Avid SmartCal Valve Positioner User Manual
Contents
1. 1 Travel High 5 Limit Switch Alert 2 Travel Low 3 Travel DB 4 Travel Alext Device Info 1 Tx 2 Poll Addr 3 Descriptor 4 Date Deviation Alert 1 Deviation DB 2 Deviation Alert Manufacturer 1 Manufacturer 2 Medel 3Devid 4 Write protect Rev G 04 20 01 tech 251 DWO11819 Page 33 of 332. 74 7 Side View Top View Inches mm Rev G 04 20 01 tech 251 DWO11819 Page 22 of 33 Appendix A Procedure to Adjust the Error 3 Setting Note The error 3 message is pre set from the factory For a low pressure positioner it is set to 15 psi and for a high pressure positioner it is set at 55 psi If these settings come out of calibration or if it is necessary to change these settings the following instructions can be followed 1 Before adjusting the Error 3 setting the positioner must be mounted and set up See sec tion 3 of this manual 2 To adjust the setting of the Error 3 message to indicate low input pressure there is an adjustment screw located on the top of the transducer See Figure Below 3 To set the Error 3 for an explicit pressure value loosen the lock nut on the adjustment screw and gently turn the screw clockwise as far as it will go Do not force the screw past its limit or the Error 3 diaphragm assembly may be damaged 4 Regulate the supply pressure to the pressure you would like to set as a low input pressure flag 5 Turn the adjustment screw slowly counter clockwise to the point where the Err 3 message appears on from the display 6 Set this point by tightening the lock nut Be careful not to effect the adjustment screw set ting 7 Re regulate the supply air to the normal operating pressure Error 3 Adjustment Screw With Locknut Transducer Rev G 04 20 01 tech
3. ANSI NFPA 70 Install in accordance with Canadian Electrical Code Part 1 Rev G 04 20 01 tech 251 DWO11819 Page 31 of 33 Appendix G Procedure to Reset the EEprom to Factory Settings The SmartCal Positioner is a digital device Positioner operation relies on data that is stored in the positioner s EEprom chip Calibration and configuration data that has been established during the posi tioner s calibration is stored in the EEprom Under abnormal conditions this stored information can become corrupted If this occurs it is necessary to reset the chip and re calibrate the positioner 1 2 3 4 5 6 7 Remove power to the positioner This can be done by removing the plug in style terminal strip Press and hold the CAL button while replacing the terminal strip returning power The LCD will show TYCO SmartCal Positioner Rev for several seconds while holding down the CAL button Continue to hold the CAL button until the LCD shows reset EEprom values to Mfg values When this statement appears release the CAL button After releasing the CAL button you will be prompted to enter 4 0 mA Change your input to the positioner to exactly 4 0 mA and press the CAL button If your zero position signal is other than exactly 4 0 mA then use the Up Down arrow buttons to adjust the value shown on the posi tioner s LCD to match the zero position mA and press the CAL button You will then be prompted to enter
4. of positioner Err 6 Error 6 Calibration Error Positioner could not successfully perform calibration ALR Alert 3 Valve position is not being maintained within the deadband range The deadband range EDb is set from the configuration menu during calibration Sec tion 3 The EDb must be set to other then zero 0 to enable the Alert 3 message Rev G 04 20 01 tech 251 DWO11819 Page 20 of 33 Section 7 Exploded Parts List SmartCal Parts Description Item Qty Description 1 1 Cover Assembly 2 1 Display Board Assembly 3 1 Electronics Module Assembly 4 1 Transducer Assembly 5 1 Housing Assembly 6 1 Manifold Assembly 7 1 ModMount Section 8 Product Matrix Eor SRA Se ee E SM 0 bo be be de eb E Manifold Air Port Size 1 4 NPT 0 NA Bracket Type _ D _ ModMount Remote Option D ModMount Housing R Remote Mount Housing Conduit Size 1 1 2 NPT Application General Purpose P Intrinsically Safe Product Example Code SMI1DDON SmartCal Intrinsically Safe 1 2 NPT Conduit Direct Mount Housing Direct Mount Bracket 1 4 NPT Manifold Air Port Size Rev G 04 20 01 tech 251 DWO11819 Page 21 of 33 Section 9 Dimensions SmartCal Positioner W Tyco Direct Mounting Actuator 4 25 108 1 2
5. position of a valve based on a 4 to 20 mA input sig nal The SmartCal is an instrument that derives its power directly from a control systems current loop The instrument senses valve position via a non contact Hall effect sensor and controls valve position through a current to pressure transducer Calibration of the SmartCal can transpire by two means Non Hart calibration is through an on board keypad Communi cation using Hart protocol allows calibra tion and access to on line diagnostics via a Rosemount 275 hand held terminal or through software The positioner has a local liquid crystal display which indicates valve position and set point in percentage open It also indicates whether the positioner is in cal ibration mode The SmartCal has the capability to monitor operation If a failure condition occurs an error message is displayed on the local liquid crystal display Rev G 04 20 01 tech 251 DWO11819 Page 3 of 33 1 2 Principal of Operation Unlike conventional positioners the SmartCal Positioner feeds back valve position without the need for linkages levers or rotary and linear seals Position sensing is performed totally by non contacting means permitting use of advanced control strategies where knowledge of valve position is used in predictive and other algorithms By the integration of multiple compo nents into a singular cost efficient unit microprocessor based intelligence can now be used to implement ad
6. 20 mA Change your input to the positioner to exactly 20 0 mA and press the CAL button If your full scale position signal is other then exactly 20 0 mA then use the Up Down arrow buttons to adjust the value shown on the positioner s LCD to match the full scale position mA and press the CAL button The positioner will automatically return to normal operating mode If desired follow the normal calibration procedure as described in the manual Rev G 04 20 01 tech 251 DWO11819 Page 32 of 33 Appendix H Hart Communicator Menu Flow Chart SmartCal Series Digital Valve Controller Manual Cal 1 HighCal 2 Loa PID Parameters 3 Setpoint Capture 1 P Gain Index 4 Position Capture i 2 Integral Conbol 5 Auto PID Cal 3 Integral Time 6 SersorCal 4D Gain Index 7 Transducer Cal 8 mA Meter Cal 9 Transmitter Cal Slew Speed 1 Opening peed Basic Config 2 Closing peed 1 Valve Type 2 Flow Type 3 Display Mode 4 Control Mode HART Comnamicator 1 Offlire 3 Frequency Device Cal Config Daws Limit Settings 2 Slew Speed 1 Upper Limit 3 Setpoint Capture 2 Lower TrA Limit 4 Limit 3 Cutoff Mode 5 Digital Settings 4 Limit Contol 1 Auto Cal 1 Dig Setpt 2 Digital Mode 4 Device Info Accum Alert 1 Accum Count 2 Acoum 3 DB 4 Acoum Alert Config 1 Alert 2 Acoum 3 Travel Travel Alert 4 Deviation Alert
7. 251 DWO11819 Page 23 of 33 Appendix B Procedure to Remove Display Board and Electronic Canister 1 Remove the three screws that fasten the display board See Figure Below 2 Gently pull up the display board disconnecting the board from the 30 pin connector on the upper right corner of the display board 3 Gently remove the transducer pin connector Be careful not to pull any of the wires out of the connector 4 Gently remove the hall effect sensor pin connector Be careful not to pull any of the wires out of the connector 5 At this point the display board is completely disconnected If the electronic canister is to be removed it can be done so by removing the three screws that fasten it to the housing Screw Display Board Hall Effect as Shaded Area Sensor Pin Connector 30 Pin Connector Gs Screws Transducer Pin Connector Rev G 04 20 01 tech 251 DWO11819 Page 24 of 33 Appendix C Procedure to Check Transducer Operation This procedure should only be used for trouble shooting 1 Mount the positioner and connect the pneumatics as described in section 3 of this man ual 2 Remove the Display Board as described in Appendix C of this manual The electronic can ister does not need to be removed 3 Locate Pin 2 amp Pin 4 on transducer pin connector See Figure Below Ref Pin 1 is furthest from the pressure gages Pin 10 is nearest to the to the pressure gage
8. AVII D Installation amp Operating Instructions for SmartCal Valve Positioner ANALOG POSITIONERS Rev G 04 20 01 tech 251 DW011819 Page 1 of 33 Table of Contents Section 1 Introduction Page fT DESeription OF 3 t2 Principal OF OPI AMO Morte cheese ae 4 Section 2 Initial Setup 2 1 Mounting Positioner on a Rotary 5 2 2 Mounting Remote Positioner a Rotary 6 2 3 Wiring the Remote Sencor to the 7 2 4 8 2 5 Electrical Connectoren 9 Section 3 Calibration 3 1 Enter CANNOT A 10 3 2 Configure The Positioners 10 3 8 AUTOMAlIG CalIDFAUOM 11 3 4 Advanced Calibration Optional 11 3 5 Exit Calibration canbe ces 12 3 6 Description OMNVICHU 12 13 3 7 Description OF PUNCHONG eek ee ak ea 14 16 3 8 Manually Control Valve 16 Section 4 Trouble Shooting 4 1 Preliminary CHECKS bak
9. DIV 1 GROUPS A B C D CLASS II DIV 1 GROUPS E F G CLASS MI DIV 1 ROSEMOUNT 275 HART COMMUNICATOR NOTE 4 SmartCal SERIES POSITIONER 1 NONHAZARDOUS LOCATION ASSOCIATED APPARATUS INTRINSIC SAFETY BARRIERS MTL MODEL 707 OR 787S MTL MODEL 7087 USED FOR DIGITAL ON OFF IN RTS 1 4 20 NOTE 3 ANALOG CONTROL 4 3 OUTPUT 2 EQUIPMENT NOTE 2 1 oe MAGNUM SWITCH OPTION separate shields connected to intrinsically safe Associated Apparatus ground Locations fibers using an appropriate NRTL listed cable gland fitting MAXIMUM FIELD WIRING CAPACITANCE AND INDUCTANCE HAZARDOUS LOCATION amp MAXIMUM ALLOWABLE MAXIMUM ALLOWABLE CONFIGURATION FIELD WIRING FIELD WIRING CAPACITANCE INDUCTANCE GP A OR B LOCATION W 30nF 4 0mH COMMUNICATOR GP C D E F G LOCATION 230nF 16mH W COMMUNICATOR GP AOR LOCATION 100nF 4 0mH W OUT COMMUNICATOR GP C D E F G LOCATION 300nF 16mH W OUT COMMUNICATOR Associated apparatus manufacturer s installation drawing must be followed when installing this equipment Control equipment connected to associated apparatus must not use or generate more than 250V To maintain intrinsic safety each field wiring pair 4 20 mA and Analog Output must be ru
10. Down Arrow Down Arrow From Previous Menu MCAL To Next Menu RAE UpArrow x a Up Arrow Down 1 Up Arrow Arrow Arrow Up Arrow CAL Arrow Dor Dor Dow Dow Dor ji L Eo bes Arrow gt PID arrow 515 Arow gt Trod srov MA Ron gt Set 12 mA Set 12 mA Press CAL EX Press CAL ey Press CAL Key Press CAL Key Press CAL Key Press CAL Key Press CAL Key Down 4 4 Arrow 4 4 4 4 Set mA Set mA AUT MAN Sensor Transducer Set4 0 Read Transmitter Calibration Calibration Value amp Use for Fail Position for Fail Position Press CAL Key Press CAL Key Up amp Down Arrows to Enter y Press CAL Key Present Zero Value Automatic PCAL Press CAL Key Press CAL Key PID Routine Adjust using 4 Press CAL Key Up amp Down et 20 0 mA y Arrow Keys 5 Zero Span 1 20 Up ae rrows nter Calibration Calibration Press CAL Key Press CAL Key the Desired Zero Current Typically x 40 down ICAL Ame gt ICAL T Leen ON Press CAL Key Optional Optional Selec
11. ED PAIR SHIELD SHOULD BE 0 4 20 mA OUTPUT SHLD o o TAPE SHIELD amp CONNECTED TO THE SHIELD TERMINATION TO POINT OF THE OUTPUT PAE ENT CONTACT MODULE OR TO THE POWER SUPPLY GROUND 1 gt CONNECTION FROM DCS OR PLC TO POSITIONER IS 20 GAUGE SHIELDED TWISTED PAIR BELDEN 8762 OR EQUIVALENT MAXIMUM DISTANCE IS 5000 FEET 2 gt CONNECTION FROM HART MULTIPLEXER TO POSITIONER IS 20 GAUGE SHIELDED TWISTED PAIR BELDEN 8762 OR EQUIVALENT MAXIMUM DISTANCE FROM HART MULTIPLEXER TO POSITIONER IS 6000 FEET 3 gt SHIELD SHALL BE CONNECTED TO GROUND AT ONE POINT ONLY IN ORDER TO AVOID GROUND LOOPS AND NOISE INTERFERENCE 4 THE FOLLOWING TABLE PER IEEE STD 518 1982 INDICATES THE MINIMUM DISTANCE BETWEEN CABLE TRAYS AND CONDUITS CONTAINING LEVEL 1 THIS INCLUDES 4 20 mA SIGNALS AND 120 VAC OR 480 VAC INORDER TO MINIMIZE ELECTRICAL NOISE INTERFERENCE RACEWAY 480 VAC 120 VAC TRAY 26 6 TRAY CONDUIT 18 4 CONDUIT 12 3 Rev G 04 20 01 tech 251 DWO11819 Page 26 of 33 Appendix E Pneumatic Manifold Diagram Air to Transducer Air Filter Pilot Air to Transducer T Air to Outlet Actuator Supply Port 1 Air out of Air Transducer Outlet P
12. amp 2 POSITIONER CONTROL EQUIPMENT NOTE 5 L NOTE 4 1 ANALOG OUTPUT i 1 1 NE 1 1 1 Entity parameters for each field wiring terminal pair of SmartCal Vmax 30V Imax 100mA Ci 120 pF Li OmH CSA Notes 1 oN AUN on Barrier must be a CSA certified single channel grounded shunt diode zener barrier or single channel isolating bar rier or one dual channel or two single channel barriers may be used where both channels have been certified for use together with combined entity parameters The following conditions must be satisfied Voc or Vo lt Vmax or Ui Ca gt Ci C Cable Isc or lt Imax or li La gt Li L Cable Associated apparatus manufacturer s installation drawing must be followed when installing this equipment Control equipment connected to associated apparatus must not use or generate more than 250V To maintain intrinsic safety each field wiring pair 4 20 mA and Analog Output must be run in separate cables or separate shields connected to intrinsically safe Associated Apparatus ground ROSEMOUNT 275 HART COMMUNICATOR is NOT FMRC approved for use in Class and Hazardous Locations For Class II and locations where rigid metal conduit is not used seal ICoT cable entries against dust and fibers using an appropriate NRTL listed cable gland fitting Installation should be in accordance with ANSI ISA RP12 6 and the National Electrical Code
13. bration is complete before being able to exit calibration The up arrow key can be used as described above to move to the Menu level and then to exit CAL mode 3 6 Manual Override of Input Signal Via On Board Keypad The positioner has a feature which allows the operator to override the analog signal and change valve position from the SmartCal This is done from the Stro Manual Override Stroke Menu Enter cali bration as described in section 3 1 and use the down arrow button to cycle to the Stro menu Enter this menu and control the position of the valve as shown below Up Arrow Exit Calibration Down Arrow Down Arrow From Previous Stro gt To Next Menu U Up Adjs lt gt CLs E ji cM T S Fast Valve Valve Move Full Open Closed Press Up Use Up Use Up or Down amp Down amp Down Arrow can can one time move move valve valve valve moves Slowly Slowly 5 CAL CAL AG Slow Move Press amp Hold Up or Down Arrow valve will move slowly CAL Rev G 04 20 01 tech 251 DWO11819 Page 12 of 33 3 7 Description of Menu s The calibration functions of the SmartCal positioner is organized into the following four menus Menus e Menu 1 ACAL Automatic Calibration e Menu 2 MCAL Manual Calibration e Menu 3 Cofg Configura
14. d Analog Output must be run in separate cables or separate shields connected to intrinsically safe Associated Apparatus ground 4 ROSEMOUNT 275 HART COMMUNICATOR is NOT FMRC approved for use in Class and Hazardous Locations 5 For Class II and locations where rigid metal conduit is not used seal SmartCal cable entries against dust and fibers using an appropriate NRTL listed cable gland fitting 6 Installation should be in accordance with ANSI ISA RP12 6 and the National Electrical Code ANSI NFPA 70 MAXIMUM FIELD WIRING CAPACITANCE AND INDUCTANCE HAZARDOUS LOCATION amp MAXIMUM ALLOWABLE MAXIMUM ALLOWABLE FIELD WIRING FIELD WIRING CONFIGURATION CAPACITANCE INDUCTANCE GP A OR LOCATION W 30nF 4 0mH COMMUNICATOR GP C D E F G LOCATION 230nF 16mH W COMMUNICATOR GP A OR B LOCATION 100nF 4 0mH W OUT COMMUNICATOR GP C D E F G LOCATION 300nF 16mH W OUT COMMUNICATOR ROSEMOUNT 275 HART COMMUNICATOR not used or used only on the INPUT side of associated appara Rev G 04 20 01 tech 251 DWO11819 Page 30 of 33 Appendix F Control Schematic for Wiring of Intrinsically Safe Positioner Sheet of 4 of 4 HAZARDOUS LOCATION NONHAZARDOUS LOCATION CLASS I DIV 1 GROUPS A B C D CLASS DIV 1 GROUPS E F G CLASS DIV 1 ASSOCIATED APPARATUS INTRINSIC SAFETY SmartCal SERIES BARRIERS NOTES 1
15. d CAL A eo Abby R AC Down Down Down Down mi Arrow MCAL Arrow Cofg arrow Stro Arrow See Section 3 3 See Section 3 4 See Section 3 2 See Section 3 6 3 2 Configure the Positioners Parameters From the menu level press the down arrow button until the Cofg Configuration Menu is shown on the dis play Configuration Routine Shown Below Enter this menu and change any of the parameters if other than the factory settings are needed The factory settings are highlighted Up Arrow xit Calibration Down Arrow Down Arrow From Previous Menu gt Cofg m Next Menu CAL ce Up Arrow A A Up Arrow Up Arrow Up Arrow Up Arrow Up Arrow 1 Flow r Type Arow FLOP Ast OPSP Arow CLSP Ra Arow A ets i CAL CAL CAL CAL CAL CAL CAL oe Mi Lin OFF Use UP Use UP OFF Pe Linean Fail amp Downl amp Down Flow Closed Arrows Arrows to Select to Select 5 Down Open Close CAL Speed Speed D gt Down gt Down gt 01 Slo 01 Slow ON 05 Fast 05 Fast CAL OPn r
16. e Double Acting Output Port 2 is piped to turn the actuator counter clockwise Output Port 1 is piped to turn the actuator clock wise Note 1 Drive insert must be provided with Keystone Tyco actuators for ModMount installations 2 Drive insert may need to be disengaged and rotated 90 to allow for proper mounting Positioner a Sensor Semi Circle Faces Conduit Entry Side With The Conduit Entry Mounting Assembly Drive Insert 7 Actuator Fail Position gt gt TURNS COUNTER CLOCKWISE From Fail Position Positioner Sensor Triangle Faces the Conduit Entry Side With The Conduit Entry Mounting Assembly Actuator In Fail Position Drive Insert TURNS CLOCKWISE From Fail Position Figure 2 2 Rev G 04 20 01 tech 251 DWO11819 Page 6 of 33 2 3 Wiring the Remote Sensor to the Positioner Mount positioner at a remote location wire the positioner sensor back to the positioner using the cable provided See Figure 2 3 Positioner Mounted Remote from Actuator at Users Discretion Position Sensor Mounted on Actua
17. e is opened or closed in 5 increments via the keypad In Slow move mode the valve is opened or closed slowly via the keypad This function sets the valve to the fully energized position via the keypad Outlet Port 1 Supply psi amp Outlet Port 2 0 psi This function places the positioner in digital control mode input current independent and therefor allows override of the control signal This function sets the valve to the fully denergized position via the keypad Outlet Port 1 0 psi amp Outlet Port 2 Supply psi This function places the positioner in digital control mode input current independent and therefor allows override of the control signal Rev G 04 20 01 tech 251 DWO11819 Page 16 of 33 Section 4 Trouble Shooting 4 1 Preliminary Checks Before operating the positioner check the following 1 Voltage The positioner requires a 24 volt DC nominal 4 20 mA current loop 2 Electrical Connection Check the polarity of the 4 20 mA current loop The SmartCal terminal strip visually designates the positive and negative terminal points for connection with a and respectively 3 Pneumatic Connection Single Acting Output port 1 should be piped to drive the actuator away from the valves fail posi tion Output port 2 should be plugged See Section 2 4 Double Acting Outport port 1 should be piped to drive the actuator away from the valves fail position Output port 2 should be piped to drive the actuat
18. e lan a a as ieee ain 17 4 2 COMMON 18 Section 5 19 Section 6 Error 20 Section 7 Exploded Parts 21 Section 8 Product 21 Section 9 DIMENSIONS secs geen ccs oe eta ances oa cama ne 22 Appendices Procedure to Adjust Err 3 SOW ic 23 Procedure to Remove Display Board amp Electronic 24 Procedure to Check transducer 25 D Grounding 26 Pneumatic Manifold DiaQrain 27 F Control Schematic for Wiring of Intrinsically Safe 28 31 Procedure to Reset the EEprom to Factory 32 H Hart Communicator Menu Flow Chaft ccccccccccccssessecsscsecssessecescseeseecaesaseaeenes 33 Rev G 04 20 01 tech 251 DWO11819 Page 2 of 33 Section 1 Introduction 1 1 Description of SmartCal Positioner The SmartCal Valve Positioner is an electro pneumatic servo system that continuously controls the
19. ed transmitter output typically 4 0 mA for zero and 20 0 mA for span The positioner then calculates the difference between the present and the desired output currents for zero and span and uses the dif ferential to adjust the transmitter accordingly This function allows for the setting of the flow characteristic of the positioner not to be con fused with the flow characteristic of the valve The options are Lin Linear EP Equal Percentage and Opn Quick Opening A Lin Linear positioner characteristic duplicates the inherent characteristic of the valve and is the most often used setting This function configures the positioner for the type of valve The options are rot Rotary and lin Linear This setting needs to be done in order to configure the posi tioner to recognize the type of magnetic feedback being given to the positioner This function allows the user to configure the positioner to match the failure method of the valve actuator The options are off or The option is for fail closed applications and the option is for fail open application When off is chosen the LCD will read 0 at the zero Lo Calibration and 100 at the span Hi Calibration When on is chosen the LCD will read 100 at the zero Lo Calibration and 0 at the span Hi Calibration Rev G 04 20 01 tech 251 DWO11819 Page 15 of 33 OPSP CLSP EDb Adjs OP CLs This function allows for the s
20. etting of the opening speed of the actuator valve The range is 1 thru 5 Setting 5 is the fastest opening speed and setting 1 is the slowest opening speed Setting Approx Dynamic Speed 5 100 4 80 3 60 2 40 1 20 This function allows for the setting of the closing speed of the actuator valve The range is 1 thru 5 Setting 5 is the fastest closing speed and setting 1 is the slowest closing speed Setting Approx Dynamic Speed 5 100 4 80 3 60 2 40 1 20 Thisfeature configures the positioner s operating deadband Theconfiguration options are off and The positioner is factory set as off When the deadband feature is off it oper ates with nominal value of 0 3 of full scale for deadband When the feature is turned the deadband can be set using the up and down arrow buttons to a value from 1 to 20 The value 1 lowest deadband when turned has a deadband range of 1 which is equivalent to a deadband of 0 5 The value 20 highest deadband value has a range of 20 which is equivalent to a deadband of 10 This function allows for the adjustment of the positioner to any position via the keypad This function places the positioner in digital control mode input current independent and therefor allows override of the control signal Within this function there are Fast and Slow move modes In Fast move mode the valv
21. he ROSEMOUNT 275 HART COMMUNICATOR is connected between the associated apparatus and the SmartCal cable inductance should be determined in accordance with ROSEMOUNT installation drawing 00275 0081 2 Associated apparatus manufacturer s installation drawing must be followed when installing this equipment 3 In cases where the ROSEMOUNT 275 HART COMMUNICATOR is connected between the associated apparatus and the SmartCal ROSEMOUNT installation drawing 00275 0081 must be followed when installing this equipment 4 Control equipment connected to associated apparatus must not use or generate more than 250V 5 To maintain intrinsic safety each field wiring pair 4 20 mA and Analog Output must be run in separate cables or separate shields connected to intrinsically safe Associated Apparatus ground 6 ROSEMOUNT 275 HART COMMUNICATOR is NOT FMRC approved for use in Class II and Hazardous Locations 7 For Class and locations where rigid metal conduit is not used seal SmartCal cable entries against dust and fibers using an appropriate NRTL listed cable gland fitting 8 Installation should be in accordance with RP12 6 and the National Electrical Code ANSI NFPA 70 9 ROSEMOUNT 275 HART COMMUNICATOR not used with Model 4100 Rev G 04 20 01 tech 251 DWO11819 Page 28 of 33 Appendix F Control Schematic for Wiring of Intrinsically Safe Positioner Sheet of 2 of 4 HAZARDOUS LOCATION CLASS I
22. he gain setting The sensor calibration is a self adjustment that sets the positoners Hall Effect circuitry This is automatically done during the ACAL Automatic Calibration routine The sensor cali bration also shows up under the MCAL menu This calibration only needs to be performed under the MCAL routine when the positioner is set up on a new application and only if the ACAL routine is not performed The purpose of this function is to calibrate the positioner s transducer The transducer is calibrated on all new positioners at the factory therefor this procedure does not need to be performed for a new positioner Perform this calibration function only if a replacement trans ducer or electronic canister was installed in the positioner This routine calibrates the positioner s electronics to recognizing input current This is done using 4 0 mA and 20 0 mA as reference points If exactly 4 0 mA or 20 0 mA can not be given as inputs the user can adjust the positioners values to the input using the arrow but tons This routine calibrates the positioner s transmitter The transmitter calibration does not require the user to change the input current although it does require the user to be able to read the transmitter s value in mA For each the zero and span the user is first prompted to enter the value that the transmitter is presently at This is done by using the up and down arrow buttons The user is then prompted to enter the desir
23. ilot Air Port 2 Assembly Rev 04 20 01 tech 251 DWO11819 Page 27 of 33 Appendix F Control Schematic for Wiring of Intrinsically Safe Positioner Sheet 1 of 4 HAZARDOUS LOCATION NONHAZARDOUS LOCATION CLASS I DIV 1 GROUPS A B C D CLASS DIV 1 GROUPS E F G CLASS DIV 1 ROSEMOUNT 275 HART COMMUNICATOR NOTES 3 6 amp 9 REMOTE HALL EFFECT SENSOR OPTIONAL No 5 IN 4TH DIGIT OF PART NUMBER 50 FT MAX LENGTH 5 CONDUCTOR 22 AWG CABLE PROVIDED WITH ASSOCIATED APPARATUS INTRINSIC SAFETY SmartCal SERIES BARRIERS NOTES 1 amp 2 POSITIONER CONTROL EQUIPMENT 4 3 5 5 L ANALOG OUTPUT L OPTION Entity parameters for each field wiring terminal pair of SmartCal Vmax 30 Imax 100mA Ci 120 pF Li OmH 1 FMRC Entity approved associated apparatus used in an approved configuration such that A SmartCal Vmax 2 Voc and Vt of associated apparatus B SmartCal Imax 2 Isc and It of associated apparatus C Ci of SmartCal Ci of ROSEMOUNT 275 HART COMMUNICATOR if used cable capacitance lt Ca of associated apparatus D In cases where the ROSEMOUNT 275 HART COMMUNICATOR is not connected between the associated apparatus and the SmartCal Li of SmartCal cable inductance lt La of associated apparatus E In cases where t
24. ions Input Signal Voltage Pressure Output Flow Rate Pressure Actuator Technical Resolution Linearity Hysteresis Repeatability Operating Temp Thermal Coefficient Air Consumption Rev G 04 20 01 4 to 20 mA two wire 12 3 Volts DC 15 45 psi Low 40 120 psi High 8 0 scfm 25 psi Low 16 2 scfm 90 psi High 0 to 45 psi Low 0 to 120 psi High Single Acting or Double Acting 2 Full Travel 5 Full Scale Rotary 1 Full Scale Linear 2 Full Scale 2 Over One Hour 40 85 40 F to 185 2 100 30 scfm 25 psi Low 71 scfm 90 psi High Hazardous Rating Stroke Position Feedback Diagnostics Enclosure Material Class of Equipment Weight Air Connections Conduit Connection Approvals tech 251 DWO11819 Non Incendive Class I Division 2 Groups A B C D Class II Division 2 Groups F G Class III Division 2 Intrinsically Safe Class I Division 1 Groups A B C D Class II Division 1 Groups E F G Class III Division 1 EEx ib 0 to 95 Degrees Magnetic Non Contact HART Protocol Software Utilizing HART Protocol Engineered Resin NEMA type 4 7 2 Pounds 1 4 NPT 1 2 NPT FM CSA Page 19 of 33 Section 6 Error Codes Err 3 Error 3 Low Input Pressure or Clogged Filter Err 5 Error 5 Intergrator Overflow Position of actuator does not match setpoint
25. ition and set point as shown on the LCD does not match the input signal e The flow characteristic during calibration was set to equal percentage or quick open ing not linear If linear is desired enter calibration and make this change See Cal ibration Instructions section 3 5 After removing power to the positioner there is full pressure to output port 1 and zero pressure to output port 2 e On loss of power the positioner fails full air pressure to output port 2 If this does not happen the positioner is damaged Contact factory Rev G 04 20 01 tech 251 DWO11819 6 An Err 6 Calibration Error is returned during a Lo or Hi Calibration e In the case of a rotary application the bea con may be mis oriented e In the case of a rotary application the actuator may not have enough rotation The positioner requires the actuator to stroke a minimum of 45 degrees 7 An Err 5 Integrator Overflow message is shown on the display e This messages indicates a deviation between position and set point This error message does not clear itself after the problem ceases therefore try clearing the message This can be accomplished by entering then exiting calibration See sec tion 3 e Ifthe Err 5 returns make sure all the pre liminary checks as described earlier in this section have been made If still the cause for the Err 5 can not be diagnosed call the factory for help Page 18 of 33 Section 5 Specificat
26. n in separate cables or ROSEMOUNT 275 HART COMMUNICATOR is NOT FMRC approved for use in Class and Hazardous For Class and locations where rigid metal conduit is not used seal SmartCal cable entries against dust and Installation should be in accordance with ANSI ISA RP12 6 and the National Electrical Code ANSI NFPA 70 ROSEMOUNT 275 HART COMMUNICATOR not used or used only on the INPUT side of associated apparatus Rev G 04 20 01 tech 251 DWO11819 Page 29 of 33 Appendix F Control Schematic for Wiring of Intrinsically Safe Positioner Sheet of 3 of 4 HAZARDOUS LOCATION NONHAZARDOUS LOCATION CLASS I DIV 1 GROUPS A B C D CLASS II DIV 1 GROUPS E F G CLASS MI DIV 1 ASSOCIATED APPARATUS ROSEMOUNT 275 HART INTRINSIC SAFETY COMMUNICATOR NOTE 4 BARRIERS MTL MODEL 3045 NOTE 1 MTL MODEL 7087 FOR DIGITAL ON OFF INPUTS SmartCal SERIES POSITIONER I 3 1 CONTROL 2 EQUIPMENT NOTES L NOTE 2 3 1 ANALOG OUTPUT 4 2 4 1 oe 5 2 MAGNUM SWITCH OPTION 4 1 5 2 1 Associated apparatus manufacturer s installation drawing must be followed when installing this equipment 2 Control equipment connected to associated apparatus must not use or generate more than 250V 3 To maintain intrinsic safety each field wiring pair 4 20 mA an
27. ns allow display speed and valve characteristic changes from standard factory set tings Menu 4 Stro Manual Override of Input Signal Entering 1 this menu allows you access to the following three stroking functions via the keypad Adjs Adjustment of Positioner to Any Position Using Keypad Arrows 2 OP Open Sets the Valve to the Full Open Position 3 CLs Close Sets the Valve to the Full Closed Position These functions set the positioner to digital control mode input current independent and therefore allow override of the control signal 3 8 Description of Functions LO HI This function serves to set the fail position of the actuator valve Initially during this calibra tion the valve is driven to the fail position hard stop The user will notice full pressure to Outlet Port 2 and zero pressure to Outlet Port 1 After a short period of time pressure will increase in Outlet Port 1 and the valve will be driven to the fully energized position and then back to the fail position After approximately 30 seconds pressure will again increase in Out let Port 1 and the valve will be driven off of the hard stop approx 10 of full travel and then driven back to the hard stop The calibration is making note of the torques required to fully seat and un seat the valve from the hard stop At this point the user has the option to select the hard stop as low zero position or to select an arbitrary position as low zero posi
28. olt DC power supply 5 After all connections have been made recon nect the terminal strip and replace positioner Slide Off Terminal Strip cover from Keypad assembly 000000000000000000000 ANALOG INPUT _ ANALOG OUTPUT CIIXIIIIXIIIIIIIIIIII DISPLAY BOARD Figure 2 5 Rev G 04 20 01 tech 251 DWO11819 Page 9 of 33 Section 3 Calibration If during the calibration routine you need more information describing any of the menus or functions refer to Sec tions 3 7 and 3 8 The SmartCal positioners also has an on board help menu that can be accessed by pressing the Cal button and either arrow button simultaneously anytime during calibration 3 1 Enter Calibration Menu Level Enter the calibration routine by pressing and holding the CAL button Continue to hold the CAL button until ACAL appears on the LCD ACAL Auto Cal Menu is the first of four menus By pressing the down arrow button you can cycle through the four menus The remaining three menus are MCAL Manual Cal Menu Cofg Configuration Menu Stro Manual Position Override Menu The menu level is shown below Normal Operation Displayed on LCD Pr re I
29. on HART Protocol The SmartCal positioner responds to HART commands for seeking the valve closed position and assigns an instrument signal of 4 mA to this position The counterpart of the operation for a full open state is implemented next by setting the span value Action reversal is also configured Additionally provisions are made for altering internal servo loop tuning via the HART link In this manner positioner performance may be optimized with a wide combination of valves and actua tors Rev G 04 20 01 tech 251 DWO11819 Page 4 of 33 Section 2 Initial Setup 2 1 Mounting Positioner on a Rotary Actuator Condition 1 Actuator fails in a clockwise direction Turns counter clockwise from fail position Spring Return Output Port 2 is plugged Output Port 1 is piped to turn the actuator counter clockwise Double Acting Output Port 2 is piped to turn the actuator clock wise Output Port 1 is piped to turn the actuator counter clockwise Condition 2 Actuator fails in a counter clockwise direction Turns clockwise from fail position Spring Return Output Port 2 is plugged Output Port 1 is piped to turn the actuator clock wise Double Acting Output Port 2 is piped to turn the actuator counter clockwise Output Port 1 is piped to turn the actuator clock wise Note 1 Drive insert must be provided with Keystone Tyco actuators for ModMount installations 2 Drive insert may need to be di
30. or towards the valves fail position See Section 2 4 4 Magnetic feedback to the Positioner The magnetic beacon should be set in the proper orientation based on the direction of failure See Section 2 1 or 2 2 Rev G 04 20 01 tech 251 DWO11819 Page 17 of 33 5 Supply Pressure The supply pressure should be regulated appropriately with regard to the actuator If there is ques tion as to the proper supply pressure the actuator manufacturer should be contacted 4 2 Common Problems Listed here are some common problems encountered with the SmartCal positioner Possible causes are given and steps to help rectify the problem are offered 1 The LCD remains blank even after power is applied to the positioner e The positioner should be given a mini mum of 14 VDC The voltage across the positioner can be checked by removing the cover and connecting a voltmeter across TP1 and TP2 on the display board 2 The positioner has power but the position as shown on the LCD does not seem to match the actual position of the actuator valve e May need to be calibrated Beacon may be mis oriented 3 The positioner is properly set up and air is applied to the positioner When powering up the positioner the actuator goes into a state of constant oscillation e The gain settings are to high for the actua tor valve assembly Enter the calibration mode and reduce the PCAL ICAL and DCAL settings 4 After a successful calibration pos
31. ot On ee eli Quick Rotary Fail Use UP Opening Valve Open amp Down Arrows Dawa to Adjust CAL Down Down IDeadband gt CAL CAL EP CAL Equal Percentag Down CAL Rev G 04 20 01 tech 251 DWO11819 Page 10 of 33 3 3 Automatic Calibration The Automatic Calibration ACAL performs several self adjustments as well as a zero calibration a span calibration and tunes the positioners PID gain settings Enter and start the Automatic Calibration from the Menu level From the menu level press the down arrow button until ACAL is shown on the display ACAL Routine Shown Below Up Arrow Exit Calibration Down Arrow gt To Next Menu Down Arrow From Previous Menu gt AC AL Auto Calibrate 1 Sensor Cal 2 Trnd 3 Lo 4 Hi 5 Auto PID 3 4 Proceed to Exiting Calibration or Perform Advanced Calibration At this point the calibration of the positioner is complete The Automatic Calibration that was performed in Section 3 3 is adequate for most applications If no advanced calibration is required proceed to Section 3 5 to exit calibration If the user requires to use the advanced settings to fine tune the positioner he may pro ceed with the remainder of this step and perform adjustments and calibrations in the Manual Calibration Menu MCAL From the menu level press the down arrow button until MCAL is shown on the display MCAL Routine shown below Up Arrow Exit Calibration
32. s 4 Connect positive lead of the signal generator to Pin 2 and connect negative lead to Pin 4 Note Make sure power on the signal generator is turned off before connecting it to the pins Note Make sure the two leads are not shorting by both coming in contact with Pin 3 5 Turn on the 4 20 mA signal generator Note The transducer operates between 0 and 3 3 mA Therefore make sure when turn ing on the current supply s power the current is turned down within this range Applying a current greater then 3 3 mA can damage the transducer 6 Apply the supply air to the positioner 7 The transducer consists of a spool that will channel air between the two output ports of the positioner As the current is raised air is removed from Output Port 2 and applied to Out put Port 1 of the positioner 8 To check the operation of the positioner raise and lower the current between 0 and 4 mA This should allow you to open and close the actuator You should also be able to control the position of the actuator by adjusting the current supply at an intermediary idle current somewhere between 0 and 3 3 mA To Pin 2 Red To Pin 4 Black 4 20 mA Signal Generator Do Not Exceed 3 3 mA Rev G 04 20 01 tech 251 DWO11819 Page 25 of 33 Appendix D Grounding Schematic TO HPORT MUX HART INTERFACE AA 2 gt gt SmartCal PLC OR DCS POSITIONER V TWISTED SHIELD
33. sengaged and rotated 90 to allow for proper mounting Port 1 Port 2 4 Supply Semi Circle Faces The Front of the Positioner a Actuator Drive Fail Position TURNS COUNTER CLOCKWISE From Fail Position Triangle Faces the _ Front of the 22 ModMount Positioner l di Actuator Drive In Fail Position 1 4 gt TURNS CLOCKWISE From Fail Position Figure 2 1 Rev G 04 20 01 tech 251 DWO11819 Page 5 of 33 2 2 Mounting Remote Positioner on a Rotary Actuator Condition 1 Actuator fails in a clockwise direction Turns counter clockwise from fail position Spring Return Output Port 2 is plugged Output Port 1 is piped to turn the actuator counter clockwise Double Acting Output Port 2 is piped to turn the actuator clock wise Output Port 1 is piped to turn the actuator counter clockwise Condition 2 Actuator fails in a counter clockwise direction Turns clockwise from fail position Spring Return Output Port 2 is plugged Output Port 1 is piped to turn the actuator clock wis
34. t Arbitrary Select Arbitrary Press CAL Key Zero Using Up Span Using Up Press CAL Key Read Transmitter amp Down Arrow amp Down Arrow ICAL Value amp Use Keys Up amp Down Keys Adjust using Arrows to Enter The Up amp Down Present Span Value T Arrow Keys Press CAL Key L p Press CAL Key Press CAL Key 1 5 When Complete When Complete T Press CAL Key Use Up amp Down Arrows to Enter DCAL the Desired Span Adjust using Current Typically Up amp Down 200 T Arrow Keys Press CAL Key 1 20 When Complete Press CAL Key When Complete Rev G 04 20 01 tech 251 DWO11819 Page 11 of 33 3 5 Exiting Calibration To exit calibration mode and return to normal operation use the up arrow key as follows If the positioner is at Menu level in the calibration as determined by LCD displaying a Menu name only MCAL etc press the up arrow key once to exit CAL mode If the positioner is at function level the calibration as determined by LCD displaying a function and Menu name only MCAL Lo etc press the up arrow key once to enter the Menu level and once more to exit CAL mode e When the calibration mode is exited the Menu and function names will no longer be dis played by the LCD The LCD will be displayed Exiting can not be done during a calibration procedure When a calibration function is initiated the user must wait until the function s cali
35. tion Menu 4 Stro Manual Override of Input Signal Menu desciptions are as follows Menu 1 ACAL Automatic Calibration Entering this menu allows you to initiate an approximately seven minute self calibration function The SmartCal positioner will automatically enter digital control mode and perform a shallow input current independent calibration in the following sequence Function Snsr Sensor Calibration Trnd Transducer Calibration Lo Low Zero Calibration Hi High Span Calibration Auto Automatic PID Tuning Menu 2 MCAL Manual Calibration Entering this menu allows you access to the following four calibration functions via the keypad Lo Low Zero Calibration Hi High Span Calibration PID Proportional Integral and Derivative Gain Adjustment Snsr Sensor Calibration Trnd Transducer Calibration Milliampere Calibration Xmr Transmitter Calibration NOOR WD Rev G 04 20 01 tech 251 DWO11819 Page 13 of 33 Menu 3 Cofg Configuration Entering this menu allows you access to the following five configuration functions via the keypad Flow Positioner Output Flow Characteristics Positioner Recognition of Magnetic Feedback Rotary or Linear Flop Positioner Fail Position Open or Closed OPSP Positioner Opening Speed Adjustment CLSP Positioner Opening Speed Adjustment These functio
36. tion This function serves to set the fully energized full travel position of the actuator valve ini tially during this calibration the valve is driven to the fully energized full travel position hard stop The user will notice full pressure to Outlet Port 1 and zero pressure to Outlet Port 2 After a short period of time pressure will increase in Outlet Port 2 and will be driven off of the hard stop approx 10 of full travel and then driven back to the hard stop The calibration is making note of the torques required to fully seat and un seat the valve from a hard stop At this point the user has the option to select the hard stop as the high span position or to select an arbitrary position as the high span position Rev G 04 20 01 tech 251 DWO11819 Page 14 of 33 PID Snsr trnd mA Xmr Flow Type FLOP The PID function allows the user to enter or change the PID settings of the positioner This function is most often used to fine tune the PID values obtained from the automatic calibra tion function ACAL This function will allow the user to optimize the dynamic response of the positioner with respect to speed of response overshoot and percent error by varying the appropriate gain settings The Proportional PCAL and Derivative DCAL gain settings can be varied incrementally on a scale from 1 20 The Integral ICAL gain setting can be varied incrementally on a scale from 1 5 The larger the number the higher t
37. tor as Described in Section 2 2 1 2 Actuator F Top View 4 Conductor Cable Cut to Required Length and Run Through Conduit A 4 Conductor Shielded Cable 8 5 SHIELD YELLOW BLACK S oneen SENSOR O 2 RED WHITE Pin Connector To Display Board of Positioner Positioner Sensor Wiring Schematic Figure 2 3 Rev G 04 20 01 tech 251 DWO11819 3 4 NPT F Page 7 of 33 2 4 Pneumatic Connection Single Acting Actuator Spring Return actuator away from the fail position Increas For single acting actuators Outlet Port 2 is to ing signal causes pressure to increase in Outlet be plugged Outlet Port 1 is to be piped Port 1 of the positioner and pressure to actuator inlet port that acts against the decrease in Outlet Port 2 of the positioner spring Increasing signal causes pressure to increase in Outlet Port 1 of the positioner Note Air supply to the positioner must be clean dry oil free instrument air per ISA S7 3 Double Acting Actuator Double Return Maximum suppl
38. vanced functions such as early warning diagnostics and fugitive emissions monitoring The SmartCal positioner provides intelligence for the control valve through a microprocessor based diagnostic system utilizing the HART protocol Accurate measurement of valve stem position input signal actuator pressure and travel time can be recorded during normal oper ation thereby providing information for control valve signature generation Non Contact Position Feedback To provide consistently accurate performance information all linkages levers and connect ing rods from the positioner to the control valve have been eliminated from the design Valve position sensing is performed totally by non contacting means based upon characterization of flux strength as a function of position Remote Position Control Since valve position feedback to the SmartCal positioner is accomplished by non contacting means the SmartCal has the unique ability to be mounted remotely up to a distance of 50 feet from the device it is controlling In the event the control valve is located in either a high vibra tion or extremely corrosive environment the non contact position feedback feature allows for isolated placement of the positioner Local Keypad All SmartCal positioners are provided with a 3 button membrane keypad The keypad is pro vided for zero and span adjustments as well as valve characterization and gain adjustments Intelligent Calibrati
39. y pressure is 120 psi All For double acting actuators Outlet Port 2 is pneumatic connections are 1 4 NPT piped to drive the actuator towards the fail position Outlet Port 1 is piped to drive the PA So Outlet Port 1 Inlet Port Outlet Port 2 227 Inlet Port C Gage cules Port 2 Gage Om Mn Quet Port 1 Gage 1 Single Acting Spring Return Plug Outlet Port 2 increas ing signal causes pressure to increase in Outlet Port 1 2 Double Acting Double Return Pipe Outlet Port 2 to drive actuator towards the desired failure direction increasing signal causes pressure to decrease in Outlet Port 2 and pressure to increase in Outlet Port 1 Notes 1 On loss of power pressure fails to Outlet Port 2 Figure 2 4 Rev G 04 20 01 tech 251 DW011819 Page 8 of 33 2 5 Electrical Connection Remove positioner cover 2 Locate terminal strip and carefully disconnect slide off 3 Connect the 4 to 20 mA loop signal to termi nal points marked and See figure 2 5 for a wiring schematic 4 If using the analog transmitter connect out put wiring to terminal points 5 amp 6 Polari ties Shown Below The 4 to 20mA analog output requires an external 24 v
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