cmd ADC value corresponding to 20mA 0 to 16384 40054 RW DAC 1 output code 0 to 65535 40055 RW DAC 1 value corresponding to 0 position 0 to 65535 40056 RW D
10. 13 14 Configure device using on of the following three methods 1 StarPac 3 Device Local User Interface a b c Navigate to the Analog In 2 Menu and select Valve Delta Pressure Config gt gt Accept gt gt Next gt gt Anlg In2 gt gt Valve Delta Pressure gt gt Accept Enter the MaxDP psig value recorded in step 8 Accept Enter the zero calibration point Accept 2 StarTalk DTM Software a b c d Navigate to the Special Configuration menu Select the DP Cell Wizard Select the Use External DP Cell option Follow the step by step instructions in the wizard 3 StarTalk XP Software mo are Navigate to the configure Analog In 2 menu Change the Function Input to Flow Calculation Change the Flow Calc Variable to Pressure Drop Enter the MaxDP psig value recorded in step 8 for the Value at 4mA Enter the zero calibration point for the Value at 20 mA Click the Apply button Close the bridge valve on the Pressure Manifold and open the upstream and downstream valves Remove the Pressure Reference and regulated pressure source from the DP Cell and replace the Vent Drain Plug Remove the Current Meter from the current loop and reconnect the wire to Terminal No 5 on the StarPac User Interface Block Replace the covers on both ends of the DP cell or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 w
11. Current process variable in user defined units Designated as PV in the display fl Current F at present valve position Designated as fl inthe display xt Current X at present valve position Designated as xt in the display z Current compressibility factor at existing process conditions Designated as z in the display Cylinder Top Press Current pressure above the actuator piston in user defined units Designated as Ptop in the display Cylinder Bot Press Current pressure below the actuator piston in user defined units Designated as Pbot in the display Time amp Date Current time and date of the internal clock Auxiliary 4 20 Input Auxiliary input signal in percentage Designated as AuxIn in the display Flow State Liquid non choked liquid choked gas non choked gas choked Errors Alarms allows the user to view any current errors and alarms that are indicated by the flashing A and or E on the right side of the display This option displays three menu choices Figure 3 Alarms Errors Tree Sta Tune Cal Con tus brat fig Disp Err Trp Next Set Alrm Alrt Alrm Trip Alrt Next Set Set Set U Sys view Alrm Sen Dev Alrm Info Reg View sor ice Rset Alarm View Allows the user to view any current alarms using the NEXT or PREVIOUS function keys Possible alarms are Setpoint Deviation The control
12. actuator air action 16 pressure sensor calibration 13 stroke 19 air supply trip configuring 17 alarms masking 6 7 viewing 4 analog command configuring 16 analog in 1 calibration 11 analog in 2 calibration 11 configuring 16 analog out 1 calibration 11 configuring 15 analog out 2 calibration 11 configuring 16 B backup save restore 20 system 3 C calibration 10 clock setting 21 command 8 analog digital 8 communication settings 19 configuration 15 Configuration Default 21 D data logger 21 display configuration 1 contrast 20 Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 F fluid specification 21 Fluid Table 51 function keys 1 initial startup 2 J jumper alarm contact selection 22 configuration 22 discrete input range 22 RS 485 termination 22 M menu calibration 10 configuration 15 main 2 status 3 structure 2 tuning 7 mode discrete digital 9 test auto manual 9 P password setup 19 PID control action 8 control variable 10 derivative time 8 proportional band gain 8 reset integral 8 Positioner tuning 12 zero span See Actuator stroke Power supply 2 pressure sensor process calibration 12 process variable 10 pulse output configuring 21 R registers editing 20 viewing 7 20 remote transmitter configuring 16 23 reset 20 S setp
13. 02 11 15 2 Register Number Attribute Description Notes 40713 RW user units 4mA at Al 2 1E9 to 1E9 30715 RO Al 2 user units IEEE 754 40717 RW User flow unit multiplier 1E9 to 1E9 30719 RO Void Floating Point Register 0 0 30721 RO Void Floating Point Register 0 0 30723 RO Void Floating Point Register 0 0 30725 RO Positioner Command IEEE 754 40727 RW user units 20mA at DAC 1 1E9 to 1E9 40729 RW user units 4mA at DAC 1 1E9 to 1E9 40731 RW Full scale pulse relay output value 1E9 to 1E9 40733 RW Offset pulse relay output value 1E9 to 1E9 40735 RW Pulse relay full scale rate Hz 0 1 to 256 30737 RO Minimum recorded ambient temperature deg F IEEE 754 30739 RO Maximum recorded ambient temperature deg F IEEE 754 30741 RO Minimum recorded process temperature deg F IEEE 754 30743 RO Maximum recorded process temperature deg F IEEE 754 40745 RW Positioner characterization x axis input point 20 to 120 40747 RW Positioner characterization x axis input point 20 to 120 40749 RW Positioner characterization x axis input point 20 to 120 40751 RW Positioner characterization x axis input point 20 to 120 40753 RW Positioner characterization x axis input point 20 to 120 40755 RW Positioner characterization x axis input point 20 to 120 40757 RW Positioner characterization x axis input point 20 t
14. 029999 1 0 0 0 Steam 3208 250000 1165 140015 527 400024 0 998000 18 020000 0 95 14 358000 6869 500000 83 029999 1 0 0 0 Water 3208 250000 1165 140015 527 400024 0 998000 18 020000 0 95 14 358000 6869 500000 83 029999 1 0 0 0 51 52 or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Appendix D StarPac Wiring and Grounding Guidelines This guideline will help you in achieving maximum noise rejection and performance with a StarPac Intelligent Control System This guide must NOT be used to supersede local electrical code or plant safety wiring practices Shielding Versus Grounding All signals to the StarPac system should be in shielded cables Shields must be tied to a ground at only one end of the cable to provide a place for environmental electrical noise to be removed from the cable A ground wire unlike a shield is attached at both ends to provide a continuous path for electrical conductivity Grounding Screw The grounding screw by the user interface terminal block should be used to provide the unit with an adequate and reliable earth ground reference Either one of the mounting screws holding the terminal block may be used as a grounding screw This ground should be tied to the same ground as the electrical conduit Additionally the electrical conduit connecting to the StarPac unit should be earth grounded at both ends of its run The StarPac 3 grounding scr
15. 500 0 C 1700 800 0 D 2600 1200 0 E 3800 3000 5000 F 6000 4800 11000 G 8500 6500 13000 H 11000 8000 15000 Manual Edit This option allows you to view or change the gains from the default value to customize the response of the system Proportional Gain Controls the overall speed of response of the system Larger values will speed up the response of the system rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Static Gain Controls the response to steps of less than two percent Larger values will speed up the response of the system to small steps the effect of static gain is more evident on larger actuators Error Gain This is a dynamic gain variable that increases the gain with error size to speed the response in larger actuators Note that smaller values increase the gain and a setting of zero turns it off Open Loop This test is a diagnostic test to check the mechanical operation of the positioner module During this test the valve is forced to full open and full closed by driving the positioner output to its maximum and minimum values WARNING Notify personnel working nearby that the valve will stroke during this procedure otherwise serious injury may occur Step Test Allows you to monitor the response of the system to any step size that you input after pressing the function key Be aware that this operation will cause the valve to stroke The system reports the overshoot and rise tim
16. Liquid flow user units 4mA at DAC 2 0 to 1E9 40453 RW Gas flow user units 20mA at DAC 2 0 1 to 1E9 40455 RW Gas flow user units 4mA at DAC 2 0 to 1E9 40457 RW Plisa user units 20mA at DAC 2 0 1 to 1E9 40459 RW Plisa user units 4mA at DAC 2 0 to 1E9 40461 RW P2isa user units 20mA at DAC 2 0 1 to 1E9 40463 RW P2isa user units 4mA at DAC 2 0 to 1E9 40465 RW Tpro user units 20mA at DAC 2 500 to 5000 40467 RW Tpro user units 4mA at DAC 2 500 to 5000 40469 RW Calibration slope for cylinder bottom 1E9 to 1E9 40471 RW Calibration slope for cylinder top 1E9 to 1E9 40473 RW Calibration slope for 4 20mA command 1E9 to 1E9 40475 RW Calibration slope for DAC 1 1E9 to 1E9 40477 RW Calibration slope for Tamb 1E9 to 1E9 40479 RW Calibration slope for 4 20mA aux input 1E9 to 1E9 40481 RW Calibration slope for Pivlv 1E9 to 1E9 40483 RW Calibration slope for P2vlv 1E9 to 1E9 40485 RW Calibration slope for position 1E9 to 1E9 40487 RW Calibration slope for Tpro 1E9 to 1E9 40489 RW Calibration slope for DAC 2 1E9 to 1E9 40491 RW LOC Trip condition ramp rate min 1E6 to 1E6 40493 RW Maximum SP error without alarm 0 1 to 100 40495 RW Maximum SP change over 1 sec steady state 0 1 to 100 40497 RW Minimum supply pres without alarm psig 0 to 200 40499 RW Antoines A fluid coefficient 1000 to 1000 40501 RW Antoines B fluid coefficient 0 to 1E6 40503 RW Antoines C fluid coefficient 10E3 to 10E3 40505 RW Local
17. RW 200 to 598 Floating point table pointer number 52 42167 RW 200 to 598 Floating point table pointer number 53 42168 RW 200 to 598 Floating point table pointer number 54 42169 RW 200 to 598 Floating point table pointer number 55 42170 RW 200 to 598 Floating point table pointer number 56 42171 RW 200 to 598 Floating point table pointer number 57 42172 RW 200 to 598 Floating point table pointer number 58 42173 RW 200 to 598 Floating point table pointer number 59 42174 RW 200 to 598 Floating point table pointer number 60 42175 RW 200 to 598 Floating point table pointer number 61 63 64 FLOWSERVE wee Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Modbus Register Type Range Description 42176 RW 200 to 598 Floating point table pointer number 62 42177 RW 200 to 598 Floating point table pointer number 63 42178 RW 200 to 598 Floating point table pointer number 64 42211 Integer variable number 33 42212 Integer variable number 34 42213 Integer variable number 35 42214 Integer variable number 36 42215 u Integer variable number 37 42216 Integer variable number 38 42217 Integer variable number 39 42218 Integer variable number 40 42219 i Integer variable number 41 42220 Integer variable number 42 42221 E i Integer variable number 43 42222 Integer variable num
18. Usgpm US gallons per minute l m Liters per minute Ibs hr Pounds per hour kg hr Kilograms per hour cm hr Cubic meters per hour bbl dy Barrels per day 42 gal bbl Ukgpm Imperial gallons per minute CUSTOM Allows you to create your own custom units by first entering a multiplier that will operate on the StarPac native liquid flow units which are Gallons Minute to create your new units Next select the time base that relates to your flow rate of seconds minutes hours or days for the totalizer to use Then enter the name for the units you want to display The name is limited to six characters Lastly enter the name that you want the totalizer to display for the totalized units Gas Flow Sets the gaseous flow engineering units for the StarPac 3 system Use the NEXT and PREVIOUS function keys to select units from the following list Ibs hr Pounds per hour kg hr Kilograms per hour SCFH Standard cubic feet per hour MMSCFD Million standard cubic feet per day SCFM Standard cubic feet per minute SCMH Standard cubic meters per hour CUSTOM Allows you to create your own custom units by first entering a multiplier that will operate on the StarPac native gas flow units which are Pounds Hour to create your new units Next you select the time base that relates to your flow rate of seconds minutes hours or days for the totalizer to use Next enter the name for the units you want to display The name is limited to six
19. and down Use these keys to position the valve at 100 open When the 100 position is accepted the calibration procedure will continue automatically and the valve will move to the 0 open position and the calibration will be completed Upon successful completion of the process the system will momentarily flash the message Calibration Completed Auto An auto calibration should be performed if there are physical stops that limit how far the valve strokes open Valtek valves have stops which allow an Auto calibration to be performed During this calibration the valve will automatically open and close and the feedback sensor will calibrate automatically Upon successful completion of the process the system will momentarily flash the message Calibration Completed WARNING Notify personnel working nearby that the valve will stroke during this procedure otherwise serious injury may occur P1 and P2 This option simultaneously calibrates the process pressure sensors in the unit and is the recommended sensor calibration method Because it calibrates both sensors at the same time this procedure automatically moves the valve s stroke to mid stroke This calibration should always be done with the flow through the valve blocked If there is flow through the valve you must use the individual calibration options Because the valve will change position during this process you must confirm that you want to proceed You will then have three more
20. and 9999 112 5 percent The valve command is defined as 0 percent closed and 100 percent open The scaling for the process controller setpoint is shown in Table Analog Prompts the StarPac unit to use the 4 20 mA signal from the analog input as the valve position command or as the controller 57 rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee setpoint depending on whether or not the unit is in Manual or Automatic mode It can be set so that 4 20 mA 0 to 100 percent or 100 to 0 percent using integer register 40046 1 normal 2 inverted The scaling for the process controller setpoint is shown in Table I Remote Configures the unit so that floating point register 40705 sets the controller setpoint in percent of maximum see Table I or the valve position command in percent open depending on the selected mode Remote differs from Digital in that the remote register must be updated within the number of seconds set in integer register 40109 or the unit will go into a Loss of Command Trip mode When the Loss of Command Trip occurs the system will initially hold the last setpoint if in auto or the last position if in manual for the number of seconds specified in integer register 40047 When the timer expires the valve will then ramp open or closed at the rate set in floating point register 40491 a negative rate will ramp closed anda positive rate will ramp open Note When writing software to interface
21. and PREVIOUS function keys to select the access from the following list A R W B R W Both ports allow read write access A R W B RO A port allows read write access B port is read only A RO B R W A port is read only B port allows read write access Port B Type only when port B is selected This option allows you to configure Communication Port B port on the StarPac 3 The port can be configured for the following RS 485 You can configure Communication Port B for RS 485 communications It will be necessary to connect wires to terminals 3 and 12 on the StarPac 3 terminal block USB When a 2 0 mini Ba USB cable is plugged into the StarPac 3 on the Customer Interface Board Com Port B will automatically be configured for communication through the USB cable The baud rate will be set to 57600 When using the StarTalk XP software make sure the computer Com Port baud rate in is also configured to 57600 Infrared You can configure Communication Port B for infrared communications It will be necessary to communicate with the infrared port on the front of the StarPac 3 The port can be located directly above the StarPac 3 label located on the keypad You will need to use a PDA device with a keypad simulator to communicate with Communication Port B Transmit Delay This setting controls the time that the StarPac 3 system will wait before answering a Modbus request The 3 5 character setting provides the best
22. atmospheric pressure user units 0 1 to 1000 40507 RW Liquid flow fudge factor mulitplier 0 1 to 100 39 rr FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 40509 RW Gas flow fudge factor multiplier 0 1 to 100 40511 RW Fluid critical pressure 0 1 to 100E3 40513 RW Fluid critical temperature 0 1 to 100E3 40515 RW Fluid Fk coefficient 1to 10 40517 RW Fluid Molecular Weight 0 to 1000 40519 RW Fluid reference temperature 0 1 to 10E3 40521 RW Fluid specific gravity at t_ref 0 001 to 100 40523 RW Viscosity A coefficient 1E9 to 1E9 40525 RW Viscosity B coefficient 1E9 to 1E9 30527 RO Visconsity correction factor IEEE 754 40529 RW Offset for Dpisa calculation 0 to 100 40531 RW Design stroke of valve 0 001 to 100 40533 RW A1 variable used in gas flow calculation 1000 to 1000 40535 RW A2 variable used in gas flow calculation 1000 to 1000 40537 RW Cv A1 curve fit coefficient 1E9 to 1E9 40539 RW Cv B1 curve fit coefficient 1E9 to 1E9 40541 RW Cv C1 curve fit coefficient 1E9 to 1E9 40543 RW Cv D1 curve fit coefficient 1E9 to 1E9 40545 RW Cv E1 curve fit coefficient 1E9 to 1E9 40547 RW Cv A2 curve fit coefficient 1E9 to 1E9 40549 RW Cv B2 curve fit coefficient 1E9 to 1E9 40551 RW Cv C2 curve fit coefficient 1E9 to 1E9 40553 RW Cv D2 curve fit
23. characters Last enter the name that you want the totalizer to display for the totalized units Process Temperature Sets the process temperature engineering units for the StarPac 3 system Use the NEXT and PREVIOUS function keys to select units from the following list C Degrees Celsius F Degrees Fahrenheit R Degrees Rankine K Degrees Kelvin Actuator Pressure Sets the actuator pressure engineering units for the StarPac 3 system Use the NEXT and PREVIOUS function keys to select units from the following list PSIG Pounds per square inch gauge or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wes PSIA Pounds per square inch absolute kPaG Kilopascals gauge kPaA Kilopascals absolute kgscmG Kilograms per square centimeter gauge kgscmA Kilograms per square centimeter absolute Bar G Bar gauge Bar A Bar absolute Stroke Unit Sets the stroke engineering unit for the StarPac 3 system Use the NEXT and PREVIOUS function keys to select units from the following list INCH Inches MM Millimeters CM Centimeters Angle Degrees Percent Tag Name This option allows the user to enter a tag name that will be used as an identifier for the unit on a Modbus network Password This option sets up a password to control access to the local interface Access to the TUNE CALIBRATE and CONFIGURE menus is allowed only with the password after the password has been enabled The
24. for basic valve and process information Table 10 Common Floating Point Registers Floating Point Register Number Description 30379 Ambient Temperature in Degrees Fahrenheit 30393 Liquid flow rate in selected units 30395 Gas flow rate in selected units 30397 Upstream pressure in selected units 30399 Downstream pressure in selected units 30401 Valve pressure drop in selected units 30403 Process temperature in selected units 30407 Valve position in percent open 30411 Current setpoint in selected units note that this tracks the PV when in manual mode 30413 Current process variable in selected units 30371 Totalized liquid flow in selected units since last reset reset by writing a 1 into register 40078 30373 Totalized gas flow in selected units since last reset reset by writing a 1 into register 40078 30369 Totalized time in seconds since last reset reset with 40078 above 30707 Actuator pressure in the top of the actuator in psig 30709 Actuator pressure in the bottom of the actuator in psig Scaled Integers Several scaled integer registers provide access to process information using integer registers for those devices that do not support floating point registers These registers are listed in Table Ill The scaling registers must be set for the variable scale registers before the scaled value can be interpreted The minimum scale register sets the engineering value that will equal a r
25. gt Register 70070 ADCmin gt Register 40069 CalSlope gt Register 70486 Register Locations for Local User Interface and Modbus Access Tmin gt Register 70687 ADCmax gt Register 70071 ADCmin gt Register 40070 CalSlope gt Register 70487 Additional Information StarPac 3 Equations The StarPac 3 uses the following equation to calculate the process temperature Tprocess F ADC Current ADC min Cal Slope Tmin F ADC Current gt Register 30009 Local User Interface ADC Current gt Register 30008 StarTalk Software or ValveSight DTM NOTE You must use the temperature in Fahreheit F values for these calculations as those are the native units the StarPac 3 calculates It then converts this calculation to the desired units and outputs the result to Process Temperature User Units ADC value process temp gt Register 30009 Local User Interface ADC value process temp gt Register 3008 StarTalk Software or ValveSight DTM If you want to fine tune the reading make small adjustments to the slope value in register for CalSlope Increasing the value will increase the reading and decreasing the value will decrease the reading CalSlope gt Register 30487 Local User Interface CalSlope gt Register 30486 StarTalk Software or ValveSight DTM Cryogenic Usage Because of how the type K Thermocouple reacts at cryogenic temperatures we recommend calibrating the system at the workin
26. how steady the pressure is in the valve body Next enter the actual pressure applied in the indicated engineering units and press ACCEPT P2 This option calibrates the downstream process pressure sensor in the unit You will then have two more menu options to set for Zero and Span Zero Apply the atmospheric pressure or the minimum pressure you want to use for your reference and press ACCEPT The number on the right side of the display indicates how steady the pressure is in the valve body Next enter the actual pressure applied in the indicated engineering units and press ACCEPT Span Apply the maximum pressure you want to use for your reference and press ACCEPT The number on the right side of the display indicates how steady the pressure is in the valve body Next enter the actual pressure applied in the indicated engineering units and press ACCEPT Thermocouple This option is used to calibrate the Type K thermocouple temperature sensor in the unit You will then have two more menu options to set for Zero and Span Normally this calibration is done using a temperature controlled bath or a Type K thermocouple simulator connected to terminals 9 yellow and 10 red on the sensor terminal which can be found a the bottom of the main PCB circuit board assembly If a temperature controlled bath or Type K thermocouple simulator is not available refer to Appendix Zero Apply a signal equal to the minimum temperature you want to use for your
27. input channel gets its signal from a temperature transmitter Up Stream Pressure Uses the signal from an external pressure transmitter connected to the Auxiliary input channel as the process pressure for all internal calculations in place of the StarPac 3 sensor Down Stream Pressure Uses an external pressure input as the process pressure for all internal calculations in place of the StarPac 3 sensor Valve Delta Pressure Uses an external pressure input as the process differential pressure for all internal calculations in place of the StarPac 3 differential pressure calculated by the difference from the StarPac 3 internal pressure sensors The most common example is when a separate differential pressure transmitter is used for cases when the application cannot withstand pressure drops of at least ten percent of inlet pressure Molecular Weight Uses an external molecular weight input for all internal calculations in place of the static value stored in the FLOWSERVE wee StarPac 3 configuration Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Specific Gravity Uses an external Specific Gravity input for all internal calculations in place of the static value stored in the StarPac 3 configuration Liquid Multiplier This input allows you to make dynamic adjustments to the liquid flow calculation based on the value of the input Gas Multiplier This input allows you to make dynamic adjustments to the gaseous f
28. is outputting which is only used for reference during calibration Configuration of the variable and scaling for the channel is performed in the CONFIGURE menu Analog In No 1 This option is used to calibrate the first analog input of the StarPac 3 During the calibration a reference milliamp source should be connected to terminals 4 and 13 of the terminal block The display will give instructions to adjust the signal until the reference meter reads 4 mA When the 4 mA value has been accepted the user is then prompted to set the 20 mA value If the CANCEL key is pressed at any time all of the calibration values are returned to their original value The number shown at the end of the second line indicates the raw A D value that the unit is receiving and is only for reference during calibration Configuration of the variable and scaling for the channel is done in the TUNE menu Analog In No 2 This option is used to calibrate the second analog input of the StarPac 3 system During the calibration a reference milliamp source should be connected to terminals 5 and 14 of the terminal block The display will give instructions to adjust the signal until the reference meter reads 4 mA When the 4 mA value has been accepted you are then prompted to set the 20 mA value If the CANCEL key is pressed at any time all of the calibration values are returned to their original value The number shown at the end of the second line indicates the raw A D
29. line pressure defined as six pipe diameters downstream of the valve ISA Delta Pressure Current differential pressure using the pressure definitions above Process Temperature Current process temperature Gas Flow Current gaseous flow rate Auxiliary 4 20 Input Re transmits the 4 20 mA signal from analog in No 2 Analog Command This option sets up the first analog input analog No 1 in the StarPac 3 system This analog channel is reserved as a control input The signal is used either as a valve position command if the StarPac 3 is in Manual mode or as the controller setpoint if the StarPac 3 is in Auto mode The source of the command or setpoint is selected in the TUNE menu after it has been configured here When this option is selected you are first prompted for the interpretation of the analog signal The signal can be interpreted as Normal 4 20 mA 0 100 which means that 4 mA will indicate the 0 percent signal or as Reverse 4 20 mA 100 0 which then interprets 20 mA as the 0 percent signal Next you are prompted for the hold time in seconds that you want the system to hold the last command if the 4 20 mA signal should be lost defined as having the signal drop below 3 mA The last prompt requests a ramp rate that the system will use to fail the valve if the signal has been lost and the hold time has expired A negative value will ramp the valve closed at the selected rate and a positive value will open the valve at
30. no control Process Variable Select Selects the process variable that will be used to control the process Liquid Flow Sets the system to control liquid flow If the flow is gaseous the system will read the liquid flow value as zero and respond accordingly ISA Up Stream Press Sets the system to control using the current compensated upstream line pressure Definedas two pipe diameters upstream of the valve ISA Dn Stream Press Sets the system to control using the current compensated downstream line pressure Defined as six pipe diameters downstream of the valve ISA Delta Pressure Current differential pressure using the pressure definitions above Process Temperature Sets the system to control the process temperature Gas Flow Sets the system to control gaseous flow if the flow is liquid the system will read the gas flow value as zero and respond accordingly Auxiliary 4 20 Input Sets the system to use a 4 20 mA signal attached to Analog Input 2 as the process variable Process Variable Scaling This option sets the full scale process value that the controller will use in the PID algorithm using the units that have been selected in the CONFIGURE menu except for Auxiliary which is always in units of percent This step should be completed before tuning because the relative size of the error is determined by the scaling entered Totalizer Mode This option allows the user to set the totalizer to liquid or gas mode
31. not update the indicated pressures temperatures flow or PID values nor does it respond to any setpoint or command changes Test mode is the beginning mode after an initialization and is used during calibration If power is lost during a calibration setup the unit remains in Test mode and the mode has to be reset to Auto or Manual for proper operation Any time the unit is in Test mode the letter T flashes on the right side of the display for StarPac 3 Base Mode Source The base mode source controls where the StarPac 3 unit receives the mode information Integer register 40037 sets the mode source for how the unit is changed between Automatic and Manual modes Valid values are 0 Digital 1 Discrete 2 Remote Digital Mode Source Configures the unit so that Integer register 40038 sets the operating mode Valid values are 0 Calibration 1 Manual 2 Auto NOTE Every time that a 2 is written to register 40038 the StarPac system performs a bumpless transfer on the setpoint It does this calculation even if the previous value was a 2 in register 40038 The bumpless transfer function sets the setpoint in register 40035 equal to the current PV If the system needs to continuously update the mode register see remote mode source description below Discrete Mode Source Configures the StarPac system so that an external signal applied to the discrete input terminals 9 and 18 for StarPac 3 will be used to switch the unit between Automatic a
32. only 42293 Floating point variable 26 Flowserve use only 42295 Floating point variable 27 Flowserve use only 42297 Floating point variable 28 Flowserve use only 42299 Floating point variable 29 Flowserve use only 42301 Floating point variable 430 Flowserve use only 42303 si Floating point variable 31 Flowserve use only 42305 Floating point variable 432 Flowserve use only 42307 Floating point variable 33 42309 Floating point variable 434 42311 ig Floating point variable 35 42313 i Floating point variable 36 42315 Floating point variable 37 42317 Floating point variable 38 42319 Floating point variable 439 42321 Floating point variable 440 42323 Floating point variable 41 42325 gt Floating point variable 42 42327 ig Floating point variable 43 42329 Floating point variable 444 42331 Floating point variable 45 42333 bg Floating point variable 446 42335 gt Floating point variable 47 42337 ig Floating point variable 48 42339 Floating point variable 49 42341 ig Floating point variable 450 42343 ig Floating point variable 51 42345 Floating point variable 52 42347 Floating point variable 453 47 48 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 42349 z Floating point variable 54 42351 5 Floating
33. or Manual mode If the system displays a flashing E or A on the left side of the display check the cause of the error or alarm using the ERR ALRM option in the STATUS menu If the Alarm is a trip condition then you can view the cause of the trip by setting the ROW1 variable to show Mode Status in the STATUS menu System will not respond to discrete commands Check jumper selection to make sure the input is set to the proper range and that the system is notin Test mode Pressure sensors appear to saturate prematurely Check the rating of the sensors in the system information option of the STATUS menu to verify the rating the rating is also etched on the sensor Check the sensor gain set in the CALIBRATE menu in the P1 amp P2 option the standard range is 30 mV lt out lt 60 mV Stroke calibration aborts or hangs Check the air supply and make sure it is stable A regulator may be required to stabilize the air supply in some systems 23 or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Nes Appendix A System Setup Checklist A 24 Power 24 VDC Power at least 100 mA 150 mA if using StarPac 3 power for the Analog Inputs Polarity correct Local Display ON If not check Power Supply System Communications if connectedto a remote computer RS 485 converter properly installed or attached to computer Signal polarity correct Modbus device address set in StarPac 3 device
34. performance for most systems Available transmit delays are 3 5 characters 50 millisecond 75 millisecond 100 millisecond 150 millisecond 250 millisecond 500 millisecond and 1 second LCD Contrast This option adjusts the viewing angle of the LCD Use the Up and Dn function keys to adjust the viewing angle AGA Equations This option allows you to view and select the AGA equations for calculating gas flows Enable or Disable will be displayed onthe screen Enabling the AGA equations must be accompanied by a download of the AGA gas tables Enable This option allows you to enable the AGA equations Disable This option allows you to disable the AGA equations Technician This option allows you to view and manipulate internal Modbus registers backup a configuration in non volatile RAM and reset the system operation These options are selected from the TECHNICIAN menu See Figure 16 below Figure 16 Technician Menu AGA Te Data Time Equ Log Set View Edit Rset N xt Reg Reg SPac Save Load Load Bkup Bkup Dfit View Register This option allows you to view any integer or floating point Modbus register A register map is located in the appendix String registers cannot be viewed with this function however they can be viewed by using the StarTalk software Edit Register This option allows you to view and change any read write integer or floating point Modbus register Aregister map is locat
35. refer to StarPac 3 IOM Start StarTalk software or DTM Configure communications in software and hardware to match Refer to Communications section of this manual and the onboard Help in the StarTalk XP Software or DTM If using USB cable the configuration is automatically 57600 Baud Communications work If not recheck settings Calibration Checks Air supply turned on Check status screens to verfy system calibration refer to software section Valve stroke calibration to remove installation and handling offsets refer to calibration section Verify process sensor calibration recalibrate if needed It is recommended that a Quick Cal before after the valve is installed on site System Configuration refer to Configure StarPac section for details Set or verify failure modes Set or verify analog output Set or verify command and mode source Set or verify stroke limits Set or verify LCD display options Check positioner response and set gain to control speed Set units Set or verify tag name Automatic PID Operation refer to Tune PID section Select process variable Input full scale range Set initial PID parameters Default PID settings should be P Band 250 50 D 0 Begin Automatic mode and tune system Other Options refer to Monitor Operation section Reset Totalizer Other Options refer to Data Acquisition section Set and start Data Logger function Collect and save installed signature if desired
36. referring to the action at which the rate of change of output is proportional to the errorinput Reset is the parameter that controls how the integral control action affects the final control element The larger the value the faster the system tries to eliminate the offset error Register 40034 sets the Reset in units of repeats min Derivative Time sets the time on the derivative control action of the PID controller This time is the interval at which the rate action advances the effect of the gain on the final control element Derivative action in normally not used since it tends to amplify noise that exists in most process measurements Register 40033 sets the Derivative Time in units of Seconds PID Action This variable determines the response of the controller to error Reverse action will cause an air to open valve to begin to close when the process variable is greater than the setpoint Direct action has the opposite effect Register 40040 sets is controller action O Reverse action 1 Direct action Basic Floating Point Registers The easiest way to read the process information is through the floating point registers using the IEEE format Since floating point numbers are 32 bits and Modbus registers are only 16 bits two consecutive registers are used for each floating point number When requesting only one register in the floating point range an error will be indicated Table II contains a list of commonly accessed floating point registers
37. set the Row Two variable to valve position Use the TUNE menu to put the unit in to Manual mode with a digital command ga ne 9 Using the Command option in the TUNE menu enter a 0 percent command and verify that the position follows to within 0 5 percent NOTE Command is a term with two meanings For a traditional control valve the command is the signal a controller sends to the I P to position the stem For the StarPac 3 this meaning refers to the signal sent to the positioning module When the StarPac 3 is in Manual mode Command also refers to the signal sent to the StarPac 3 via analog input No 1 a digital Modbus channel or the front keypad These commands may differ due to the internal stroke calibration and an inverted signal for air to close valves 7 Using the Command option in the TUNE menu enter a 100 percent command and verify that the position follows to within rer FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 10 11 12 13 14 15 16 17 18 we 0 5 percent Ifthe unit fails either of the tests above perform a QUICK CALin the CALIBRATE menu Use the STATUS menu and set the Row Two variable to be ISA upstream pressure Verify that the unit is correctly indicating the ambient pressure Use the STATUS menu and set the Row Two variable to be ISA downstream pressure Verify that the unit is correctly indicating ambient pressure If the unit fails
38. 16 bytes ASCII String 41563 RW Miscellaneous data 16 bytes ASCII String 41571 RW Miscellaneous Data 16 bytes ASCII String 41579 RW Miscellaneous Data 16 bytes ASCII String 41587 RW Fluid Type Name 16 bytes ASCII String 41595 RW User Unit Flow Type String 16 bytes ASCII String 41603 RW User Unit Totalizer Type string 16 bytes ASCII String 41611 RW User text string 5 16 bytes ASCII String 41619 RW User Text string 6 16 bytes ASCII String 41627 RW User Text string 7 16 bytes ASCII String 41635 RW User Text string 8 16 bytes ASCII String 41643 RW User Text string 9 16 bytes ASCII String 41651 RW User Text string 10 16 bytes ASCII String 41659 RW User Text string 11 16 bytes ASCII String 41667 RW Password string 16 bytes ASCII String 49 50 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 41675 RW Actuator Calibration Date 16 bytes ASCII String 41683 RW Positioner Calibration Date 16 bytes ASCII String 41691 RW Thermocouple Calibration Date 16 bytes ASCII String 31699 RO Tamb Low Time Date 32 bytes ASCII String 31715 RO Tamb High Time Date 32 bytes ASCII String 31731 RO Tpro Low Time Date 32 bytes ASCII String 31747 RO Tpro High Time Date 32 bytes ASCII String 31763 RO Void String Register 16 bytes ASCII Spaces 32043 RO Void String Register 16 bytes ASCI
39. 2 bytes ASCII String 31355 RO Description of device 16 bytes ASCII String 31363 RO Logger real time date data 32 bytes ASCII String 41379 RW Trim Number 16 bytes ASCII String 41387 RW Trim Characteristics 16 bytes ASCII String 41395 RW Trim Type 16 bytes ASCII String FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 41403 RW Pressure Class 16 bytes ASCII String 41411 RW Valve Model 16 bytes ASCII String 41419 RW Flow Direction 16 bytes ASCII String 41427 RW Body Size 16 bytes ASCII String 41435 RW Body Material 16 bytes ASCII String 41443 RW Packing Style 16 bytes ASCII String 41451 RW Packing 16 bytes ASCII String 41459 RW Gasket Material 16 bytes ASCII String 41467 RW Actuator Size 16 bytes ASCII String 41475 RW Spring 16 bytes ASCII String 41483 RW Spring Type 16 bytes ASCII String 41491 RW Air Action 16 bytes ASCII String 41499 RW Electronics S N 16 bytes ASCII String 41507 RW EPROM Version 16 bytes NA for StarPac 3 ASCII String 41515 RW Pressure Sensor Rating 16 bytes ASCII String 41523 RW Sensor Drawing Number 16 bytes ASCII String 41531 RW P1 Serial Number 16 bytes ASCII String 41539 RW P2 Serial Number 16 bytes ASCII String 41547 RW P1 Calibration Date 16 bytes ASCII String 41555 RW P2 Calibration Date
40. 30353 RO Fluid specific gravity IEEE 754 30355 RO Process temperature deg R IEEEE754 30357 RO Calculated FI IEEE 754 30359 RO Calculated z IEEE 754 30361 RO Calculated Xt IEEE 754 30363 RO Valve delta pressure to produce choked flow IEEE 754 30365 RO Valve delta pressure IEEE 754 30367 RO Totalized flow user units IEEE 754 30369 RO Totalized time seconds IEEE 754 30371 RO Totalized liquid flow user units IEEE 754 38 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 30373 RO Totalized gas flow user units IEEE 754 30375 RO Position before temperature comp IEEE 754 30377 RO DAC 2 output IEEE 754 30379 RO Ambient Temperature deg F IEEE 754 30381 RO P1 valve psig IEEE 754 30383 RO P2 valve psig IEEE 754 30385 RO Cylinder bottom pressure user units IEEE 754 30387 RO Cylinder top pressure user units IEEE 754 30389 RO DAC 1 output IEEE 754 30391 RO Valve Cv at current position IEEE 754 30393 RO Calculated liguid flow user units IEEE 754 30395 RO Calculated gas flow user units IEEE 754 30397 RO P1 ISA user units IEEE 754 30399 RO P2 ISA user units IEEE 754 30401 RO Delta P ISA user units IEEE 754 30403 RO Process temperature user units IEEE 754 30405 RO 4 20mA command IEEE 754 30407 RO Position feedback IEE
41. 4 30837 RO Travel accumulator same units as MECH_STROKE IEEE 754 40839 RW Travel accumulator deadband 0 01 to 100 40841 RW Travel accumulator limit alert 0 to 1E20 30843 RO Cycle counter IEEE 754 40845 RW Cycle counter deadband 0 01 to 100 40847 RW Cycle counter limit alert 0 to IE2O rer FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 40849 RW High minimum positioner command cutoff 20 to 120 40851 RW Stroke open rate limit min Oto 1E5 40853 RW Stroke close rate limit min Oto 1E5 40855 RW Gas Composition 1 0 to 100 40857 RW Gas Composition 2 0 to 100 40859 RW Gas Composition 3 0 to 100 40861 RW Gas Composition 4 0 to 100 40863 RW Gas Composition 5 0 to 100 40865 RW Gas Composition 6 0 to 100 40867 RW Gas Composition 7 0 to 100 40869 RW Gas Composition 8 0 to 100 40871 RW Gas Composition 9 0 to 100 40873 RW Gas Composition 10 0 to 100 40875 RW Gas Composition 11 0 to 100 40877 RW Gas Composition 12 0 to 100 40879 RW Gas Composition 13 0 to 100 40881 RW Gas Composition 14 0 to 100 40883 RW Gas Composition 15 0 to 100 40885 RW Gas Composition 16 0 to 100 40887 RW Gas Composition 17 0 to 100 40889 RW Gas Composition 18 0 to 100 40891 RW Gas Composition 19 0 to 100 40893 RW Gas Composition 20 0 to 100 40895 RW Gas Composition 21 0 to 100 408
42. 40605 RW Xt B1 curve fit coefficient 1E9 to 1E9 40607 RW Xt C1 curve fit coefficient 1E9 to 1E9 40609 RW Xt D1 curve fit coefficient 1E9 to 1E9 40611 RW Xt E1 curve fit coefficient 1E9 to 1E9 40613 RW Xt A2 curve fit coefficient 1E9 to 1E9 40615 RW Xt B2 curve fit coefficient 1E9 to 1E9 40617 RW Xt C2 curve fit coefficient 1E9 to 1E9 40619 RW Xt D2 curve fit coefficient 1E9 to 1E9 40621 RW Xt E2 curve fit coefficient 1E9 to 1E9 40623 RW Xt curve fit break point 0 to 100 40625 RW Liquid flow min scaling variable 0 to 1E9 40627 RW Liquid flow max scaling variable 0 1 to 1E9 40629 RW Gas flow min scaling variable 0 to 1E9 40631 RW Gas flow max scaling variable 0 1 to 1E9 40633 RW Plisa min scaling variable Oto 1E9 40635 RW Plisa max scaling variable 0 1 to 1E9 40637 RW P2isa min scaling variable Oto 1E9 40639 RW P2isa max scaling variable 0 1 to 1E9 40641 RW Delta Pisa min scaling variable 0 to 1E9 40643 RW Delta Pisa max scaling variable 0 1 to 1E9 42 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 40645 RW Process temp min scaling variable 500 to 5000 40647 RW Process temp max scaling variable 500 to 5000 40649 RW Auxiliary input min scaling variable 1E9to 1E9 40651 RW Auxiliary input max scaling variable 1E9 to 1E9 40653 RW Ramp
43. 491 100 Ramp closed rate of 100 percent min when time in 40047 expires 40425 500 Full scale flow of 500 gpm for controller Control Register for Automatic Mode Register Value Description 40705 45 225 gpm Setpoint in percent of the process max set in 40425 500gpm Registers for Monitoring Process Register Description 30407 Reads the current valve position in percent 30393 Reads the current liquid flow rate in engineering units 30403 Reads the current process temperature in engineering units 30397 Reads the current upstream process pressure in engineering units FLOWSERVE wee Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Example 2 StarPac system is attached to a PLC that has only integer Modbus communication capability When in operation the StarPac will be in automatic mode controlling gas flow at approximately 4500 LB HR with a range of 0 to 5000 LB HR The PLC needs to monitor the valve position flow rate process temperature and upstream pressure regardless of the current operating mode The pressure will range from 100 to 600 psi and the temperature will range from 30 to 300 degrees Fahrenheit 1 to 149 Celsius Initialization Values for Automatic Mode Register Value Description 40037 0 Sets the mode source to Digital 40038 2 Puts the unit into Automatic mode 40041 1 Sets the setpoint s
44. 6 000000 0 75 12 500000 7897 640137 149 100006 1 0 0 0 Ethane 708 531006 549 719971 329 399994 0 548000 30 070000 0 85 1 718000 2720 500000 30 889999 1 0 0 0 Ethylene 730 578003 508 320007 293 399994 0 577000 28 054001 0 89 1 591000 2424 600098 32 669998 1 0 0 0 Fluorine 757 046997 259 739990 153 000000 1 510000 37 997002 0 97 11 724000 1285 400024 10 800000 1 0 0 0 Fuel Oil 330 000000 10000 000000 1335 000000 0 880000 0 000000 0 00 6 910000 0 000000 100 000000 1 0 0 0 Gasoline 367 500000 529 640015 67 400002 0 695000 114 232002 0 75 11 797400 5278 500000 104 540001 1 0 0 0 Glycol 1117 189941 1161 000000 527 400024 1 114000 62 069000 0 78 16 304001 10840 000000 50 879998 1 0 0 0 Helium 32 929699 9 340000 7 700000 0 123000 4 003000 1 19 8 306000 60 720001 3 220000 10 0 0 Hydrogen 188 156006 59 759998 36 000000 0 071000 2 016000 1 00 9 688000 296 820007 5 740000 1 0 0 0 Hydrogen Chloride 1205 380005 584 280029 338 600006 1 193000 36 460999 1 00 12 158000 3085 600098 59 669998 1 0 0 0 Isobutane 529 187988 734 580017 527 400024 0 557000 58 124001 0 78 11 592000 3658 899902 59 669998 1 0 0 0 Isobutylene 580 640991 752 219971 527 400024 0 594000 56 108002 0 79 11 807000 3826 300049 59 669998 1 0 0 0 Kerosene 350 000000 10000 000000 935 000000 0 820000 3 000000 0 00 8 730000 4091 399
45. 902 159 199997 1 0 0 0 Methane 667 375000 343 079987 201 100006 0 425000 16 042999 0 94 13 470000 2880 510010 69 860001 10 0 0 Natural Gas 667 375000 343 079987 201 100006 0 425000 16 042999 0 94 13 470000 2880 510010 69 860001 10 0 0 Nitrogen 492 445007 227 160004 140 600006 0 804000 28 013000 1 00 11 009000 1059 699951 11 880000 1 0 0 0 Nitrous Oxide 1051 089966 557 280029 330 500000 1 226000 44 013000 0 91 12 181000 2711 500000 46 779999 1 0 0 0 Oxygen 732 046997 278 279999 162 000000 1 149000 31 999001 1 00 11 462000 1322 099976 11 610000 1 0 0 0 Phosgene 823 187988 819 000000 527 400024 1 381000 98 816002 0 84 11 811000 3901 100098 77 669998 1 0 0 0 Propane 615 921997 665 640015 415 799988 0 582000 44 097000 0 81 11 780000 3370 300049 45 290001 1 0 0 0 Propylene 670 312012 657 000000 401 399994 0 612000 42 018002 0 82 11 757000 3253 500000 47 070000 1 0 0 0 Refrigerant 11 639 437988 848 159973 0 000000 0 000000 137 369995 0 80 11 906000 43323 000000 65 339996 1 0 0 0 Refrigerant 12 598 281006 693 000000 284 399994 1 7500000 120 910004 0 79 3 946000 0 000000 0 000000 1 0 0 0 Refrigerant 22 721 953003 664 500000 520 200012 1 230000 86 500000 0 84 11 600000 3068 600098 74 300003 1 0 0 0 Sea Water 3200 000000 1165 140015 672 000000 0 940000 18 000000 0 95 14 390000 6910 799805 83
46. 94 RW FB 17 input 1 variable pointer 1 to 1023 40095 RW FB 17 input 2 variable pointer 1 to 1023 40096 RW FB 17 input 3 variable pointer 1 to 1023 40097 RW FB 17 input 4 variable pointer 1 to 1023 40098 RW FB 17 input 5 variable pointer 1 to 1023 40099 RW FB 17 input 6 variable pointer 1 to 1023 40100 RW FB 17 input 7 variable pointer 1 to 1023 29 30 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 40101 RW FB 17 input 8 variable pointer 1t0 1023 40102 RW FB 17 input 9 variable pointer 1 to 1023 40103 RW FB 17 input 10 variable pointer 1 to 1023 30104 RO Alarm status 32768 to 32767 30105 RO Hardware status 32768 to 32767 30106 RO Sensor status 32768 to 32767 30107 RO Alert Trip status 32768 to 32767 40108 RW Time to hold SP on loss of pressure sec 0 to 9999 40109 RW Remote command refresh rate sec 0 to 30000 40110 RW Enable mask for alarm_source bit fields 0 to 1023 40111 RW Relay function 0 alarm output 1 pulse output 40112 RW Communication port access 0 A RW B RW 1 A RW B RO 2 A RO B RW 40113 RW Flow factor time base 0 sec 1 min 2 hr 3 day 40114 RW Perform positioner calibrations Oto4 40115 RW Return Message delay time see table below O
47. 97 RW AGA Z parameter 1 10 to 10 40899 RW AGA Z parameter 2 10 to 10 40901 RW AGA Z parameter 3 10 to 10 40903 RW AGA Z parameter 4 10 to 10 40905 RW AGA Z parameter 5 10 to 10 40907 RW AGA Z parameter 6 10 to 10 40909 RW AGA Z parameter 7 10 to 10 40911 RW AGA Z parameter 8 10 to 10 40913 RW AGA Z parameter 9 10 to 10 40915 RW AGA Z parameter 10 10 to 10 46 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 40917 RW AGA Z parameter 11 10 to 10 40919 RW AGA Z parameter 12 10 to 10 40921 RW AGA Z parameter 13 10 to 10 40923 RW AGA Z parameter 14 10 to 10 40925 RW AGA Z parameter 15 10 to 10 40927 RW AGA Z parameter 16 10 to 10 40929 RW AGA Z parameter 17 10 to 10 40931 RW AGA Z parameter 18 10 to 10 40933 RW AGA Z parameter 19 10 to 10 40935 RW AGA Z parameter 20 10 to 10 40937 RW AGA Z parameter 21 10 to 10 40939 RW Stable Wise Lock window percent 0 to 100 40941 RW Stable Wise Unlock window percent 0 to 100 30943 RO Void Floating Point Register 0 0 31249 RO Void Floating Point Register 0 0 42243 7 Floating point variable 1 Flowserve use only 42245 Floating point variable 2 Flowserve use only k 42247 Floating point variable 3 Flowserve use only 42249 Floating point variable 4 Flowserve use only
48. AC 1 value corresponding to 100 position 0 to 65535 40057 RW DAC 2 output code 0 to 65535 40058 RW DAC 2 value corresponding to 4mA output 0 to 65535 40059 RW DAC 2 value corresponding to 20mA output 0 to 65535 40060 RW Tamb ADC value corresponding to 0 degrees F 327680 to 32767 40061 RW Tamb ADC value corresponding to 185 degrees F 32768 to 32767 40062 RW Aux ADC value corresponding to 4mA 0 to 16384 40063 RW Aux ADC value corresponding to 20mA 0 to 16384 40064 RW P1 ADC value corresponding to 0 psig 32768 to 32767 40065 RW Value corresponding to PROC_MAX_PRESS 32768 to 32767 40066 RW P2 Adc value corresponding to 0 psig 32768 to 32767 40067 RW Value corresponding to PROC_MAX_PRESS 32768 to 32767 40068 RW Value corresponding to 0 position 32768 to 32767 40069 RW Value corresponding to 100 position 32768 to 32767 40070 RW Value corresponding to minimum Tpro 0 to 16384 40071 RW Value corresponding to PROC_MAX_TEMP 0 to 16384 40072 RW Number of seconds between data points 0 to 9999 40073 RW Triggers a totalizer reset 0 totalize normally 1 reset totalizer 40074 RW Triggers a travel accumulator reset 0 accumulate travel normally 1 reset travel accumulator FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Register Number Attribute Description Notes 40075 RW Triggers a cycle counter reset 0 accumulate cycles normally 1 re
49. E 754 30409 RO 4 20mA auxiliary input IEEE 754 30411 RO Set point command user units IEEE 754 30413 RO Current process variable user units IEEE 754 40415 RW Measured mechanical stroke of valve 0 0001 to 100 40417 RW Fixed scale normalized max position stop 20 to 120 40419 RW Fixed scale normalized min position stop 20 to 120 40421 RW Auxiliary input equal to 100 of PV 0 1 to 10E3 40423 RW Dpisa user units equal to 100 of PV 0 1 to 1E9 40425 RW Liquid flow user units 100 of PV 0 1 to 1E9 40427 RW Gas flow user units equal to 100 of PV 0 1 to 1E9 40429 RW Plisa user units equal to 100 of PV 0 1 to 1E9 40431 RW P2isa user units equal to 100 of PV 0 1 to 1E9 40433 RW Tpro user units equal to 100 of PV 500 to 5000 40435 RW Tpro user units equal to 0 of PV 500 to 5000 40437 RW Position equal to 20mA at DAC 2 0 1 to 10E3 40439 RW Position equal to 4mA at DAC 2 20 to 120 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 40441 RW Auxiliary input equal to 20mA at DAC 2 0 1 to 10E3 40443 RW Auxiliary input equal to 4mA at DAC 2 20 to 120 40445 RW Dpisa user units 20mA at DAC 2 0 1 to 1E9 40447 RW Dpisa user units 4mA at DAC 2 0 to 1E9 40449 RW Liquid flow user units 20mA at DAC 2 0 1 to 1E9 40451 RW
50. ENMN0066 02 11 15 2 Register Number Attribute Description Notes 42058 RW Integer table pointer 8 Flowserve use only 0 to 349 42059 RW Integer table pointer 9 Flowserve use only 0 to 349 42060 RW Integer table pointer 10 Flowserve use only 0 to 349 42061 RW Integer table pointer 11 Flowserve use only 0 to 349 42062 RW Integer table pointer 12 Flowserve use only 0 to 349 42063 RW Integer table pointer 13 Flowserve use only 0 to 349 42064 RW Integer table pointer 14 Flowserve use only 0 to 349 42065 RW Integer table pointer 15 Flowserve use only 0 to 349 42066 RW Integer table pointer 16 Flowserve use only 0 to 349 42067 RW Integer table pointer 17 Flowserve use only 0 to 349 42068 RW Integer table pointer 18 Flowserve use only 0 to 349 42069 RW Integer table pointer 19 Flowserve use only 0 to 349 42070 RW Integer table pointer 20 Flowserve use only 0 to 349 42071 RW Integer table pointer 21 Flowserve use only 0 to 349 42072 RW Integer table pointer 22 Flowserve use only 0 to 349 42073 RW Integer table pointer 23 Flowserve use only 0 to 349 42074 RW Integer table pointer 24 Flowserve use only 0 to 349 42075 RW Integer table pointer 25 Flowserve use only 0 to 349 42076 RW Integer table pointer 26 Flowserve use only 0 to 349 42077 RW Integer table pointer 27 Flowserve use only 0 to 349 42078 RW Integer t
51. F1 and F2 keys labeled NEXT and PREVIOUS The second type uses the F1 and F2 keys to adjust a value up or down and the third type uses the F1 and F2 keys to move the cursor to a position The keypad is used to enter characters In all of the options the F3 key is used to cancel the operation If the F3 key is pressed before the system returns to the menu then all variables are returned to their old values The F4 key is used to accept the current values in the display and continue Figure 1 Home Menu Manual Mode Dig Cmd Posn 0 056 Sta Ki Cal Con tus brat fi The HOME menu has selections of STATUS TUNE CALIBRATE and CONFIGURE Each of these menus has several sub menus The bottom two lines define the function keys that control the individual menus The top two lines in the display are user configurable and may not look like Figure 1 The menus shown in the figures in this manual represent how the information is laid out in the local display menu tree The top row of the figures shows the bottom two rows of the display One of the fields is in Bold type Press the F key under this field to bring up the choices shown on the bottom row If you see the word Next then push the F4 button to bring up the continuation of that row To move back up the menu tree push the button labeled Last Option to see the preceding row 5 Initial Startup The StarPac 3 system is designed to interface with a variety of DCS systems using analog d
52. Flowserve use only 350 to 1248 42145 RW Floating point table pointer 31 Flowserve use only 350 to 1248 42146 RW Floating point table pointer 32 Flowserve use only 350 to 1248 42147 RW Floating point table pointer 33 350 to 1248 42148 RW Floating point table pointer 34 350 to 1248 42149 RW Floating point table pointer 35 350 to 1248 42150 RW Floating point table pointer 36 350 to 1248 42151 RW Floating point table pointer 37 350 to 1248 42152 RW Floating point table pointer 38 350 to 1248 42153 RW Floating point table pointer 39 350 to 1248 42154 RW Floating point table pointer 40 350 to 1248 42155 RW Floating point table pointer 41 350 to 1248 42156 RW Floating point table pointer 42 350 to 1248 42157 RW Floating point table pointer 43 350 to 1248 42158 RW Floating point table pointer 44 350 to 1248 42159 RW Floating point table pointer 45 350 to 1248 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 42160 RW Floating point table pointer 46 350 to 1248 42161 RW Floating point table pointer 47 350 to 1248 42162 RW Floating point table pointer 48 350 to 1248 42163 RW Floating point table pointer 49 350 to 1248 42164 RW Floating point table pointer 50 350 to 1248 42165 RW Floating point table pointer 51 350 to 1248 42166 RW Floating po
53. I Spaces RO Read Only RW Read Write Dependent upon the selected register FLOWSERVE wee Appendix C Table 7 Fluid Table Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Name Critical Press Critical Temp Temp Ref Spec Gr Mol Wt Ratio of Ant A AntB Ant C Visc Visc Spec A B Heat Fk Air 492 445007 227 160004 140 600006 0 804000 28 980000 1 00 11 009000 1059 699951 11 880000 10 0 0 Ammonia 1636 089966 730 080017 491 799988 0 639000 17 031000 0 94 3 002000 3838 500000 59 630001 1 0 0 0 Argon 707 062012 271 399994 162 000000 1 373000 39 948002 1 19 1 287000 1260 900024 10 510000 1 0 0 0 Benzene 710 000000 1011 780029 520 200012 0 885000 78 113998 0 79 1 955000 5019 299805 94 250000 1 0 0 0 Butane 551 250000 765 359985 527 400024 0 579000 58 124001 0 78 1 733000 3878 800049 61 959999 1 0 0 0 Carbon Dioxide 1070 189941 547 559998 527 400024 0 777000 44 009998 0 92 3 734500 3803 010010 14 539000 10 0 0 Carbon Monoxide 507 148010 239 220001 148 800003 0 803000 28 010000 1 00 10 423000 954 359985 23 670000 1 0 0 0 Chlorine 1117 189941 750 599976 430 399994 1 563000 70 905998 0 95 2 015000 3560 899902 48 619999 1 0 0 0 Dowtherm A 454 695007 1386 800049 960 000000 0 870000 16
54. OWSERVE wee Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Register Number Attribute Description Notes 40029 RW Atmospheric press unit selection Inactive 40 pounds square inch gage 41 pounds square inch absolute 42 kilopascals gage 43 kilopascals absolute 44 kilograms square centimeter gage 45 kilograms square centimeter absolute 46 bar gage 47 bar absolute 48 59 expansion 40030 RW Mechanical stroke unit selection 70 percent 71 inches 72 millimeters 73 centimeters 74 degrees rotation 30031 RO Process variable unit type 0 to 70 see unit list above 40032 RW PID proportional band 1 to 9999 40033 RW PID derivative time minutes 0 to 9999 40034 RW PID reset rate repeats minutes 0 to 9999 40035 RW Fixed scale normalized digital SP 0 to 9999 40036 RW Fixed scale normalized digital command 0 to 9999 40037 RW Base mode source digital discrete remote 0 digital 1 discrete 2 remote 40038 RW Base mode selection 0 calibration mode 1 manual mode 2 automatic mode 40039 RW Process variable source 1 liquid flow 2 upstream P1 pressure 3 downstream P2 pressure 4 differential pressure 5 process temperature 6 gas flow 7 auxiliary 4 20mA input 40040 RW PID reverse direct action 0
55. STATUS menu is still accessible even when the password is enabled To enable the password press F1 and enter the password The default password is 1234 If the system is initialized by pressing the O while powering up the unit the password will be reset to 1234 Note that control and communication parameters will also be reset with an initialize To disable the password press F2 To change the password select F3 and enter the old password then enter the new password Note that when entering a new password the characters are visible on the screen for verification Communication Settings This option configures the communication settings for the Modbus communications ports on the StarPac 3 system Both COMM port A and COMM port B use the same settings they cannot be set independently The communication settings are set in the COMM PORT menu Figure 15 Figure 15 Comm Port Menu Pass Comm LCD Nexd Word Port Cont Port Port A B Addr Baud Par ar ess Rate _ ity RTU Port TX PrtB ASCI Accs Dly Type Port B only Port A Port B This option allows the user to configure Port A and Port B independently By selecting Port B there is an added menu item to be able to select which input from Port B to use Address This option sets the Modbus address of the StarPac 3 system Both the A and B COMM ports have the same address therefore they cannot be hooked together on the same networ
56. StarPac User Interface Block Verify that power is reaching the StarPac 3 electronics 6 Connect a computer loaded with StarTalk XP or the ValveSight DTM to the StarPac 3 Run StarTalk XP find the device and establish a connection Go tothe Calibration menu and select Analog Input 2 7 Perform the Zero calibration on the Analog Input 2 and the DP Cell by doing the following Verify that the upstream and downstream valves on the Pressure Manifold are closed and that the bridge valve is open Adjust the Zero Adjustment Screw on the DP Cell until the Current Meter reads 4 mA From the StarTalk XP software accept the zero point calibration 8 Perform the Span calibration on the Analog Input 2 and the DP Cell by doing the following e Close the bridge valve on the Pressure Manifold i Expose the downstream side of the DP Cell to atmospheric pressure by opening the downstream valve on the Pressure Manifold Using the regulator adjust the pressure on the upstream side of the DP Cell to the desired Max DP Record the Max DP for future use e Adjust the Span Adjustment Screw on the DP Cell until the Current Meter reads 20 mA s From the StarTalk XP software accept the span point calibration 55 56 m FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 we Check the Zero and Span output of the DP Cell and reading on the Analog Input 2 Channel to verify that the calibration is successful 10 11 12
57. able pointer 28 Flowserve use only 0 to 349 42079 RW Integer table pointer 29 Flowserve use only 0 to 349 42080 RW Integer table pointer 30 Flowserve use only 0 to 349 42081 RW Integer table pointer 31 Flowserve use only 0 to 349 42082 RW Integer table pointer 32 Flowserve use only 0 to 349 42083 RW Integer table pointer 33 0 to 349 42084 RW Integer table pointer 34 0 to 349 42085 RW Integer table pointer 35 0 to 349 42086 RW Integer table pointer 36 0 to 349 42087 RW Integer table pointer 37 0 to 349 42088 RW Integer table pointer 38 0 to 349 42089 RW Integer table pointer 39 0 to 349 42090 RW Integer table pointer 40 0 to 349 42091 RW Integer table pointer 41 0 to 349 rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 42092 RW Integer table pointer 42 0 to 349 42093 RW Integer table pointer 43 0 to 349 42094 RW Integer table pointer 44 0 to 349 42095 RW Integer table pointer 45 0 to 349 42096 RW Integer table pointer 46 0 to 349 42097 RW Integer table pointer 47 0 to 349 42098 RW Integer table pointer 48 0 to 349 42099 RW Integer table pointer 49 0 to 349 42100 RW Integer table pointer 50 0 to 349 42101 RW Integer table pointer 51 0 to 349 42102 RW Integer table pointer 52 0 to 349 42103 RW Integer table poin
58. ac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Selection Value Table 2 Auto Tune Multipliers A 0 30 B 0 44 C 0 66 D 1 00 E 1 50 F 2 20 G 3 30 H 5 00 Up and Down This option allows the user to scroll through the available gain multipliers The gain multipliers are listed in Table 1 Cancel This option returns to the top level menu with no action taken Accept Accepts the selected gain multiplier then prompts the user to either exit with only the new multiplier change or to do a complete gain calculation Mult Only Accepts the selected gain multiplier and returns to the top level menu Cancel This option returns to the top level menu with no action taken This will not change the multiplier Gain Calc Commands the positioner to calculate the proportional gain static gain and error gain automatically These gains are based on the stroke time of the valve This option will cause the value to open and close Manual Presets This option sets the default gain for the positioner Select the desired default gains from the list using the UP and Down function keys on the menu Default selections exist for A H Note that the factory default setting is E The following table shows the default gains associated with each setting Table 3 StarPac 3 Default Gains Selection Prop Gain Static Gain Error Gain A 500 300 0 B 1000
59. ale normalized 4 20mA command 0 to 9999 30020 RO Fixed scale normalized position 0 to 9999 30021 RO Fixed scale normalized set point command 0 to 9999 30022 RO Data from parallel input channel 32768 to 32767 30023 RO Device address of valve Oto 255 40024 RW Process Pressure Unit Selection 40 Pounds square inch gage 41 pounds square inch absolute 42 kilopascals gage 43 kilopascals absolute 44 kilograms square centimeter gage 45 kilograms square centimeter absolute 46 bar gage 47 bar absolute 48 59 expansion 40025 RW Liquid flow unit selection 1 US gallons minute 2 liters minute 3 pounds hour 4 kilograms hour 5 cubic meters hour 6 barrels day 7 UK gallons minute 8 User supplied conversion 9 19 expansion 40026 RW Gas flow unit selection 20 pounds hour 21 kilograms hour 22 standard cubic feet hour 23 million standard cubic feet day 24 standard cubic feet minute 25 standard cubic meters hour 26 User supplied conversion 27 39 expansion 40027 RW Actuator press unit selection 40 Pounds square inch gage 41 pounds square inch absolute 42 kilopascals gage 43 kilopascals absolute 44 kilograms square centimeter gage 45 kilograms square centimeter absolute 46 bar gage 47 bar absolute 48 59 expansion 40028 RW Process temperature unit selection 60 degrees Celsius 61 degrees Fahrenheit 62 degrees Rankine 63 degrees Kelvin 64 69 expansion 26 FL
60. ameter that controls how the integral control action affects the final control element The larger the value the faster the system tries to eliminate the offset error Units are repeats min Derivative Time Sets the time on the derivative control action of the PID controller This time is the interval at which the rate action advances the effect of the gain on the final control element Units are in minutes PID Action This variable determines the response of the controller to error Reverse action will cause an air to open valve to begin to close when the process variable is greater than the setpoint Direct action has the opposite effect The following table gives some rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Mode Has two options for defining the current mode and the source of the mode Figure 6 Mode Menu Mode Set Com Next pnt mand Man o Mode Auto Srce Man Auto This option selects or changes the operating mode if the mode source has been set to digital If the mode source is set to Remote or Discrete the mode can only be changed using the discrete input or the remote register In Manual mode the unit operates as a normal control valve positioning the valve according to its current command signal In Auto mode the unit will operate as a controller using the PID settings process variable and control action currently defined using a bumpless transfer algorithm Note t
61. amp to the spring failure position at the specified Low Air Ramp Rate Travel limits Travel limits are limits set and maintained by the system s electronics and software These limits are only in effect when the unit has power and is not in Test mode When power has failed or cut off to the StarPac 3 the valve will fail to its mechanical stops or limits This option allows you to set software limits on the travel of the valve These limits are active in Auto and Manual modes but they do not affect failure modes There are three limit settings that can be independently set Minimum Soft Limit This setting will stop the valve from closing beyond the specified limit even when commanded to close further Default value is 10 percent of travel so as to not affect valve operation Maximum Soft Limit This setting will stop the valve from opening beyond the specified limit even when commanded to open further Default value is 110 percent of travel so as to not affect valve operation Minimum Travel Alert This setting activates an alert any time that the position is below the specified limit Default value is 10 percent of travel turn off the indication in the normal travel range Maximum Travel Alert This setting activates an alert any time that the position is above the specified limit Default value is 110 percent of travel turn off the indication in the normal travel range Low Minimum Signal Cutoff When the signal drops below the specifie
62. ate the first analog output of the StarPac 3 device During the calibration procedure a reference milliamp meter in series with a power supply nominal 24 VDC must be connected to terminals 6 and 15 of the terminal block The display will give instructions to use the F1 and F2 keys to adjust the signal until the reference meter reads 4 mA When the 4 mA value has been accepted you will be prompted to set the 20 mA value If the CANCEL key is pressed at any time all of the calibration values are returned to their original value The number shown at the end of the second line indicates the raw D A value that the unit is outputting which is only used for reference during calibration Configuration of the variable and scaling for the channel is performed in the CONFIGURE menu Analog Out No 2 This option is used to calibrate the second analog output of the StarPac 3 system During the calibration procedure a reference milliamp meter in series with a power supply nominal 24 VDC should be connected to terminals 7 and 16 of the terminal block The display will give instructions to use the F1 and F2 keys to adjust the signal until the reference meter reads 4 mA When the 4 mA value has been accepted the user is then prompted to set the 20 mA value If the CANCEL key is pressed at any time all of the calibration values will be returned to their original value The number shown at the end of the second line indicates the raw D A value that the unit
63. ber 34 42085 RW 0to 199 Integer table pointer number 35 42086 RW 0to 199 Integer table pointer number 36 42087 RW 0to 199 Integer table pointer number 37 42088 RW 0to 199 Integer table pointer number 38 42089 RW 0to 199 Integer table pointer number 39 42090 RW 0to 199 Integer table pointer number 40 42091 RW 0to 199 Integer table pointer number 41 42092 RW 0to 199 Integer table pointer number 42 42093 RW Oto 199 Integer table pointer number 43 42094 RW 0to 199 Integer table pointer number 44 42095 RW 0to 199 Integer table pointer number 45 42096 RW 0to 199 Integer table pointer number 46 42097 RW 0to 199 Integer table pointer number 47 42098 RW 0to 199 Integer table pointer number 48 42099 RW 0to 199 Integer table pointer number 49 42100 RW 0to 199 Integer table pointer number 50 42101 RW Oto 199 Integer table pointer number 51 42102 RW 0to 199 Integer table pointer number 52 42103 RW 0to 199 Integer table pointer number 53 42104 RW 0to 199 Integer table pointer number 54 42105 RW 0to 199 Integer table pointer number 55 42106 RW 0to 199 Integer table pointer number 56 42107 RW 0to 199 Integer table pointer number 57 42108 RW Oto 199 Integer table pointer number 58 42109 RW Oto 199 Integer table pointer number 59 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15
64. ber 44 42223 Integer variable number 45 42224 Integer variable number 46 42225 i Integer variable number 47 42226 Integer variable number 48 42227 t s Integer variable number 49 42228 ij F Integer variable number 50 42229 Integer variable number 51 42230 ii Integer variable number 52 42231 h Integer variable number 53 42232 u i Integer variable number 54 42233 Integer variable number 55 42234 Integer variable number 56 42235 Integer variable number 57 42236 F Integer variable number 58 42237 Integer variable number 59 42238 Integer variable number 60 42239 Integer variable number 61 42240 Integer variable number 62 42241 is Integer variable number 63 rer FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Modbus Register Type Range Description 42242 a ig Integer variable number 64 42307 a Floating point variable number 33 42309 ig Floating point variable number 34 42311 Floating point variable number 35 42313 Floating point variable number 36 42315 Floating point variable number 37 42317 ig Floating point variable number 38 42319 ig Floating point variable number 39 42321 a Floating point variable number 40 42323 Floating point variable number 41 42325 Floating point variable number 42 42327 a ka Floating point variable n
65. ble 42 42221 Integer variable 43 42222 42223 Integer variable 44 Integer variable 45 42224 Integer variable 46 42225 Integer variable 47 42226 Integer variable 48 42227 Integer variable 49 rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 42228 Integer variable 50 42229 Integer variable 51 t 42230 Integer variable 52 42231 Integer variable 53 42232 Integer variable 54 42233 Integer variable 55 i 42234 Integer variable 56 42235 Integer variable 57 42236 i Integer variable 58 42237 Integer variable 59 42238 Integer variable 60 42239 Integer variable 61 42240 Integer variable 62 42241 Integer variable 63 42242 Integer variable 464 RO Read Only RW Read Write Dependent upon the selected register Floating Point Registers Notice that floating point register numbers go up by two instead of up by one This is because floating point registers consist of two adjacent registers this allows the device to have a four byte area in which to store IEEE floating point values Table 5 Floating Point Registers Register Number Attribute Description Notes 30351 RO Fluid vapor pressure IEEE 754
66. coefficient 1E9 to 1E9 40555 RW Cv E2 curve fit coefficient 1E9 to 1E9 40557 RW Cv curve fit break point 0 to 100 40559 RW DP A1 curve fit coefficient 1E9 to 1E9 40561 RW DP B1 curve fit coefficient 1E9 to 1E9 40563 RW DP C1 curve fit coefficient 1E9 to 1E9 40565 RW DP D1 curve fit coefficient 1E9 to 1E9 40567 RW DP E1 curve fit coefficient 1E9 to 1E9 40569 RW DP A2 curve fit coefficient 1E9 to 1E9 40571 RW DP B2 curve fit coefficient 1E9 to 1E9 40573 RW DP C2 curve fit coefficient 1E9 to 1E9 40575 RW DP D2 curve fit coefficient 1Ei to 1E9 rer FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 40577 RW DP E2 curve fit coefficient 1E9 to 1E9 40579 RW DP curve fit break point 0 to 100 40581 RW FI A1 curve fit coefficient 1E9 to 1E9 40583 RW FI B1 curve fit coefficient 1E9 to 1E9 40585 RW FI C1 curve fit coefficient 1E9 to 1E9 40587 RW FI D1 curve fit coefficient 1E9 to 1E9 40589 RW FI E1 curve fit coefficient 1E9 to 1E9 40591 RW FI A2 curve fit coefficient 1E9 to 1E9 40593 RW FI B2 curve fit coefficient 1E9 to 1E9 40595 RW FI C2 curve fit coefficient 1E9 to 1E9 40597 RW FI D2 curve fit coefficient 1E9 to 1E9 40599 RW FI E2 curve fit coefficient 1E9 to 1E9 40601 RW Fl curve fit break point 0 to 100 40603 RW Xt Al curve fit coefficient 1E9 to 1E9
67. d cutoff point the positioner will fully saturate the actuator in the closed position Default value is 1 to insure tight shutoff at 0 signal level High Minimum Signal Cutoff When the signal rises above the specified cutoff point the positioner will fully saturate the actuator in the open position Default value is 99 to insure full opening at 100 signal level Units The StarPac 3 system has individually configurable units for Process Pressure Liquid flow Gas flow Process temperature and actuator pressure Units for each type of process variable are set in the Unit menu See Figure 14 Figure 14 Units Menu Soft Unit Lmts Tag Next Name Proc Liq Pres Flow Next Proc Act Temp Pres Gas Flow Str oke 17 or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wes Process Pressure This option sets the process pressure engineering units for the StarPac 3 system Use the NEXT and PREVIOUS function keys to select units from the following list PSIG Pounds per square inch gauge PSIA Pounds per square inch absolute kPaG Kilopascals gauge kPaA Kilopascals absolute kgscmG Kilograms per square centimeter gauge kgscmA Kilograms per square centimeter absolute Bar G Bar gauge Bar A Bar absolute Liquid Flow Sets the liquid flow engineering units for the StarPac 3 system Use the NEXT and PREVIOUS function keys to select units from the following list
68. e Tr for each step Pressing ACCEPT will continue to stoke the system up and down and report on the response for each step To quit the positioner tuning press CANCEL Stablewise If Stablewise is not enabled the StarPac 3 constantly attempts to obtain zero position deviation with respect to the command signal that it is receiving On high friction valves a small amount of hunting can occur If Stablewise is enabled additional stability will be provided on a high friction valve Ena Dis This allows the Stablewise feature to be enabled or disabled Lock Set This determines the range of deviation within which the Stablewise algorithm will be active When the Stem Position falls inside this window lock point the positioner will not continue to hunt for zero deviation Rel Set This determines the range of deviation that will need to occur for the positioner to initiate valve movement If the positioner deviation is outside the window unlock point the positioner will cause valve movement to occur until the deviation is back in an acceptable range Configuration Menu The CONFIGURE menu is used to set up the variables and scaling for the analog inputs and outputs actuator configuration air supply and trip limits units tag name communications LCD controls and individual register editing and viewing Before entering the CALIBRATE menu the display will indicate that the system will be taken off line and ask you to accept
69. e between training log data points sec 0 to 9999 40140 RW Number of data points taken before amp after an event 1to 20 40141 RW Loads a training log packet into register space Oto1 30142 RO Number of logger packets available 0 to 300 40143 RW Triggers the training log buffer to be filled with O s Oto1 30144 RO Void Integer Register 0 40145 RW External keypad data entry see Keypad doc 0 to 255 40146 RW Enable mask for alert_status bit fields Oto 511 40147 RW 1 Store to baseline 2 Read from baseline 0to2 40148 RW AGA 8 gas equations enable 1 enable O disable Oto1 40149 RW AGA Table download Index 0 to 512 40150 RW Inner Loop Gain value Oto 16 40151 RW Inner Loop Neg Gain value Oto 16 40152 RW Auto Tune Enabled 1 enabled O disabled Otol 40153 RW Tuning switch Position A H 0to8 40154 RW Stable Wise Enabled 1 enabled O disabled Otol 40155 RW Reset alarms 1 reset Otol 30350 RO Void Integer Register 0 42051 RW Integer table pointer 1 Flowserve use only 0 to 349 42052 RW Integer table pointer 2 Flowserve use only 0 to 349 42053 RW Integer table pointer 3 Flowserve use only 0 to 349 42054 RW Integer table pointer 4 Flowserve use only 0 to 349 42055 RW Integer table pointer 5 Flowserve use only 0 to 349 42056 RW Integer table pointer 6 Flowserve use only 0 to 349 42057 RW Integer table pointer 7 Flowserve use only 0 to 349 31 32 FLOWSERVE Starpac 3 Intelligent Control System FCD VL
70. e without notice Should any question arise concerning these provisions the purchaser user should contact Flowserve Corporation at any one of its worldwide operations or offices 2006 Flowserve Corporation Irving Texas USA Flowserve is a registered trademark of Flowserve Corporation flowserve com
71. ed in the appendix CAUTION Changing register values will affect the operation of the system String registers cannot be edited with this function You must use the StarTalk software to edit string registers Reset StarPac 3 This option will reset the system s operation the same as powering up the unit and will also reset some error conditions while displaying the firmware revision on the display Save Backup This option will backup the current configuration to a safe area in the non volatile RAM Flowserve suggests that you use this option before attempting to reconfigure your system to ensure that you can restore the configuration should something go wrong Load Backup This option allows you to restore a known configuration to the system by working registers from the backup NVRAM or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Load Default This option will overwrite the complete register map in the StarPac 3 with default data If you choose this option all of the flow characterization data configuration data and calibration data will be lost This option should only be used in the rare case that the configuration of a system has become so corrupt that all of the data will be re entered from scratch It is recommended that you use the StarTalk for windows software to reload your system information from the factory supplied disk Data Logger This option sets the interval between data points on t
72. ee Appendix G Primary Control Registers and Modes for StarPac 3 Systems Using Modbus Introduction This document covers the basic knowledg of the operating mode and key control registers when a host device such as a PLC or DCS is being used to directly access a StarPac intelligent control system For complete access to the StarPac system both integer and floating point registers must be accessed However basic operation can be accomplished using only integer registers if necessary This paper describes some of the basic registers and how to use them for general operation All of the registers described here are supported in StarTalk for Windows software Most applications could have the scaling and control registers setup using StarTalk for Windows and then have the host device only responsible for working with those registers necessary for the process Operating Modes The StarPac system has three operating modes Manual Automatic and Test The mode is set as described in the mode source section below In Manual mode the unit operates as a normal control valve positioning the valve according to its current command signal that can be received digitally via Modbus or from a 4 20 mA signal In Auto mode the unit operates as a controller using the PID settings process variable and control action currently configured The setpoint can be received digitally via Modbus or from a 4 20 mA signal Test mode takes the unit off line and the system does
73. egister value of 0 and the maximum scale register sets the engineering value that will equal a register value of 9999 After changing the scaling registers you must 59 60 rer FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 write a 1 to register 40081 to signal the system to recalculate the scalar range after they have been changed resetting the system will also force the system to recalculate the scalar range StarPac 3 devices with outerloop code V3 0 or higher no longer require this The scaler ranges are no calculated constantly Table 11 Scale Integer Registers Modbus Type Range Minimum Maximum Scale Description Register Scale Register Register 30012 RO 0t0 9999 40625 40627 Variable scale normalized liquid flow in currently selected engineering units 30013 RO 0to 9999 40629 40631 Variable scale normalized gas flow in currently selected engineering units 30014 RO 0 to 9999 40633 40635 Variable scale normalized P1 isa in currently selected engineering units 30015 RO 0to 9999 40637 40639 Variable scale normalized P2 isa in currently selected engineering units 30016 RO Oto 9999 40641 40643 Variable scale normalized delta P in currently selected engineering units 30017 RO 0t0 9999 40645 40647 Variable scale normalized process temperature in currently selected engineering units 30018 RO Oto 9999 40649 40651 Variable scale normalized auxilia
74. ent Control System FCD VLENMN0066 02 11 15 Nes Setpoint User Units Allows the direct input of the setpoint in the configured engineering units provided the unit is in Auto mode withthe digital setpoint selected Analog Digital This option selects where the StarPac 3 system will receive the setpoint information Digital indicates that the keypad or the StarTalk software can be used to change the setpoint Analog prompts the StarPac 3 to use the 4 20 mA signal from analog input No 1 asthe controller setpoint Remote is used when a host system such as a PLC or DCS is used to write the setpoint to the unit digitally Remote Refresh Rate This option sets up a time out on the receipt of fresh setpoint data when set to operate with a remote setpoint If the setpoint is not refreshed within the time frame entered in this field the unit will go into a loss of command trip as set up in the CONFIGURE menu A value of 0 disables this feature and makes the electronics think that the Mode source is digital Note that if the digital source is selected the unit will hold at the last setpoint indefinitely Command Provides three options used to change the valve position command and configure the source of the valve command Figure 8 Command Menu Mode Set Com Next pnt mand Cmd Ana Rmt Dig Rate Command Allows the direct input of the valve position command asa percentage of valve travel Zero perce
75. ering units The minimum is fixed at zero flow 7 40421 Full scale auxiliary input control range in percent used if an external sensor is attached to the 4 20mA input as the process feedback The minimum is fixed at zero percent Writing Scaled Setpoint or Valve Command When using the digital setpoint source the setpoint for register 40035 or valve command for register 40036 is calculated using the following formula SCALED INTEGER 80 x SP 412 5 As shown in the equation SP is the setpoint in percent of the scaled process maximum set in the register described in Table I for register 40035 or the valve command in percent open for register 40036 Tuning Registers The PID tuning parameters for Proportional band Reset Rate Derivative Time and controller action are all set using integer registers Once tuning values are properly set they normally do not require adjustment unless the process gain has changed significantly Each of the tuning parameters has a different affect on the controller performance rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 we Proportional Band sets the gain for the controller Proportional Band 100 gain or gain 100 prop band Since proportional band is the inverse of gain the larger the band value the smaller the controller gain Register 40032 sets the Proportional Band in units of percent Reset Rate is the integrator term in the PID controller
76. ever if one of these registers reports a value other than zero the device is not functioning correctly Refer to Read and Interpret StarPac Alarms and Errors in the next section for more details The following tables show you the register and mapping for each indicator rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Alarm Register 30104 Bit Meaning 0 Setpoint error 1 Positioner deviation error 2 Trip condition present 3 Not used 4 Not used 5 Not used 6 Sensor malfunction 7 Hardware malfunction 8 Not used 9 Not used 10 Not used 11 15 Not used If bit number 6 is ON check the sensor status register This register indicates the status of all sensors See the next table for sensor status If bit number 7 in the alarm register is ON check the hardware status register This register contains the status of the StarPac electronics See the following table for the mapping of these registers Sensor Status Register 30106 Hardware Status Register 30105 Bit Meaning Bit Meaning 0 P1 sensor error 0 Watchdog reset occurred 1 P2 sensor error 1 SRAM R W failure 2 Top actuator sensor error 2 EPROM checksum error 3 Bottom actuator sensor error 3 NVRAM R W failure 4 Thermocouple sensor error 4 MCU Comm failure 5 Ambient temperature sensor error 5 Not used 6 Position sensor error 6 Not used 7 15 N
77. ew should not be used to terminate any signal shield wires 24VDC Power The 24 VDC connection points will work best with shielded twisted pair wire with the shield wire connected only at the source The input power is isolated within the StarPac 3 system and may be referenced to whatever level is necessary For best performance the 24 VDC power supply should not be connected to earth ground RS 485 Communication RS 485 wiring requires shielded twisted pair wire Maximum performance will be attained when using cable with a characteristic impedance of 120 ohms The shield should be connected only at the source not in the StarPac unit The StarPac 3 internal system ground is isolated and not earth ground referenced The RS 485 port can float to whatever common mode voltage appears at its input terminals These signals are referenced to the StarPac internal system ground and because of this it is the main fault path when one of the isolation points fail For this reason special care must be taken to ensure that the RS 485 cable is wired correctly The RS 485 allows only a 7 to 12V common mode voltage differential between stations This means that an RS 485 network connected to multiple devices must not have more than one grounding point Flowserve s RS 232 RS 485 converter is not a grounded connection it is fully isolated and is not a ground point However PC s with internal RS 485 cards are often earth grounded and if another communication device is o
78. flow at approximately 225 gpm with a range of 0 to 500 gpm Normal system updates should be at two second intervals If the system looses communications then the system should initially stay on line for five minutes and then close the valve if no update is received The PLC needs to monitor the valve position flow rate process temperature and upstream pressure regardless of the current operating mode Initialization values for Manual startup mode Register Value Description 40037 0 Sets the mode source to Digital 40038 1 Puts the unit into Manual mode 40041 1 Sets the setpoint source to Digital in Digital mode the data never expires even when not updated Control Register for Manual Mode Register Value Description 40036 2280 Valve Command scaled as an integer 0 9999 with 0 12 5 and 9999 112 5 16 Example 16 gt 16 12 5 1000 counts 125 2280 counts Initialization Values for Automatic Mode Register Value Description 40037 0 Set the mode source to Digital 40038 2 Puts the unit into Automatic mode 40041 2 Sets the setpoint source to Remote 40109 5 Sets the communication timeout to 5 seconds maximum between updates to register 40705 40047 300 Sets the hold last position to 300 seconds 5 minutes if register 40705 is not updated within the time interval set in 40109 5 seconds 40039 1 Selects liquid flow as the control variable 40
79. g temperature Use the actual ADC values read from ADC Current gt Register 30009 Local User Interface ADC Current gt Register 30008 StarTalk Software or ValveSight DTM and the corresponding temperatures in the above equations to accomplish the calibration The StarPac 3 will indicate correctly at the narrow operating temperature range but will not be correct at ambient temperatures due to the response curve of the thermocouple This is normal operation for cryogenic applications Please contact Flowserve Springville APD Engineering if you need more help with you application An Excel program is available from Flowserve Springville APD Engineering which will calculate the amount of error you can expect The formula for converting to C from F is C F 32 1 8 And from F to C is F 1 8 C 32 or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 we Appendix F DP Cell Calibration Procedure for StarPac 3 WARNING Depressurize the line to atmospheric pressure and drain all fluids from the valve body and pressure sensor tubing before working on the valve Failure to do so can cause serious injury Set the StarPac 3 jumpers to configure the analog input power selection for the DP cell On the lower tight hand side of the electronic board assembly on the bottom of the board are two 8 position jumper arrays labeled JP1 and JP2 Each of the 4 20 mA analog inputs can be configured fo
80. hat if the unit is using an analog command source the system will bump because the 4 20 signal will change from indicating position command to process setpoint Test mode takes the unit off line and the system DOES NOT update the indicated pressures temperatures flow or PID values nor does it support setpoints or any analog or digital commands Test mode is the beginning mode after an initialization and is used during calibration If power is lost during a calibration setup the unit will remain in Test mode and the mode will have to be reset If the unit is in Test mode the letter T will flash on the right side of the display Mode Source This selects where the StarPac 3 unit will receive the mode information Digital indicates that the keypad or the StarTalk software can be used to change the mode Discrete indicates that an external signal applied to terminals 9 and 18 will be used to switch the unit between Auto and Manual modes The definition is fixed with an energized state indicating Auto mode Remote mode is used when a host system such as a PLC or DCS is used to set the mode via digital communications Remote Mode Source Configures the unit so that floating point register 40703 sets the operating mode Valid values are 0 Manual 100 Auto Remote Mode Source is used when a host system such as a PLC or DCS or a Flowserve StarPac Analog Interface Box SPAIF is used to set the mode via digital communications T
81. he difference between Remote and Digital modes is that in Remote mode the only time that the bumpless transfer calculation is done is after the mode in register 40703 has changed from one value to another With a Digital mode source selected every time that any value is written even if it is not changed to register 40038 the StarPac system executes a transfer algorithm that may impede control Setpoint Provides four options used to change the setpoint and configure the source of the setpoint Figure 7 Setpoint Menu Mode Set Com Next pnt mand SP SP Ana Rmt Unit Dig Rate Setpoint Allows the direct input of the controller setpoint as a percentage of maximum as setup with the process variable provided the unitis in the Auto mode with the digital setpoint selected 10 FLOWSERVE wee guidelines for control action settings Table 1 PID Action Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Process Variable Air to Open Valve Air to Close Valve Flow Reverse Direct Upstream Pressure Direct Reverse Downstream Pressure Reverse Direct Differential Pressure Direct Reverse Process Temperature Depends on Installation Depends on Installation Auxiliary 4 20 Input Depends on Installation Depends on Installation Ifthe PID action is not set correctly the controller will hold the valve either full open or full closed and there will be
82. he electronic board assembly on the bottom board are two 8 position jumper arrays labeled JP1 and JP2 Each of the 4 20 mA analog inputs can be configured for either an external power supply such as exists in a DCS or powered internally so a transmitter or other 2 wire device can be directly connected to the terminals JP1 configures analog input 1 and JP2 configures analog input 2 The jumpers should be configured as shown for the desired operation Figure 19 Analog Input Power Jumpers External Internal Loop Power Loop Power Setting Setting 12 Troubleshooting If you experience problems with your system check the following list for some common solutions LCD blank and no system response Check 24 VDC supply polarity and capacity gt 100 mA Verify top board connector is fully engaged LCD Hard to view Inthe CONFIGURE menu adjust the contrast for a better viewing angle LCD active unit will not respond to position or control commands and the analog outputs do not change Check to see if the unit is in Test mode by looking for a flashing T on the right side of the display The unit will be in Test mode any time you are in the CALIBRATE or CONFIGURE menu If you are in the CALIBRATE or CONFIGURE menu use the LAST OPTION key to move up to the top of the menu and exit from Test mode If that does not clear the flashing T from the display go to the TUNE menu and use the mode command to put the system in Auto
83. he internal data logger NOTE You must use StarTalk software to download a data logger file from the StarPac 3 Time Set This option sets the internal StarPac 3 clock The internal clock is battery driven and keeps time whether the unit is powered or not Use the F1 and F2 function keys to select the field to edit Note that the time is in the 24 hour format and the date is the mm dd yy format Discreet Output The discreet output on the StarPac 3 can be configured for an Alarm Relay Output or a Pulse Relay Output Alarm Relay Output When the discreet output is configured for Alarm Relay output mode then the alarm relay will trip when an alarm occurs The relay can be configured for normally open or normally closed See the Contact Relay setting instructions on page 31 of this manual Pulse Relay Output Configures the Pulse Out channel on the StarPac 3 system for the process variable and scaling First you must select a variable from the list using the Next and Previous function keys on the menu Next you are asked for a full scale output value in your selected user units This is the process value that corresponds to the maximum frequency The last step is to enter the offset or zero output value in your selected user units this is the process value that corresponds to 0 Hz Available output variables are the following Valve Position Current valve position Liquid Flow Current liquid flow rate ISA Up Stream Press Current com
84. ibrated range of the pressure sensors Use the Row 1 Variable MODE STATUS menu selection to display the type of trip The low flow trip will only occur when the StarPac is in AUTO mode and the Process Variable is Liquid Flow or Gas Flow Override Condition Indicates the controller is not currently capable of doing any more to achieve the setpoint or valve position This can be any of the trip conditions or a mechanical or software travel limit has been reached and the controller has exceeded the 5 percent current limit or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Sensor Malfunction One of the sensors has a suspect output See sensor errors for detail Device Malfunction The electronics has an internal error See device errors for detail Trip Set Allows the user to enable or disable trips generated by the StarPac 3 in response to user programmed limits of operation Trips are conditions that take the StarPac 3 system out of service and drive it to a fail condition Note that disabling the indication does not stop the trip from occurring Position Sensr Fault Supply Air Loss Trip Anlg Signl Loss Trip Rmt Cmd Timeout Trip Alert Set Allows the user to enable or disable individual alert functions Alerts inform the user of conditions or limits that are currently active Alerts are configured by the user to limit response or inform that a limit is affecting the operation of the unit Stro
85. iguring a StarPac 3 NS option NS means that the StarPac has no integrated process sensors attached However an external 4 20 mA process transmitter can be used as the process variable input to the StarPac PID controller Hence it is a high performance valve positioner with a PID controller feature The StarTalk DTM software that supports the StarPac 3 has a special configuration option in the Configuration menu that makes setting up the SP3 NS very easy Refer to the StarTalk DTM User s Manual VLENSFO001 00 10 13 for more information This document is an addendum to the StarPac Users Interface manual and outlines setting up StarPac using the local keypad 1 As processor sensors are not physically wired to the StarPac module their alarm functions must be disabled to prevent nuisance alarming This is accomplished by using the alarm masking feature of the StarPac On the StarPac key pad under the STATUS menu press NEXT gt Alrm Set Use the NEXT PREV buttons to choose Sensor Malfunction Press Disable Alarm will indicate Disabled Press Last Option 2 Press Alrt Set Select Low dp Alert Press Disable Alert will indicate Disabled Press Last Option 3 Press NEXT gt Sensor Set Select Upstream Pressure Downstream Pressure Process Temperature each in turn and disable each sensor Press Last Option to return to top menu You have now disabled and masked off the sensor alerts and alarms 4 Next go to the Configuration menu Pres
86. in N FLOWSERVE User Instructions Nas User StarPac 3 Interface Intelligent Control System Man ual 71 1 a ABAAA a Experience In Motion FLOWSERVE wee Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Contents 1 Getting Started ss dei 1 2 Restrictions mere 3 StarPac 3 Local Interface vs PLC DCS Conflicts StarPac 3 1 4 Local Interface Structure amp Operation ee Re Re 1 5 initial StartUp inienn RR einen dndien 2 6 Status MENU usseren ikea 3 7 Tune Menu sn DEE OE OE OE OR 7 8 Calibration Menu ie EER SR RE SS E 10 9 Configuration Menu 15 10 Edit amp View Fluid Specifications rrrrrnnvrrnrrrnvnrrnrrrnvrrnnrrrvnrrnnnrnnr 21 11 Setting the JUMPers ies ESE Nee en 22 12 Troubl shooting AA EE EE AET 23 Appendices A System Setup Checklist niinniin 24 B Detailed StarPac 3 Register Map iese see Re RR RA Re Re 25 Integer Registers Floating Point Registers String Registers C Fluid Table ves see 51 D StarPac Wiring and Grounding Guidelines sesers 52 E StarPac 3 Temperature ADC Factors eise ese ese ee ee ee ee 53 F DP Cell Calibration Procedure essere RA RR Re RA 55 G Primary Control Registers and Modes esse ese ee Re Re RA 57 H StarPac 3 NS No Sensors Setup iese RR Re ee Re nn 69 or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 we Operation 1 Getting Started This manual is designed to help you become fami
87. int table pointer 52 350 to 1248 42167 RW Floating point table pointer 53 350 to 1248 42168 RW Floating point table pointer 54 350 to 1248 42169 RW Floating point table pointer 55 350 to 1248 42170 RW Floating point table pointer 56 350 to 1248 42171 RW Floating point table pointer 57 350 to 1248 42172 RW Floating point table pointer 58 350 to 1248 42173 RW Floating point table pointer 59 350 to 1248 42174 RW Floating point table pointer 60 350 to 1248 42175 RW Floating point table pointer 61 350 to 1248 42176 RW Floating point table pointer 62 350 to 1248 42177 RW Floating point table pointer 63 350 to 1248 42178 RW Floating point table pointer 64 350 to 1248 42179 Integer variable 1 Flowserve use only 42180 t Integer variable 2 Flowserve use only ig 42181 Integer variable 3 Flowserve use only 42182 Integer variable 4 Flowserve use only ig 42183 ig Integer variable 5 Flowserve use only 42184 k Integer variable 6 Flowserve use only 42185 Integer variable 7 Flowserve use only 42186 Integer variable 8 Flowserve use only 42187 i Integer variable 9 Flowserve use only 42188 Integer variable 10 Flowserve use only ig 42189 Integer variable 11 Flowserve use only 42190 Integer variable 12 Flowserve use only 42191 i Integer variable 13 Flowserve use only 42192 Integer variable 14 Flowserve use only 42193 Integer variable 15 Flowserve use onl
88. iring hardware replacement if it persists This error can only be cleared by turning the device off and then turning it on again 5V reference Out of Tolerance An internal power supply is operating out of tolerance Illegal Pointer One of the configurable arrays is using an invalid register StarTalk Software can be used to find and correct the invalid pointer NVRAM Checksum Error A value in the non volatile RAM was changed without resetting the checksum Performing any write function such as a setpoint or command change should reset the error If the system behaves erratically after receiving an or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee error the NVRAM may have been corrupted and you should reload the factory configuration table from the disk provided using the StarTalk for Windows software Divide by Zero The StarPac 3 unit attempted an illegal math operation due to bad calibration or configuration settings Reload the factory configuration table from the disk provided using StarTalk software MCU SPI Comm failure The StarPac 3 has experienced an internal communications failure The StarPac 3 will attempt to correct this problem automatically If this persists the StarPac 3 will stop functioning A power reset may clear this problem if the StarPac 3 stops functioning Alarm Reset Allows the user to clear all alarms and alerts Trip Alert View Allows the user to view Trips or alert
89. iscrete and digital communications Because of the processing power of the StarPac 3 system a separate 24 VDC power connection is required and connected to terminals 1 and 10 This power supply should have a minimum current capacity of 100 mA and 150 mA if using to power Analog Inputs or using StarPac power for Analog Outputs Before powering up the unit Read the section Setting the System Jumpers and set them according to the instructions and particular application Powering up the unit on the bench When the unit is first powered up the display will show the version number of the firmware for two seconds before beginning operation The StarPac 3 system sensors are calibrated at the factory and the fluid data is entered as specified on the order However due to the differing nature of installations the units and ranges of the analog and discrete I O are not configured at the factory The suggested process for setting up anew system on the bench is 1 Inthe CONFIGURE menu select the engineering units you will be using 2 Ifyou will be using analog I O signals use the CONFIGURE menu to set up the analog channels to indicate the proper process variables and ranges you will be using Note that the StarPac 3 system treats gas flow and liquid as different variables and they must each be specified Connect the instrument air supply 40 150 psi to the inch NPT air supply port located on the back of the unit Use the STATUS menu and
90. k and must be connected to different networks The default address for a StarPac 3 is 1 after an initialization Use the Up or Dn function keys to select the proper address If using multiple StarPac 3 devices begin your addressing at 2 and go up from there Baud Rate This option sets the Baud Rate for the Modbus communications Available Baud Rate settings are 2400 9600 19200 38400 and 57600 The default setting is 19200 Baud after an initialization Use the Up or Dn function keys to select the desired Baud Rate The baud rate will automatically change to 57600 when the USB connection is used W Parity This option sets the Parity for the Modbus communications Available Parity settings are None Even and Odd The default setting is Odd after an initialization Use the NEXT or PREVIOUS function keys to select the proper Parity RTU ASCII This option sets the communication mode for the Modbus communications Available communications mode settings are ASCII and RTU The default setting is RTU after an initialization Use the NEXT or PREVIOUS function keys to select the proper communication mode When ASCII mode is selected Parity must be set to None 19 20 or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Port Access This option allows you to control the priority of the communication ports A port may be configured so that it can only be used for monitoring by a remote device Use the NEXT
91. ke Rate Limit Soft Limit Alert High Min Sig Cutoff Low Min Sig Cutoff Low dP Alert Anti Reset Wnd Alert Position Travel Alrt Travel Accumulator Cycle Counter Alert System Information Allows the user to check the factory hardware configuration for reference or spare parts The following list shows the items listed Valve Serial Number Spring Trim Number Spring Type Trim Characteristic Air Action Trim Type Pressure Electronics S N Class Valve Model EPROM Version Flow Direction Sensor Rating Body Size Sensor Drawing No Body Material P1 Serial Number Packing Style P2 Serial Number Packing P1 Calibration Date Gasket Material P2 Calibration Date Actuator Size Miscellaneous No 1 Miscellaneous No 2 Actuator Calibration Date Positioner Calibration Date Thermocouple Calibration Date View Registers Allows the user to view any internal integer or floating point Modbus register using the register map provided see appendix for a list of registers String registers cannot be viewed with this function 7 Tune Menu The TUNE menu is used to view and configure the controller variables and gains change modes and reset the totalizer The TUNE menu is arranged as shown in Figure 5 Figure 5 Tune Menu Tree Sta Tune tus Mode Next Prop Rset Der Next Band Rate Time PID PV PV Next Actn Slct Scal Totl Rset Mode Totl rer FLOWSE RVE Starpac 3 Intellig
92. kway Springville Utah 84663 0903 NOTE This manual is not intended to be a replacement for the many manuals already available for teaching and understanding instrumentation and process control such as the Instrument Society of America s Instrument Engineers Handbook Revised Edition 1982 etc A copy of these manuals may prove valuable to the user in determining what StarPac 3parameters need to be set with respect to a particular application or process 3 StarPac 3 Local Interface vs LC DCS Conflicts The StarPac 3 allows the user the ability to control and program a field device remotely through a PLC or DCS interface Since the StarPac 3 has a local interface it is important to remain cognizant of who has command of the StarPac 3 control system If the StarPac 3 is being commanded by a PLC or DCS it is possible that any calibrations or mode changes being made at the local user interface will be overwritten by the supervisory PLC or DCS Be sure to disable or suspend communications with the supervisory system while using the local user interface It is recommended that an off line feature be programmed into the supervisory system to only monitor the system so that the local user interface can be used This will prevent someone from modifying the StarPac 3 without permission of the control room 4 StarPac 3 Local Interface Structure amp Operation The StarPac 3 local user interface allows complete user access to configure and calib
93. ler is unable to maintain the process at the current setpoint Sensitivity is adjusted using StarTalk software Positioner Deviation The positioner is unable to maintain the valve position at the current command Sensitivity is adjusted using StarTalk software Trip Condition The unit is in a trip condition of either loss of command low supply air or a low flow cutoff Low flow is determined when the pressure drop across the valve is less than 0 5 of the calibrated range of the pressure sensors The valve must be in or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee AUTO mode for the low flow trip to occur Use the Row 1 Variable MODE STATUS menu selection to display the type of trip Override Condition Indicates the controller is not currently capable of doing any more to achieve the setpoint or valve position This can be any of the trip conditions or a mechanical or software travel limit has been reached and the controller has exceeded the 5 percent current limit Sensor Malfunction One of the sensors has a suspect output See sensor errors for detail Device Malfunction The electronics has an internal error See device errors for detail Sensor Errors Allows the user to view any current sensor errors using the NEXT or PREVIOUS function keys Possible sensor errors are Upstream Pressure The output of the upstream pressure sensor is out of range Downstream Pressure The output
94. liar with and efficiently operate the StarPac 3 Intelligent Control System While the information presented in this manual is believed to be accurate it is supplied for informative purposes only and should not be considered to be certified or as a guarantee of satisfactory results by reliance thereon Specific instructions for the installation wiring operation and maintenance of the StarPac 3 are contained in the StarPac 3 IOM manual For information on Personal Computer software see the StarTalk XP Manual Because Flowserve is continually improving and upgrading its product design the specifications and information included herein are subject to change without notice Flowserve will continue to provide its customers with the best possible products and service available Should you have any questions about these provisions or about Flowserve products contact your local Flowserve representative or the Advanced Product Development Group directly 801 489 8611 You can also access Flowserve information via the internet HTTP www flowserve com 2 Restrictions Copyright 2009 Flowserve Corporation All rights reserved No part of this manual may be reproduced in any form without the written permission of the publisher Due to product changes and periodic review the information contained in this manual is subject to change without notice All correspondence should be addressed to Flowserve Control Division Marketing 1350 Mountain Springs Par
95. low calculation based on the value of the input Air Action Used to set up the StarPac 3 for the configured actuator failure mode ATO Air to Open is normally used for fail closed valves ATC Air to Close is normally used for fail open valves If ATC is selected and you will be using an analog command source configure the analog command to reverse so that 4 mA equals the 100 percent position open The following table lists the possible configurations for linear actuators Table 4 Actuator Air Actions Failure Mode Output 2 bottom Output 1 top port Spring Failure Position Air Action port is Connected to is Connected to Air loss fail closed Actuator Top Actuator Bottom Above Position ATO Power loss fail closed Air loss fail closed Actuator Bottom Actuator Top Above Piston ATC Power loss fail open Air loss fail open Actuator Bottom Actuator Top Below Piston ATC Power loss fail open Air loss fail open Actuator Top Actuator Bottom Below Piston ATO Power loss fail close Low Air This option is used to set the trip parameters for low supply air to the system which is continuously monitoring the air supply in the actuator Using the actuator pressures the StarPac 3 can infer the supply pressure to within five to 10 psi If the supply pressure drops below the Low Air Trip Pressure then the positioner will attempt to hold the valve for the time specified in the hold parameter and then r
96. menu options to set for ZERO SPAN and SENSOR GAIN Zero Apply the atmospheric pressure or the minimum pressure you want to use for your reference and press ACCEPT The two numbers on the right side of the display are register values that indicate how steady the pressure is in the valve body Next enter the actual pressure applied in the indicated engineering units and press ACCEPT Span Apply the maximum pressure you want to use for your reference and press ACCEPT The two numbers on the right side of the display indicate how steady the pressure is in the valve body Next enter the actual pressure applied in the indicated engineering units and press ACCEPT Sensor Gain This option configures the input amplifier range for the installed sensors using the Up and Dn function keys Flowserve s standard sensors normally use the 30mV lt out lt 60mV selection Normally you should not have to change this option If you have guestions consult your Flowserve representative P1 This option calibrates the upstream process pressure sensor in the unit You will then have two more menu options to set for Zero and Span Zero Apply the atmospheric pressure or the minimum pressure you want to use for your reference and press ACCEPT The number on the right side of the display indicates how steady the pressure is in the valve body Next enter the actual pressure applied in the indicated engineering units and press ACCEPT 13 rn FLOWSE RVE Starp
97. mple register number 30001 would become variable number 0 Table 4 Integer Registers Register Number Attribute Description Notes 30001 RO ADC value for cylinder bottom pressure 32768 to 32767 30002 RO ADC value for cylinder top pressure 32768 to 32767 30003 RO ADC value for 4 20mA command 0 to 16383 30004 RO ADC value for ambient temperature 32768 to 32767 30005 RO ADC value for 4 20mA auxillary 0 to 16383 30006 RO ADC value for P1 channel 32768 to 32767 30007 RO ADC value for P2 channel 32768 to 32767 30008 RO ADC value for position channel 0 to 65535 30009 RO ADC value for process temperature channel 0 to 16383 30010 RO Current flow state liquid gas 0 liquid choked 1 liquid non choked 2 gas non choked 3 gas choked 30011 RO Fixed scale normalized process variable 0 to 9999 30012 RO Variable scale normalized liquid flow 0 to 9999 30013 RO Variable scale normalized gas flow 0 to 9999 300014 RO Variable scale normalized P1 isa 0 to 9999 30015 RO Variable scale normalized P2 isa 0 to 9999 30016 RO Variable scale normalized delta P 0 to 9999 30017 RO Variable scale normalized process temperature 0 to 9999 25 FLOWSERVE wee Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Register Number Attribute Description Notes 30018 RO Variable scale normalized auxiliary input 0 to 9999 30019 RO Fixed sc
98. n the network that also has an earth ground a fault condition will almost certainly exist due to transient and steady state differences in ground potential 4 20 mA Command Input Auxiliary Input and Feedback Output These signals are isolated but shielded twisted pair wire should be used to reduce crosstalk from other signals Again the shield should be connected only at the source Discrete Input and Output These signals are isolated yet because they are frequently used to switch high voltage 120 VAC they should be runin separate shielded wire paths away from the other StarPac signals FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Appendix E Manual Thermocouple Calibration The best way to calibrate a StarPac 3 thermocouple is to do a calibration while using a thermocouple calibrator If a temperature calibrator is not available the following instructions can be used to calibrate a StarPac 3 in the field Use the following table to enter the calibration ADC factors for the temperature sensing of the StarPac 3 This is one of the advantages of using a K type thermocouple and the linearization circuit as we do You can obtain an acceptable temperature calibration by simply these values into the StarPac 3 calibration factors 1 Determine the working temperature range Remember to try and keep the window as small as possible The temperature range of the type K thermocouple is large and non linear By kee
99. nd Manual modes The definition is fixed with an energized state indicating Automatic mode Remote Mode Source Configures the unit so that floating point register 40703 sets the operating mode Valid values are 0 Manual 100 Auto Remote Mode Source is used when a host system such as a PLC or DCS or a Flowserve StarPac Analog Interface Box SPAIF is used to set the mode via digital communications The difference between Remote and Digital modes is that in Remote mode the only time that the bumpless transfer calculation is done is after the mode in register 40703 has changed from one value to another With a Digital mode source selected every time that any value is written even if it is not changed to register 40038 the StarPac system executes a transfer algorithm that may impede control Setpoint source This controls where the StarPac unit receives the valve command or controller setpoint information Integer register 40041 sets the setpoint source for how the unit receives control information Valid values are 0 4 20 mA 1 Digital 2 Remote Digital Configures the unit so that integer register 40035 sets the controller setpoint as a scaled integer if the StarPac unit is in Automatic mode Integer register 40036 sets the valve position command as a scaled integer if the StarPac unit is in Manual mode The scale for digital source using the integer registers is fixed for both position command and controller setpoint with 0 12 5 percent
100. nt is closed and 100 percent is open provided the unit is in Manual mode with the digital command selected Analog Digital This option selects where the StarPac 3 system will receive the valve position command information Digital indicates that the keypad or the StarTalk software can be used to change the valve position command Analog prompts the StarPac 3 to use the 4 20 mA signal from analog input No 1 as the valve position command Remote is used when a host system such as a PLC or DCS is used to write the valve position command to the unit digitally Remote Refresh Rate This option sets up a timeout on the receipt of fresh valve position command data when set to operate with a remote command If the valve position command is not refreshed within the time frame entered in this field the unit will go into a loss of command trip as set up in the CONFIGURE menu A value of 0 disables this feature Note that if the digital source is selected the unit will hold at the last valve position command indefinitely Proportional Band Sets the proportional band for the controller Proportional Band 100 gain or gain 100 prop band Since proportional band is the inverse of gain the larger the band value the smaller the controller gain Reset Rate This is the integrator term in the PID controller referring to the action at which the rate of change of output is proportional to the error input Reset is the par
101. o 120 40759 RW Positioner characterization x axis input point 20 to 120 40761 RW Positioner characterization x axis input point 20 to 120 40763 RW Positioner characterization x axis input point 20 to 120 40765 RW Positioner characterization x axis input point 20 to 120 40767 RW Positioner characterization x axis input point 20 to 120 40769 RW Positioner characterization x axis input point 20 to 120 40771 RW Positioner characterization x axis input point 20 to 120 40773 RW Positioner characterization x axis input point 20 to 120 40775 RW Positioner characterization x axis input point 20 to 120 40777 RW Positioner characterization x axis input point 20 to 120 40779 RW Positioner characterization x axis input point 20 to 120 43 44 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 2 Register Number Attribute Description Notes 40781 RW Positioner characterization x axis input point 20 to 120 40783 RW Positioner characterization x axis input point 20 to 120 40785 RW Positioner characterization x axis input point 20 to 120 40787 RW Positioner characterization y axis output point 20 to 120 40789 RW Positioner characterization y axis output point 20 to 120 40791 RW Positioner characterization y axis output point 20 to 120 40793 RW Po
102. of the downstream pressure sensor is out of range Cylinder Top Press The output of the top actuator pressure sensor is out of range Cylinder Bot Press The output of the bottom actuator pressure sensor is out of range Process Temperature The output of the process temperature sensor is out of range Ambient Temperature The output of the ambient temperature sensor is out of range Position Feedback The output of the position feedback sensor is out of range Device Errors Allows the user to view any device errors using the NEXT or PREVIOUS function keys Possible device errors are Watch Dog Timeout The watchdog timer error on the StarPac is an indication of the health of the unit and its installation This error does not prevent the StarPac from operating Itis triggered by instability of the CPU This is usually caused by the following events 1 Lowpower If the power supply drops to around 18 Vdc instead of the required 24 Vdc this will cause the timing of the CPU to become erratic and triggers the error 2 Excessive noise and spikes on the power supply A good regulated 24 Vdc power supply is required for the StarPac 3 Bad power may eventually damage the unit 3 Improper Grounding and Shielding of the wiring Proper instrumentation wiring techniques must be used when installing the StarPac system This is a high precision instrument and should be installed accordingly Refer to Installation Operation and Maintenance Instr
103. oint 9 analog digital 9 soft limits travel limits 17 String Registers 48 system information viewing 7 T tag name setting 19 Temperature sensor calibration 12 totalizer resetting 10 units selection 17 Units selection custom gas flow 18 custom liquid flow 18 ans N FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 71 72 ans N FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 ans N FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 73 FLOWSERVE wee Flowserve Headquarters 5215 N O Connor Blvd Suite 2300 Irving TX 75039 USA Telephone 1 972 443 6500 Control Valve Manufacturing 1350 Mountain Springs Parkway Springville UT 84663 3004 USA Telephone 1 801 489 3719 Singapore 12 Tuas Ave 20 638824 Republic of Singapore Telephone 65 862 3332 Austria Kasernengasse 6 Villach Austria 9500 FCD FLENMNO066 02 Printed in USA 11 15 Telephone 43 0 4242 41181 0 To find your local Flowserve representative Australia 14 Dalmore Dr Scoresby Victoria Australia 3179 F inf ti bout FI ti or more information about Flowserve Corporation Telephone 61 3 9759 3300 visit www flowserve com or call USA 1 800 225 6989 China 585 Hanwei Plaza 7 Guanghua Road Beijing China 100004 Telephone 86 10 6561 1900 Flowserve Corporation has established industry leader
104. ot used 7 Not used 8 Not used 9 Not used 10 Not used 11 Not used 12 Illegal pointer assignment 13 10V reference failure 14 NVRAM checksum error 15 Divide by Zero trap rer FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Virtual registers The StarPac system has 32 virtual floating point registers and 32 virtual integer registers that can be used to group registers for better block read and write support from remote devices To use the virtual registers load the pointer register with the desired internal register in the corresponding virtual register The pointer register must use the actual StarPac internal register number not the Modbus register number To determine the internal StarPac register number take the Modbus register number and remove the first digit and any remaining zeros preceding the significant digits and then subtract one For example to put the current valve position in the first virtual floating point register 71361 floating point variable number 33 set the corresponding pointer register 41201 floating point table pointer number 33 to a value of 252 corresponding to Modbus register 70253 Table 12 Virtual Register Table Variable Description Modbus Register Type Range Description 42083 RW 0to 199 Integer table pointer number 33 42084 RW 0to 199 Integer table pointer num
105. ource to Digital 40039 6 Selects gaseous flow as the control variable 40427 5000 Full scale flow of 5000 LB HR for controller must be set using Valtek StarTalk user interface because it is a floating point register Control Register for Automatic Mode Register Value Description 40035 8200 Setpoint scaled as an integer 0 9999 with 0 11 25 a 125 4500 Ib hr 90 of 5000 Ib hr and 8200 counts represents scaled 90 range of the maximum process variable set in register 70271 Example 90 gt 90 12 5 1000 counts 125 8200 counts NOTE Any setpoint must be written after setting the mode to auto because the bumpless transfer that occurs when the unit is switched from auto to manual overwrites the existing setpoint with the current PV When the mode change occurs any value that is in the setpoint register is overwritten even if the value was placed there just prior to the mode change Scaling the Integer Registers Variable Minimum Maximum Description Scale Scale Register Register Gas Flow 40629 40631 Sets the normalized range for gaseous flow in Ib hr these must be set using set to 0 set to 5000 Valtek StarTalk user interface because they are floating point registers Upstream 40633 40635 Sets the normalized range for upstream pressure in psi these must be set Pressure set to 100 set to 600 using Valtek StarTalk user interface because they are floating point registers
106. pensated upstream line pressure defined as two pipe diameters upstream of the valve ISA Dn Stream Press Current compensated downstream line pressure defined as six pipe diameters downstream of the valve ISA Delta Pressure Current differential pressure using the pressure definitions above Process Temperature Current process temperature Gas Flow Current gaseous flow rate Auxiliary 4 20 Input Re transmits the 4 20 mA signal from analog in No 2 Positioner Output Current positioner output Register Number Allows the selection of any internal register value as an output 10 Edit amp View Fluid Specifications The StarPac 3 system must be configured for the exact fluid that you have in your process The factory configures the system with fluid data for your system using the information supplied with the order Verify that the fluid data is correct for your process The StarPac system requires the following fluid data for accurate flow calculation Antoine s A coefficient register 40499 Antoine s B coefficient register 40501 Antoine s C coefficient register 40503 Critical Pressure in psia register 40511 Critical Temperature in 2R register 40513 F coefficient K 1 4 register 40515 Molecular Weight register 40517 Specific Gravity Reference temp in register 40519 SR Specific Gravity at reference register 40521 temp Viscosity A register 40523 Viscosity B register 40525 21 22 rn FLOWSE RVE Starpac 3 Intelligent Con
107. ping the window small the accuracy of the temperature is increased Example The process runs between 100 F and 200 F with little or no chance of seeing a temperature outside of the range Calibrate 70 F to 212 F Select you Tmax and Tmin and corresponding ADCmax and ADCmin from the table below Ref Temperature F StarPac 3 ADC Counts 400 675 350 715 300 777 250 860 200 959 150 1073 100 1202 60 1313 40 1371 0 1491 32 1591 70 1712 100 1810 150 1975 200 2140 212 2180 260 2337 300 2466 350 2626 400 2784 450 2943 500 3105 550 3267 600 3432 650 3597 700 3762 750 3928 800 4095 850 4262 900 4429 950 4597 1000 4764 1050 4931 1100 5098 2 Calculate the calibration slope for the thermocouple Use the information gathered from the table above in the equation Tspan F Tzero F CalSlop en ADC span ADC zero 53 54 FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 ds 3 Use the EDIT REGISTER OR Edit Variables to enter the gathered information to the device Use the StarTalk XP software the ValveSight DTM software or the local user interface of the device Be sure to use the variable name to ensure you are modifying the correct location regardless of the method used Register Locations for StarTalk software Tmin gt Register 70686 ADCmax
108. point variable 455 42353 Floating point variable 56 42355 Floating point variable 57 42357 Floating point variable 58 42359 Floating point variable 59 42361 Floating point variable 60 42363 Floating point variable 61 42365 Floating point variable 62 g 42367 Floating point variable 63 i 42369 Floating point variable 64 RO Read Only RW Read Write Dependent upon the selected register String Registers The register numbers in this table are not consecutive because of the varying length of each string in this area of the StarPac 3 memory Most of these strings are available as RW strings however we suggest that you write to 50617 TAGNAME and 50625 Real time and date and leave the others as they are because that information is factory set NOTE Trying to access the middle of a string will result in an exception response from the device Table 6 String Registers Register Number Attribute Description Notes 31251 RO Embedded software version 16 bytes ASCII String 41259 RW Valve serial number 16 bytes ASCII String 41267 RW Local process identifying text 16 bytes ASCII String 41275 RW Real time amp date information 32 bytes ASCII String 41291 RW User Text string 1 32 bytes ASCII String 41307 RW User Text string 2 32 bytes ASCII String 41323 RW User Text string 3 32 bytes ASCII String 41339 RW User Text string 4 3
109. r either an external power supply such as exists in a DCS or powered internally so a transmitter or other 2 wire device can be directly connected to the terminals The JP2 configures the analog input 2 The jumpers should be configured as shown for the desired operation The JP2 jumpers should be configured as shown in the picture below for the desired operation depending on your choice of internal or external loop power External Internal Loop Power Loop Power Setting Setting Wire Connections e Negative Terminal on the DP Cell to Terminal No 14 onthe StarPac 3 User Interface Block Positive Terminal on the DP Cell to Terminal No 5 on the StarPac User Interface Block Set SPI on IP2 as shown in figure 19 1 Close the upstream and downstream valves and open the bridge valve on the Pressure Manifold 2 Remove the Vent Drain Plug from the upstream side of the DP Cell Connect a calibrated pressure reference and a regulated pressure source to the Vent Drain Plug port 3 Remove the covers from both ends of the DP Cell Verify that the DP Cell is wired according to the description above and that the Span Switch on the DP Cellis set to the appropriate range 4 Connect a Current Meter in series in the current loop by disconnecting the wire from Terminal No 5 on the StarPac 3 User Interface Block and connecting it to the positive terminal on the Current Meter Connect the negative terminal on the Current Meter to Terminal No 5 on the
110. rate a StarPac 3 Intelligent Control Valve System The interface consists of a Liquid Crystal Display LCD and a membrane covered keypad The LCD is a 4 X 20 character display with the top two lines user configured for normal operation or for displaying instructions or options during configuration The bottom two lines are used to indicate menu options that are selected with the four function keys To the right of the menu options on the bottom two lines are two normally blank spaces that indicate Alarm or Error conditions indicated by a flashing A and or E A flashing T on the right side of the display indicates that the unit is in Test mode and will not respond to commands until the unit is set to Manual or Auto mode in the TUNE menu The keyboard has three types of keys the menu control keys which consist of the LAST OPTION F1 F2 F3 and F4 keys the alpha numeric keys and the colored shift keys The F1 F2 F3 and F4 keys refer to the menu options listed in the LCD of the interface The LAST OPTION key is used to move back through the menus The alpha numeric keys are used to enter data requested in various options The red blue and green shift keys are used to select the corresponding colored letter on the alpha numeric keypad or FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 we The various menu options have three basic forms The first type is a list that is scrolled through by using the
111. reference and press ACCEPT The number on the right side of the display indicates how steady the temperature input is reading Next enter the actual temperature applied in the indicated engineering units and press ACCEPT Span Apply a signal equal to the maximum temperature you want to use for your reference and press ACCEPT The number on the right side of the display indicates how steady the temperature input is reading Next enter the actual temperature applied in the indicated engineering units and press ACCEPT Positioner This option is used to set the control gains for the positioner and also test for proper response Figure 11 Positioner Menu Tree Thrm Psnr cple Tune Auto Man Man Ned Mult Prst Edit Open __Step Stbl Loop Test Wise Auto Tune Multiplier This option allows the user to adjust the gain multiplier and or commands the positioner to automatically compute the gains to be used by the positioner based upon the stroke time of the valve Figure 12 Auto Tune Multiplier Auto Man Man Next Mult Prst Edit Up Down Can Acc cel ui Mult Can Gain Only cel Calc Displayed on Row 1 will be the multiplier value with selections from A to H These are represented in table 2 These values are multiplied by the final gain to allow the user to adjust the responsiveness of the valve rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Man Next Cal
112. rk Count the host computer as any other device For example a single StarPac 3 system is communicating with a host PC in the control room The StarPac 3 unit and the RS 485 driver in the host computer would each require a termination jumper Remove the termination jumpers in the devices not considered to be the most remote Using more than two termination jumpers in a network may cause the RS 485 communications to fail Contact Relay Setting On the lower right hand side of the electronic board assembly on the bottom board is a three position jumper labeled JP3 This jumper if set in the A B position configures the relay to Normally open operation If set to the B C position the jumper configures the relay to Normally closed operation Figure 17 Contact Relay Jumper Normally Open Normally Closed Discrete Input Range Selection On the lower right hand side of the electronic board assembly on the bottom board is a six position jumper labeled JP4 There are 2 jumpers that must be moved together to set the voltage input range The jumpers are oriented vertically and with both jumpers in the upper position the input is set to trigger on 120V AC or DC With both jumpers in the lower position the input is set to trigger on 24V AC or DC Figure 18 Discrete Input Range Jumper rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Analog input power selection On the lower right hand side of t
113. ry input in percent 30019 RO 0t0 9999 Fixed at 12 5 Fixed at 112 5 Fixed scale normalized 4 20mA command in percent 30020 RO Oto 9999 Fixed at 12 5 Fixed at 112 5 Fixed scale normalized position in percent 30021 RO 0 to 9999 Fixed at 12 5 Fixed at 112 5 Fixed scale normalized set point command in percent of maximum See Table 9 40078 RW Oor1 N A N A Register 40078 must be set to 1 in order to signal the system to recalculate the scalar range after the range has been changed This step is longer reguired with outerloop codes of V3 0 or or higher Scaled integers can be interpreted using the following method LE D_MAX SCALED_MIN SCALE D_MIN SCALED_INTEGER SCA ENGINEERING VALUE 10000 For example to read the process temperature with a range of 15 to 100 Celsius set register 40645 to 15 and register 40647 to 100 The StarPac will then calculate a scaled integer for register 30017 based on the current temperature If the value in register 30017 is 4378 then the temperature in engineering units will be 4378 TEMPERATURE ES 100 15 15 52 213 Alarm registers In the StarPac registers three integer registers contain alarm sensor and hardware error status information The user can decode this information to determine the state of the StarPac device If these registers contain zeroes the device is functioning correctly How
114. s Current compensated downstream line pressure in user defined units Defined as six pipe diameters downstream of the valve designated as P2isa in the display ISA Delta Pressure Current differential pressure using the pressure definitions above in user defined units Designated as dPisa in the display Process Temperature Current process temperature in user defined units Designated as Temp in the display Liquid Flow Totalizer Totalized liquid flow in user defined units Designated as TotlQ in the display the totalizer is reset from the TUNE menu Gas Flow Totalizer Totalized gas flow in user defined units Designated as TotIW in the display the totalizer is reset from the TUNE menu Totalizer Time Operating time since the totalizer was last reset Designated as TotTm in the display Valve Cv Current valve G at present valve position Designated as Cv in the display Setpoint Controller setpoint as a percent of the maximum Designated as SP in the display The process maximum is set inthe TUNE menu with the process variable for the controller operation Process Variable Process variable in percent of maximum Designated as PV inthe display The process maximum is set inthe TUNE menu with the process variable for the controller operation Setpoint units Current controller setpoint in user units Designated as SP in the display PV units
115. s Accept to take the StarPac Offline Press NEXT gt Anlg In 2 If not selected use NEXT PREV buttons to select External PID Sensor Press Accept Press Last Option to return to top menu You will need to press Accept to put the StarPac back online Indicated by the flashing T on the right side of the display will disappear This has now told the PID controller to look at the 4 20 mA input signal connected to the Analog In 2 Auxiliary Input terminals for the PV to control 5 Goto the TUNE menu Press NEXT twice gt PV Sict Use NEXT PREV buttons to select Auxiliary 4 20 mA Input Press Accept You have now selected your 4 20 mA signal from your process transmitter as the process variable to control for the PID controller The default scaling for this variable is 0 100 6 You must now go to PID Actn to set the proper controller action for the process variable you want to control Either Direct or Reverse acting This will depend on your actual control loop construction This is the same functionality as any PID controller You have now configured the StarPac 3 NS as the controller for your process variable You are now ready when safe conditions exist to change the controller Mode to Automatic and tune your control via the Prop Band Rset Rate and Der Time variables in the menu structure Refer to pages 7 11 of the User Interface Manual for details of using the Tune menu and options 69 70 FLOWSERVE wee Index A
116. s generated by the StarPac 3 in response to user programmed limits of operation Figure 4 Trip Alert Menu Sta Tune Cal Con tus brat fig Disp Err Trp Next Set Alrm Alt Alrm Trip Alrt Next Set Set Set sys View Trip Alrt Info Reg View View Trip View Trips are conditions that take the StarPac 3 system out of service and drive it to a fail condition Position Sensr Fault Supply Air Loss Trip Anlg Signl Loss Trip Rmt Cmd Timeout Trip Alert View Alerts inform the user of conditions or limits that are currently active Alerts are configured by the user to limit response or inform that a limit is affecting the operation of the unit Stroke Rate Limit Soft Limit Alert High Min Sig Cutoff Low Min Sig Cutoff Low dP Alert Anti Reset Wnd Alert Position Travel Alrt Travel Accumulator Cycle Counter Alert Alarm Set Allows the user to enable or disable individual alarm functions Setpoint Deviation The controller is unable to maintain the process at the current setpoint Sensitivity is adjusted using StarTalk software Positioner Deviation The positioner is unable to maintain the valve position at the current command Sensitivity is adjusted using StarTalk software Trip Condition The unit is in a trip condition of either loss of command low supply air or a low flow cutoff Low flow is determined when the pressure drop across the valve is less than 0 5 of the cal
117. set cycle counter 40076 RW Loads real time register 41275 from 0 normal operation the RTC 1 triggers transfer of time date to register 41275 40077 RW Loads the RTC from real time register 0 normal operation 41275 1 triggers setting of rime date to register 41275 40078 RW Triggers scaler factors to be recalculated 0 normal operation 1 triggers recalculation 40079 RW Signature flag 0 function complete 1 start ramp test 2 start step test 40080 RW Number of data packet to be read 1to 650 40081 RW Loads a signature packet into 0 normal operation register space 1 triggers packet number requested 40080 to be loaded in packet registers 30661 30681 40082 RW Loads a logger packet into register space 0 normal operation 1 triggers packet number requested in 40080 to be loaded in packet registers 30661 30685 30083 RO Number of signature packets available 0 to 650 30084 RO Number of logger packets available 0 to 300 30085 RO Signature Logger ttl_in data 32768 to 32767 30086 RW Variable pointer for Tpro flow calc 1 to 1023 40087 RW Variable pointer for P1 flow calc 1 to 1023 40088 RW Variable pointer for P2 flow calc 1 to 1023 40089 RW Variable pointer for gf flow calc 1 to 1023 40090 RW Variable pointer for M flow calc 1 to 1023 40091 RW Variable pointer for liquid correction factor 1 to 1023 40092 RW Variable pointer for gas correction factor 1 to 1023 40093 RW Variable pointer for dP flow calc 1 to 1023 400
118. ship in the design and manufacture of its products When properly selected this Flowserve product is designed to perform its intended function safely during its useful life However the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions Although Flowserve can and often does provide general guidelines it cannot provide specific data and warnings for all possible applications The purchaser user must therefore assume the ultimate responsibility for the proper sizing and selection installation operation and maintenance of Flowserve products The purchaser user should read and understand the Installation Operation Maintenance IOM instructions included with the product and train its employees and contractors in the safe use of Flowserve products in connection with the specific application While the information and specifications contained in this literature are believed to be accurate they are supplied for informative purposes only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon Nothing contained herein is to be construed as a warranty or guarantee express or implied regarding any matter with respect to this product Because Flowserve is continually improving and upgrading its product design the specifications dimensions and information contained herein are subject to chang
119. signature rate min 10 to 150 40655 RW Step signature time sec 1to 20 40657 RW Signature starting position 10 to 110 40659 RW Signature stopping position 10 to 110 30661 RO Signature time data IEEE 754 30663 RO Signature Logger Ptop data IEEE 754 30665 RO Signature Logger Pbot data IEEE 754 30667 RO Signature Logger dac1 data IEEE 754 30669 RO Signature Logger posn data IEEE 754 30671 RO Signature Logger Tpro data IEEE 754 30673 RO Signature Logger Plisa data IEEE 754 30675 RO Signature Logger P2isa data IEEE 754 30677 RO Signature Logger flow_q data IEEE 754 30679 RO Signature Logger flow_w data IEEE 754 30681 RO Signature Logger aux data IEEE 754 30683 RO Logger setpoint data IEEE 754 30685 RO Logger process variable data IEEE 754 40687 RW Calibration offset for Tpro deg F 10E3 to 10E3 40689 RW Maximum Posnr error without alarm 0 1 to 100 40691 RW Maximum Posnr chg over 1 sec steady state 0 1 to 100 40693 RW LOP Trip condition ramp rate min O to 1E6 40695 RW Cylinder supply pressure psig 0 to 200 30697 RO Set point command IEEE 754 30699 RO Current process variable IEEE 754 30701 RO Alarm state as float 0 to 100 40703 RW Remote mode change register 50 to 150 40705 RW Remote command 50 to 150 30707 RO Cylinder top pressure psig IEEE 754 30709 RO Cylinder bottom pressure psig IEEE 754 40711 RW user units 20mA at Al 2 1E9 to 1E9 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066
120. sitioner characterization y axis output point 20 to 120 40795 RW Positioner characterization y axis output point 20 to 120 40797 RW Positioner characterization y axis output point 20 to 120 40799 RW Positioner characterization y axis output point 20 to 120 40801 RW Positioner characterization y axis output point 20 to 120 40803 RW Positioner characterization y axis output point 20 to 120 40805 RW Positioner characterization y axis output point 20 to 120 40807 RW Positioner characterization y axis output point 20 to 120 40809 RW Positioner characterization y axis output point 20 to 120 40811 RW Positioner characterization y axis output point 20 to 120 40813 RW Positioner characterization y axis output point 20 to 120 40815 RW Positioner characterization y axis output point 20 to 120 40817 RW Positioner characterization y axis output point 20 to 120 40819 RW Positioner characterization y axis output point 20 to 120 40821 RW Positioner characterization y axis output point 20 to 120 40823 RW Positioner characterization y axis output point 20 to 120 40825 RW Positioner characterization y axis output point 20 to 120 40827 RW Positioner characterization y axis output point 20 to 120 40829 RW Low minimum positioner command cutoff 20 to 120 40831 RW Upper position alert 20 to 120 40833 RW Lower position alert 20 to 120 30835 RO Time of operation hours IEEE 75
121. ssure defined as two pipe diameters upstream of the valve ISA Dn Stream Press Current compensated downstream line pressure defined as six pipe diameters downstream of the valve 13 16 rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee ISA Delta Pressure Current differential pressure using the pressure definitions above Process Temperature Current process temperature Gas Flow Current gaseous flow rate Auxiliary 4 20 Input Re transmits the 4 20 mA signal from analog in No 2 Positioner Output Current positioner output Register Number Allows the selection of any internal register value as an output If a string register is selected zero will be displayed in the data field Analog Out 2 This option configures the second analog output channel Select a variable from the list using the NEXT and PREVIOUS function keys on the menu You will then be asked for a full scale output value in your selected user units This is the process value that corresponds to 20 mA The last step is to enter the offset or zero output value in your selected user units This is the process value that corresponds to 4 mA Available output variables are Valve Position Current valve position Liquid Flow Current liquid flow rate ISA Up Stream Press Current compensated upstream line pressure defined as two pipe diameters upstream of the valve ISA Dn Stream Press Current compensated downstream
122. ter 53 0 to 349 42104 RW Integer table pointer 54 0 to 349 42105 RW Integer table pointer 55 0 to 349 42106 RW Integer table pointer 56 0 to 349 42107 RW Integer table pointer 57 0 to 349 42108 RW Integer table pointer 58 0 to 349 42109 RW Integer table pointer 59 0 to 349 42110 RW Integer table pointer 60 0 to 349 42111 RW Integer table pointer 61 0 to 349 42112 RW Integer table pointer 62 0 to 349 42113 RW Integer table pointer 63 0 to 349 42114 RW Integer table pointer 64 0 to 349 42115 RW Floating point table pointer 1 Flowserve use only 350 to 1248 42116 RW Floating point table pointer 2 Flowserve use only 350 to 1248 42117 RW Floating point table pointer 3 Flowserve use only 350 to 1248 42118 RW Floating point table pointer 4 Flowserve use only 350 to 1248 42119 RW Floating point table pointer 5 Flowserve use only 350 to 1248 42120 RW Floating point table pointer 6 Flowserve use only 350 to 1248 42121 RW Floating point table pointer 7 Flowserve use only 350 to 1248 42122 RW Floating point table pointer 8 Flowserve use only 350 to 1248 42123 RW Floating point table pointer 9 Flowserve use only 350 to 1248 42124 RW Floating point table pointer 10 Flowserve use only 350 to 1248 42125 RW Floating point table pointer 11 Flowserve use only 350 to 1248 34 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15
123. that condition While the CONFIGURE menu is open the system is in Test mode and will not respond to control signals To put the unit back on line press the LAST OPTION key until the display asks do you want to put the unit back on line and press ACCEPT When you are in the CALIBRATE menu a flashing T on the right side of the display will indicate that the unit is in Test mode Certain functions may cause valve position to change unexpectedly that could affect the process if the unit is not properly isolated The CONFIGURE menu is arranged as shown in Figure 13 Figure 13 Configuration Menu Tree Sta Tune Cal __Con tus brat fis EE Out1 Out2 Cmd Anlg Air Low _ Next In2 Actn Air Try Unit Tag Net Lmts Name Pass Comm LCD Next Word Port Cont AGA Tech Data Next Equ Log Time Dsct_Trvi Cycl Set Out Acc Cnt Analog Out 1 This option configures the first analog output channel Select a variable from the list using the NEXT and PREVIOUS function keys on the menu You will then be asked for a full scale output value in your selected user units This is the process value that corresponds to 20 mA The last step is to enter the offset or Zero output value in your selected user units This is the process value that corresponds to 4 mA Available output variables are Valve Position Current valve position Liquid Flow Current liquid flow rate ISA Up Stream Press Current compensated upstream line pre
124. the above tests re zero the transducers using the P1 amp P2 option in the CALIBRATE menu You may also need to pressurize the sensors and verify the Span if the calibration is suspect Use the STATUS menu and set the Row Two variable to be process temperature Verify that the unit is correctly indicating ambient temperature If the unit fails the above test re calibrate the transducer using the thermocouple optioninthe CALIBRATE menu This calibration requires a Type K thermocouple simulator or a temperature bath Use the CALIBRATE menu to check the analog channels that you will be using Finally use the TUNE menu to select the process variable that you will be controlling and set the range Putting The Unit Online menu to configure the setpoint signal to the proper source for your DCS system If you will be using the system inthe Automatic mode adjust the Proportional Integral Derivative PID parameters so the loop responds satisfactorily Backing up the system When you have your unit calibrated and working according to your needs back up the configuration into the safe memory area This is done in the Save Backup choice in the Tech option of the CONFIGURE menu 6 Status Menu The STATUS menu is used to view information about the configuration and operation of the system Errors and alarms can also be viewed from this menu The STATUS menu is arranged as shown in Figure 2 Figure 2 Status Menu Sta Tune Cal
125. the selected rate Note that this value may be set different from the spring failure of the actuator Analog In 2 This option sets up the second analog input in the StarPac 3 system This input can be used as an external input that is used with the internal PID controller or as an external sensor input for the StarPac 3 to use in its internal operation If you wish to use the input as a controller input you must select the External PID Sensor option and the scaling for the PID input is done in the TUNE menu with the Process variable selection If you want to feed an external sensor into the StarPac 3 select the variable from the list using the NEXT and PREVIOUS function keys on the menu Next you will be asked for a full scale input value in your user defined units This is the process value that corresponds to the 100 percent signal The last step is to enter the offset or Zero input value in your user defined units This is the process value that corresponds to the 0 percent signal The available input variables are External PID Sensor Configures the StarPac 3 unit to ignore the input as an internal variable but the input may still be used as an input to the controller that is configured with the process variable selection inthe TUNE menu Process Temperature Uses the value from the Auxiliary input channel as the process temperature for all internal calculations in place of the StarPac 3 sensor The electronics assumes that the Auxiliary
126. to7 40116 RW LCD display mode register 32768 to 32767 40117 RW LCD row 1 variable pointer 1 to 1023 40118 RW LCD row 2 variable pointer 1 to 1023 40119 RW Positioner null deadband bump 0 to 4095 40120 RW Normal mode proportional gain for positioner 0 to 20000 40121 RW Zero velocity gain for positioner 0 to 20000 40122 RW Null offset for positioner 2250 to 3250 40123 RW Initiates FLASH program function Otol 30124 RO ADC value for inner loop hall sensor 0 to 16383 30125 RO Void Integer Register 0 30126 RO Void Integer Register 0 40127 RW Enable register for keypad password function Otol 40128 RW Variable pointer for Analog Output 1 1 to 1023 40129 RW Variable pointer for Pulse Relay Output 1 to 1023 30130 RO DAC value for positioner 0 to 4095 FLOWSERVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 ee Register Number Attribute Description Notes 40131 RW Actuator type 0 Linear 1 Rotary Otol 40132 RW P1 amp P2 ADC PGA selection Oto 14 40133 RW WDT reset exception vector CPU32 pg 6 2 Otol 40134 RW Error dependent gain for positioner 0 to 65535 40135 RW LCD viewing angle bias default 117 0 to 255 40136 RW LCD backlight on time seconds NOT ACTIVE IN SP3 1 to 3600 40137 RW Positioner characterization enable 0 Disabled 1 Enabled 40138 RW Actuator stabilization timeout sec 10 to 600 40139 RW Tim
127. trol System FCD VLENMN0066 02 11 15 wee The Antoine coefficients are used to calculate the vapor pressure of the fluid at the temperature measured by the K thermocouple in the StarPac according to the following equation B VP exp A P Ta where VP is the vapor pressure in psia T is the temperature in R and A B and Care the Antoine coefficients Viscosity is calculated according to the following equation Visc A exp B T Where Visc is the fluid viscosity in centipoise T is the process temperature measured by the thermocouple in F and Aand B arethe viscosity coefficients These registers can be checked using either the View option of the STATUS menu or the View selection in the Tech option of the CONFIGURE menu They can be changed using the Edit selection in the Tech option of the CONFIGURE menu 11 Setting the Jumpers The StarPac 3 system has several jumpers that are used to configure the digital analog and discrete O The keypad needs two retaining screws removed and the keypad connector can remain attached while the jumpers are changed or viewed as needed RS 485 Termination On the top electronic board to right of the LCD display there are two termination jumpers for the RS 485 communications The jumper labeled JP1 enables the termination resistor for Comm A and the jumper label JP2 enables the termination resistor for Comm B These jumpers should only be installed on the two most remote devices on the netwo
128. uctions IOM the StarPac 3 for guidelines 4 Excessive noise on the RS 485 data communications Noise problems on the communications can upset the CPU Follow the guidelines for wiring and termination 5 Electronics problem Very rare and unlikely Once triggered this alarm remains active until the unit is reset This can be accomplished by simply cycling the power off and on Even though the alarm is continuously indicated once it is set it does not prevent the StarPac 3 from operating Normal operation is still possible The alarm is set this way so that these transient conditions are caught and notify the operator that something is not right If the problem occurs intermittently this is a common symptom of a power supply or noise problem Re check the installation wiring and power supply SRAM R W Failure The static RAM had an error This is a serious error usually requiring hardware replacement if it persists This error can only be cleared by turning off the device and then turning it on again Flash Checksum Failure Check the integrity of the firmware This error usually occurs when the firmware is changed and must be cleared with an initialization This is done by holding down the 0 on the keypad while powering up the unit WARNING An initialization will also reset the communication parameters password and PID control parameters NVRAM R W Failure The non volatile RAM had an error This is a serious error usually requ
129. umber 43 42329 Floating point variable number 44 42331 ai Floating point variable number 45 42333 Floating point variable number 46 42335 is Floating point variable number 47 42337 ig Floating point variable number 48 42339 ig Floating point variable number 49 42341 ig Floating point variable number 50 42343 a Floating point variable number 51 42345 Floating point variable number 52 42347 z Floating point variable number 53 42349 A F Floating point variable number 54 42351 Floating point variable number 55 42353 ig Floating point variable number 56 42355 Floating point variable number 57 42357 ig Floating point variable number 58 42359 Floating point variable number 59 42361 ig Floating point variable number 60 42363 z Floating point variable number 61 42365 a Floating point variable number 62 42367 z Floating point variable number 63 42369 Floating point variable number 64 RO Read Only RW Read Write Dependent upon the selected integer 66 rn FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Example 1 StarPac system is attached to a PLC that has both integer and floating point Modbus communication capability For system startup the unit needs to be put in Manual mode and hold a position of approximately 16 percent without updates from the PLC When in operation the StarPac system will be in Automatic mode controlling liquid
130. value that the unit is receiving and is only for reference during calibration Configuration of the variable and scaling for the channel is done in the CONFIGURE menu Quick Calibration This option calibrates the actuator pressure sensors the position feedback sensor and auto calculates the positioner command gains in the unit The process requires that the valve stroke from full open to full closed several times Because the valve will change position during this process you must confirm that you want to proceed You will then be prompted for the instrument air supply pressure to the unit If the air supply varies by more than 1 psi during the calibration the test may abort Hence a regulator may be required if the air supply is not stable The unit will then complete the calibration process by stroking the valve open and closed over 30 to 60 seconds Upon successful completion the display will show the message Calibration Successful WARNING Notify personnel working nearby that the valve will stroke during this procedure otherwise serious injury may occur Manual Calibration This option gives the options to run the actuator calibration or the positioner stroke calibration independent of each other 11 12 rer FLOWSE RVE Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 wee Span Apply the maximum pressure you want to use for your reference and press ACCEPT The numbers on the right side of the display indicate
131. with the StarPac 3 where changes are being made to the operating modes and setpoints are being sent it is important to program the software to change the mode prior to sending the setpoint This is important because the bumpless transfer routine in the StarPac 3 may change the setpoint back to the previous value Process maximum Setup for the controller setpoint using any setpoint or command source Analog Digital or Remote is set in the floating point registers shown in Table according to the selected control variable selected in integer register 40039 Table 9 Control Variable Selection Variable Number Process Variable Description for Register 40039 Scaling Register 1 40425 Full scale liquid flow control range in selected engineering units The minimum is fixed at zero flow 2 40429 Full scale upstream pressure P1 control range in selected engineering units The minimum is fixed at zero pressure in engineering units 3 40431 Full scale downstream pressure P2 control range in selected engineering units The minimum is fixed at zero pressure in engineering units 4 40423 Full scale delta P control range in selected engineering units The minimum is fixed at zero differential pressure 5 40433 Full scale process temperature control range in selected engineering units 5 40435 Minimum process temperature control range in selected engineering units 6 40427 Full scale gas flow control range in selected engine
132. y 35 36 FLOWSERVE wee Starpac 3 Intelligent Control System FCD VLENMN0066 02 11 15 Register Number Attribute Description Notes 42194 Integer variable 16 Flowserve use only 42195 42196 Integer variable 17 Flowserve use only Integer variable 18 Flowserve use only 42197 Integer variable 19 Flowserve use only 42198 Integer variable 20 Flowserve use only 42199 Integer variable 21 Flowserve use only 42200 Integer variable 22 Flowserve use only 42201 Integer variable 23 Flowserve use only 42202 Integer variable 24 Flowserve use only 42203 Integer variable 25 Flowserve use only 42204 Integer variable 26 Flowserve use only 42205 Integer variable 27 Flowserve use only 42206 Integer variable 28 Flowserve use only 42207 Integer variable 29 Flowserve use only 42208 42209 Integer variable 30 Flowserve use only Integer variable 31 Flowserve use only 42210 Integer variable 32 Flowserve use only 42211 Integer variable 33 42212 Integer variable 34 42213 Integer variable 35 42214 Integer variable 36 42215 Integer variable 37 42216 Integer variable 38 42217 Integer variable 39 42218 Integer variable 40 42219 Integer variable 41 42220 Integer varia

User Instructions - Flowserve Corporation

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