Foundation Fieldbus FF-01 Option Card Installation Manual

Foundation Fieldbus FF-01 Option Card Installation Manual
Foundation Fieldbus
FF-01 Option Card
Installation Manual
Publication S179E
Issue 07/03
Foundation Fieldbus FF-01 Installation manual
Note 1:
Throughout this manual the Foundation FF-01 may simply be referred to as the module.
Note 2:
The information in this manual relates to the following firmware releases
For ITK3
V1.07 for the FB302 round card from Smar
44596-01 for the Interface card
For ITK4
V1.10 or higher for the FB302 round card from Smar
44596-02 for the Interface card
Note 3:
The FF-01 module described in this manual is only suitable for inclusion in Rotork IQ , IQT, AQ
and Q actuators.
As we are continually developing our products their design is subject to change without notice.
© The contents of this document are copyright and must not be reproduced without the written
permission of Rotork Controls Ltd.
The name Rotork is a registered trademark
Foundation is a registered trademark by Fieldbus Foundation
Windows is a registered trademark by Microsoft Corporation
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Contents
Contents
Glossary of Terms:............................................................................................................................5
Abbreviations: ...................................................................................................................................5
1
INTRODUCTION................................................................................................ 7
1.1
2
General .....................................................................................................................................8
FOUNDATION FIELDBUS FF-01 MODULE PROPERTIES ............................. 9
2.1
2.2
2.3
3
Mechanical properties ............................................................................................................9
Electrical Properties .............................................................................................................10
Operation and Storage .........................................................................................................10
FITTING THE FF-01 MODULE ........................................................................ 11
3.1
3.2
3.3
4
Inside an IQ/IQT actuator......................................................................................................11
Inside an AQ or Q actuator ..................................................................................................12
Replacing or Fitting a Foundation FF-01 Module ..............................................................13
IEC 61158 DATA HIGHWAY AND CONNECTIONS....................................... 15
4.1
4.2
4.3
5
Data Highway.........................................................................................................................15
Fieldbus Power Supply.........................................................................................................16
Termination Network ............................................................................................................17
THE ACTUATOR INPUT AND OUTPUT SIGNALS........................................ 19
5.1
Controls..................................................................................................................................19
5.1.1 Controls Priority .................................................................................................................22
5.1.2 The IQ ‘S’ contacts.............................................................................................................22
5.2 Actuator Status Feedback (Foundation).............................................................................23
5.3 Actuator Alarm Feedback (Foundation) .............................................................................25
5.4 Analogue Feedback Data (Foundation) ..............................................................................27
5.5 Actuator Feedback Data (Hard Wired) ................................................................................27
6
FUNCTION BLOCKS ...................................................................................... 29
6.1
6.2
6.3
6.4
6.5
Resource Block .....................................................................................................................30
Analogue Input Blocks .........................................................................................................30
Digital Input Blocks...............................................................................................................31
Analogue Output Block ........................................................................................................32
Digital Output Blocks............................................................................................................33
6.5.1 Control Source for DO 1 and DO 2 ....................................................................................34
6.5.2 DO 3, ESD Action ..............................................................................................................35
6.5.3 DO 4, Interlock (AQ/Q only) ...............................................................................................35
6.5.4 DO 5 to DO 8, Relay R5 to R8 outputs (IQ/IQT only) ........................................................36
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6.6
6.7
7
PID Control Block – Not Available in ITK4 version 1.10 or higher ...................................36
Transducer Block..................................................................................................................37
6.7.1 Valve Codes ........................................................................................................................45
LINK ACTIVE SCHEDULER ........................................................................... 51
7.1
7.2
8.
Creating a Schedule..............................................................................................................52
Connecting the Blocks .........................................................................................................52
SETTING UP THE FF-01 MODULE ................................................................ 53
8.1
8.2
8.3
8.2
8.3
Setting Digital Control ..........................................................................................................53
Setting Analogue Control.....................................................................................................54
Mixed Digital and Analogue Control ..................................................................................54
Controlling Digital Inputs .....................................................................................................55
Controlling the IQ/IQT Actuator Relays (DO5 to DO8) ......................................................55
8.3.1 Relay Source......................................................................................................................55
8.3.2 Relay Trigger......................................................................................................................56
8.3.3 Relay View .........................................................................................................................56
8.4 Hard-wired Input Monitoring and Control...........................................................................56
8.4.1 Aux Input Function .............................................................................................................56
8.4.2 Aux Input Condition............................................................................................................56
8.5 Viewing the Actuator Status ................................................................................................57
8.5.1 Analogue Position and Torque Data..................................................................................57
8.5.2 Digital Command and Status Readback data....................................................................57
8.5.3 Actuator Condition Report..................................................................................................58
9
UPDATING THE FF-01 FIRMWARE ............................................................... 59
9.1
9.2
9.3
9.4
9.5
10
Remove the FF-01 from the Actuator..................................................................................59
Connect the FF-01 to the PC and Power Supply ...............................................................59
Downloading the SMAR Firmware ......................................................................................61
Updating the COP8 Firmware ..............................................................................................63
Re-assemble the Actuator....................................................................................................64
DEVICE DESCRIPTION FILES ....................................................................... 65
10.1 ITK3 DD Files .........................................................................................................................65
10.2 ITK4 DD Files .........................................................................................................................65
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Contents
Glossary of Terms:
Capabilities File
A file describing the communication objects in a fieldbus device. A
configuration device can use Device Description (DD) Files and
Capabilities Files to configure a fieldbus system without having the
fieldbus devices online.
Device Description (DD)
A file that provides an extended description of each object in the
Virtual Field Device (VFD), and includes information needed for a
control system or host to understand the meaning of data in the VFD.
Fieldbus
The digital, two-way, multi-drop communication links.
Field Unit
The FF-01 card fitted to the actuator
H1
A term used to describe a fieldbus network operating at 31.25
kbit/second.
Interoperability
The capability for a device from one manufacturer to interact with that
of another manufacturer, on a fieldbus network, without loss of
functionality
Link Active Scheduler (LAS)
A deterministic, centralised bus scheduler that maintains a list of
transmission times for all data buffers in all devices that need to be
cyclically transmitted. One Link Master (LM) device functions as the
fieldbus LAS at any one time.
Schedules
Define when Function Blocks (FBs) execute and when data and status
is published on the bus.
Segment
A section of an H1 fieldbus that is terminated in its characteristic
impedance. Segments can be linked by Repeaters to form a longer
H1 fieldbus. Each Segment can include up to 32 H1 devices.
Standard Function Block (FB) These are built into fieldbus devices to achieve the desired control
functionality. The FF-01 has Analogue Input (AI), Analogue Output
(AO), Digital Input (DI), Digital Output (DO) and PID control.
Transducer Block (TB)
These blocks decouple Function Blocks (FBs) from the local
input/output (I/O) functions required to read the limit switches and
command the actuator to move.
Virtual Communication Relationship (VCR) Configured application layer channels that provide for the
transfer of data between applications.
Virtual Field Device (VFD)
A VFD is used to remotely view local device data described in the
object dictionary.
Abbreviations:
Comms
FB
FF
FU
LAS
RAM
ROM
SW
TB
Communications
Function Block
Foundation Fieldbus
Field Unit
Link Active Scheduler
Random Access Memory
Read Only Memory
Software
Transducer Block
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Introduction
1
INTRODUCTION
The Rotork FF-01 Foundation Fieldbus Module conforms to the open fieldbus standard IEC 61158. It
is suitable for use on an H1 highway and uses two copper wires for connection to the highway. It is
necessary to have a suitable power supply and termination filter on the highway for the FF-01 to
function.
The current version of the FF-01 card assembly may be fitted into the IQ, IQT, AQ or Q only. The FF01 module is an integral part of the actuator in which it is housed. The module is fitted within the main
double sealed electrical housing. This electrical housing need never be opened once the actuator
leaves the assembly plant. All adjustments to the settings for the FF-01module may be made via
Foundation data highway using a suitable network configuration tool. There is no external marking on
the actuator to show the FF-01 serial number since the module may be replaced if it should fail.
The FF-01 circuits do not impinge on the actuator control electronics; the actuator itself remains fully
self-protecting. The module performs the tasks of IEC 61158 interface, actuator data collection and the
issuing of actuator commands.
The FF-01 may command the actuator into which it is fitted to open, stop, close, perform an ESD
operation or move to a set position. Commands to the module come from the network and may be
generated in another actuator or device on the network using peer to peer, consumer/producer
communication. Additionally, digital and analogue status information relating to the actuator is
published for the other devices to read.
Electrical
Compartment
Motor
Handwheel
IQ range
Local Controls
Terminal Cover
Electrical
Compartment
Electrical
Compartment
Local Controls
Local Controls
Terminal Cover
IQT range
Handwheel
AQ range
Electrical
Compartment
Terminal Cover
Q range
Fig 1: The FF-01 Actuator Compatibility
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Foundation Fieldbus FF-01 Installation manual
Supporting Documents from the Fieldbus Foundation, Austin Texas:
Technical Overview of Foundation Fieldbus
Wiring and Installation 31.25 kbit/s,
Voltage Mode, Wire Medium
FD-043
AG-140
1.1 General
The FF-01 module is capable of performing the following functions –
a)
b)
Link Master
Link Active Scheduler
The in-built function blocks vary in availability between the different actuator types. The input and
output blocks are used to link to the transducer block and tie to the available actuator functions. For
example the AI block associated with actuator torque measurement is not available in the Q and AQ
actuators. The following table lists the function blocks and their related availability in each actuator
type. In the case of the PID block this is only available in the ITK3 version of the product. The ITK4
version does not include PID.
Function Block
IQ actuator
IQT actuator
AQ actuator
Q actuator
*
*
*
*
Digital Inputs
DI 1 (variable)
DI 2 (variable)
Digital Outputs
DO 1 Open
DO 2 Close
DO 3 ESD
DO 4 Interlock
DO 5 Relay 1
DO 6 Relay 2
DO 7 Relay 3
DO 8 Relay 4
Analogue Inputs
AI 1 Position
AI 2 Torque
Analogue Output
AO 1 Desired position
PID *
PID 1 3 term controller
* The PID block is not available in the ITK4 version of the FF-01. Consult Rotork for further details.
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FF-01 Module Properties
2
FOUNDATION FIELDBUS FF-01 MODULE PROPERTIES
2.1 Mechanical properties
The FF-01 module comprises two printed circuit boards that fit together and the assembly is fitted
inside the actuator electrical housing.
Round Card -
The circular printed circuit board (manufactured by SMAR) carries the
Foundation fieldbus highway connections and the processor handling
the data highway communication and function blocks.
Rotork Interface
Card
COP8 processor
with Rotork
software
SMAR Fbboard
(round card)
Fig 2: The FF-01 module showing the round card and Interface board (IQ actuator)
Interface Card
The larger motherboard (manufactured by Rotork) is profiled and
assembled to fit an IQ actuator as shown, or AQ/Q actuator. It carries
the processor for collecting the data from the actuator main board and
passing this data to the round card.
The primary connection to the actuator circuits is by a multipin connector on the Interface Card, which,
due to its physical shape, may only be fitted in the correct polarisation. Internal wiring harnesses
connect to the Interface card for other signals and options within the actuator. The SMAR Fbboard
round card carries the IEC 61158 connector, this couples to the wiring harness routed to the terminal
compartment of the actuator. Power for the SMAR Fbboard round card is taken from the IEC 61158
highway whilst the Interface card is powered from within the actuator.
All the connectors are polarised to prevent incorrect insertion.
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2.2 Electrical Properties
The FF-01 module Interface board connects directly to the main board of the actuator. The FF-01
does not sit in the main control path for the actuator and does not affect the actuator control integrity.
Internally stored programs control the two processors on the module. The software for the SMAR
Fbboard processor can be updated by connecting a suitable test probe and sending the new code
directly to the processor. The software for the Interface card is within the COP8 processor and cannot
be altered except by replacement of the processor chip itself. The Foundation system allows all
settings for the data highway and module communication functions to be held in non-volatile memory
on the SMAR Fbboard.
The IEC 61158 data highway connection on the SMAR round card is fully isolated from the actuator
electronics and the interface card.
2.3 Operation and Storage
The Module is designed to be stored in the actuator and operated within the same environment as the
actuator. The constraints are:
Operating temperature: -40oC to +70oC
Storage temperature:
-50oC to +85o C
Relative Humidity:
5% to 95% (<50oC) non-condensing
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Fitting the FF-01 Module
3
FITTING THE FF-01 MODULE
3.1 Inside an IQ/IQT actuator
The FF-01 module is fitted in the first option board slot inside the IQ or IQT electrical housing using
connection SK6. It is not possible to fit a second option board inside the housing.
The Interface card must be correctly profiled and loaded with the appropriate connectors to match the
IQ or IQT actuator. The illustration (Fig 3) shows the IQ/IQT version of the circuit boards.
SK6
FBBOARD-5
FBBOARD-6
CN2
FF-01
V1.10
FB 101
SK9
SK3
smar
SK4
Fig 3: The FF-01 module profiled for the IQ or IQT actuator
In the case of a IQ and IQT actuator the remote inputs are always present and there is an option to
include relay outputs. The following table shows the wiring harnesses that must be fitted and the
function of each loom for the two types of IQ actuators.
Wiring Harness
CN2 – Data highway connection (current drain 20 mA)
SK3 – Remote Output drive connections
SK9 – Remote Input connections
SK4 – ‘S’ switch setting status connections
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3000/6000
Series WD
Yes
No
Yes
Yes
3300/6300
Series WD
Yes
Yes
Yes
Yes
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3.2 Inside an AQ or Q actuator
The FF-01 is fitted in the option board position in these actuators. Only one option board may be fitted
these actuators at any one time. The necessary internal components must also be present; in this
case a potentiometer must be fitted to the actuator.
The illustration (Fig 4) shows the AQ/Q version of the circuit boards.
PL1
FFB 101
FBBOARD-5
FBBOARD-6
CN2
FF-01
V1.10
SK7
smar
SK5
SK1
Fig 4: The FF-01 module profiled for the AQ and Q actuator
The following table shows the wiring harnesses that must be fitted and the function of each loom for
these types of actuator.
Wiring Harness
AQ
Q
CN2 – Data highway connection (current drain 20 mA)
SK1 – Potentiometer
SK7 – Limit switches
Yes
Yes
Yes
Yes
Yes
Yes
The data highway connector CN2 connects to the actuator terminals.
In addition, when using the FF-01 in an AQ actuator the connection between the actuator main board
and Interface card is to PL1 using a ribbon cable. In a Q actuator there is a direct connection to SK5.
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Fitting the FF-01 Module
3.3 Replacing or Fitting a Foundation FF-01 Module
The FF-01 module can be replaced or fitted only in a suitable environment. The actuator must be
made electrically safe before opening the covers; in the case of an IQ/IQT it is advisable to disconnect
the internal battery. The electrical housing cover should be removed and the existing FF-01 carefully
unplugged from its main connector. Once removed from the main connector the wiring loom
connectors should be removed. The replacement board is fitted in the reverse order to removal. The
wiring harnesses are polarised so that only the correct one will fit its mating part on the circuit board.
If the operation is to fit a module for the first time then the necessary wiring looms must be added to
the internal wiring harness according to the above description. The actuator wiring diagram shows the
connectors and harnesses used. The wiring harnesses are fitted inside the actuator before attempting
to fit the FF-01 module. Once the looms are in place connect them to the module, then fit the module
to the main board connector.
Once the card is fitted the actuator should be re-assembled and the IQ/IQT battery replaced.
The SMAR Fbboard round card can be replaced on its own. The round card connects to the Interface
card using connector SK2. If required the firmware in the SMAR Fbboard can be updated using tools
available from Smar Equipamentos Ind. Ltda. or a subsidiary.
If only one half of the FF-01 module is replaced take care to ensure compatibility between the new and
old part and the firmware versions fitted.
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IEC 61158 Data Highway and Connections
4
IEC 61158 DATA HIGHWAY AND CONNECTIONS
4.1 Data Highway
The Foundation Fieldbus network is based on the IEC 61158 data highway using copper conductors.
The network also carries the power used to supply each node on the network. In the case of the FF-01
device the SMAR round card is powered from the fieldbus network. Only two wires are used for the
data highway and these carry both the data signal and the module power. The actuator Interface card
is powered from the actuator itself and the assembly can only report data when both the data bus and
actuator are powered up.
Fieldbus
Power
Supply
+
2 wire pair
T
Foundation
Interface
Terminator
T
Fig 5: Typical Foundation Data Highway
The data highway must be terminated with proper balancing devices at either end. The highway can
use spur or stub connections to the devices but it is recommended to keep any stub lengths to a
minimum for successful operation. The length of the highway and number of devices connected will
vary from project to project. The standard permits up to 32 devices before a repeater in the highway
must be used. Similarly the standard calls for a maximum segment length of 1900 metres before a
repeater must be used. On a 1900 metre highway the stipulated maximum length for a stub with one
actuator is 120 metres. The data highway cable type is given by the Foundation as ‘type A’, typically
Belden 3076F.
Cable Specification
Type A Cable (e.g. Belden 3076F)
Type
Shielding
Size
Resistance
Nominal Capacitance
2 cores, twisted pair plus overall screen
Minimum 90% copper shielding, braid or foil
18 AWG (0.8 mm2)
24 ohms/km max
80 pF/m
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4.2 Fieldbus Power Supply
The FF-01 module takes power from the Foundation fieldbus data highway. The SMAR round card is
powered by the fieldbus so that the internal function blocks are available for control connection
between devices even when the actuator has no power.
The power is taken from a special DC power supply connected onto the network through a suitable
filter. The power consumption of each Rotork node on the network is 18mA (nominal) and the
absolute minimum voltage at the actuator terminals is 9 volts. The power supply has to contain an
inductive network to prevent attenuation of the fieldbus signal by the low impedance of the power
supply itself. The inductive network in the power pack makes sure that its equivalent impedance is
quite high at the 31.25 kbits/sec frequency whilst still allowing a DC current to be drawn for the line
powered devices.
Since each node on the fieldbus consumes power from the DC supply great care must be taken in the
design of the installation. The design must ensure that the volt drop from the power pack to the
actuator still leaves at least 9V (absolute minimum) for the round card and ideally at least 10V. The
actuators can withstand a maximum voltage of 32V from the power pack and since the current
consumption is virtually constant a simple Ohms law calculation can be used to determine the
potential at each point in the network. On power up the inrush current of the round card will exceed the
nominal by a factor 3.
The Foundation fieldbus wiring guide (AG-140) provides examples of how to calculate the voltage at
each point.
A3
A1
A5
T
I
Fieldbus
Power
Supply
+
-
T
800 m
A2
200 m
200 m
200 m
A4
200 m
A6
200 m
Fig 6: Calculating the Voltage Drop
Example of voltage drop calculation:
Assume the cable is Type A (24 ohm per km per conductor), the resistance of each 1000 metre pair is
24x2 = 48 ohms per km.
The current drawn by each node A1 to A6 is 20 mA.
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IEC 61158 Data Highway and Connections
Voltage drop Power supply to A1 = current x resistance
= (6 x 0.020 ) x (0.8 x 48) = 4.6 volts
Voltage drop A1 to A2 = (5 x 0.020) x (0.2 x 48) = 0.96 volts
Voltage drop A2 to A3 = (4 x 0.020) x (0.2 x 48) = 0.768 volts
Voltage drop A3 to A4 = (3 x 0.020) x (0.2 x 48) = 0.576volts
Voltage drop A4 to A5 = (2 x 0.020) x (0.2 x 48) = 0.384volts
Voltage drop A5 to A6 = (1 x 0.020) x (0.2 x 48) = 0.192volts
Total system volt drop = 4.6 + 0.96 + 0.768 + 0.576 + 0.384 + 0.192 = 7.48 volts
If the power supply is a 24 V unit, then the voltage at actuator A6 will be (24 – 7.48) = 16.52 volts
which is within the specified minimum.
A1
A3
A5
T
I
Fieldbus
Power
Supply
24 V
+
-
T
4.6 V
A2
A4
0.96 V
0. 768 V 0.576 V 0.384 V
A6
0.192 V 16.52 V
Fig 7: Voltage Drop Example
4.3 Termination Network
Each highway must be terminated correctly at the two ends of the data highway. The terminator
comprises at least one resistor and capacitor in series and they provide a characteristic impedance of
100 ohm at 39 kHz. They need not be placed on the absolute ends of the highway but should be on
the ends of the main trunk section.
There are no termination facilities inside the actuator itself.
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The Actuator Input and Output Signals
5
THE ACTUATOR INPUT AND OUTPUT SIGNALS
The FF-01 module provides feedback data about its status and that of the actuator to the Foundation
highway. This data is contained in the Transducer function block and is fully listed in the section on
Function Blocks. The actuator is normally controlled by signals from the Foundation highway
connecting to the Output blocks and the Transducer block. There are local controls on the actuator
itself and there is the possibility to wire in direct contacts to control the movement. This section
explains the primary data available and the meaning of the signals generated by the actuator.
Actuator
FF-01 module
2 x AI
1 x AO
PID*
Transducer
Local
Controls
Data Highway
Interface
Board
Data Link Layer
Actuator
Main Board
Fieldbus Access Sublayer
8 x DO
Fieldbus Message Specification
2x DI
Motor and
Starter
Controls
Resource
* The PID block is not avaialble in ITK4
version of the FF-01
Hard Wired
Remote Controls
Fig 8: Actuator and FF-01 Block Diagram
Input signals are those returned by the actuator to the network about the status of the actuator and
valve whilst output signals are those used to command the actuator to move or operate its internal
relays. An actuator control signal such as a command to open is an output, whilst a reported status
such as open limit switch reached is a feedback input.
5.1 Controls
The actuator is used to position a valve. The valve may be moved fully closed, fully open or to an
intermediate position. Various controls are available to create these actions. Additionally the actuator
can make the valve adopt an Emergency Shut Down position or the actuator can be prevented from
moving by the presence of an Interlocking signal from another device on the plant.
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The control commands have three potential sources:
Foundation Fieldbus generated commands
Actuator Local Controls
Direct contact input controls
The full list of commands is shown in the table. The actuator types show whether the command is
applicable to that actuator type.
Command
IQ/IQT actuator
Foundation Network
Open
Close
Stop
Emergency Shut Down
Interlock (active prevents any motion)
Relay R5*
Relay R6*
Relay R7*
Relay R8*
Analogue Position demand
AQ actuator
Q actuator
*
*
*
*
Local Controls
Open
Close
Stop
Direct Wired Inputs
Open
Close
Stop/Maintain
Emergency Shut Down
Open Interlock (active prevents opening)
Close Interlock (active prevents closing)
Analogue Position demand
* requires additional relay board to be fitted.
The Foundation Fieldbus commands operate on the Transducer block through Digital Output (DO)
blocks that are already connected in the default configuration.
Open
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A digital command to cause the actuator to open to the fully open
position as indicated by the Open limit switch. The actuator stops
either when the open limit switch is reached, or when the torque
exceeds the value set and the open limit switch has been reached.
The reason for stopping when open depends on the way the actuator
has been set to operate during its commissioning.
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The Actuator Input and Output Signals
Close
Note:
A digital command to cause the actuator to close to the fully closed
position as indicated by the Close limit switch. The actuator stops
either when the close limit switch is reached, or when the torque
exceeds the value set and the close limit switch has been reached.
The reason for stopping when closed depends on the way the
actuator has been set to operate during its commissioning.
Many IQ multi-turn actuators are set to open until the open limit switch is reached and,
close until the closing on torque switch trips, but it is dependant on the type of valve.
The IQT, Q, and AQ normally operate 90-degree valves, use stop bolts on the actuator,
and stop when these are reached. The control room indication is always taken from the
end of travel limit switch settings
Stop
If the Open and Close commands are both replaced with zero the
actuator will stop. In the case of the local controls, the selector is
placed in the stop position. For hard-wired inputs the ‘maintain’ line is
normally closed and opens to stop the actuator.
Emergency Shut Down A digital command that causes the actuator to go to its
Emergency position. There are settings within the actuator to
determine if this is a closed, open or stay put action. ESD overrides
Open, Close or Stop from either the
Interlock
When present the actuator is prevented from opening, closing or
moving depending on the state of the command. For hard wired inputs
on the IQ/IQT actuator two interlocks are provided, one for opening
and the other for closing. (When the DO block is written to by the
Foundation there is a Transducer block mode control to view which
direction is interlocked.)
Relay R5 to R8
These 4 commands are used to energise and de-energise the
additional internal relays on the remote output board in an IQ actuator.
(These outputs are referred to as S5-S8 in the standard actuator
documentation when there is no FF-01 module in the actuator.) The
resulting outputs can be used for operating other equipment such as a
pump or indication light. The IQ/IQT actuator is not able to control
these relays directly from the main board by switch settings, they may
only be controlled by the Foundation DO blocks.
Analogue Position
This function is only available over the Foundation network.
When a value is written to the AO block parameter (range 0-100%,
resolution 1%) the valve will open to the appropriate amount and stop
in that position. If a subsequent digital command to open or close the
valve is issued, from any source, the analogue positioning mode is
inhibited. Writing to the parameter again causes the positioning mode
to recommence.
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5.1.1
Controls Priority
Since there are three potential sources for control inputs the actuator and FF-01 card assigns a priority
for those occasions when two or more commands are applied simultaneously. Commands from the
Foundation network change values in Digital and Analogue Output blocks and these connect via the
Transducer block to the actuator main board. Local controls go direct to the main board and override
any Foundation controls and any hard-wired controls except hard wired ESD. An actuator that has
Local selected cannot be controlled over the Foundation network.
Hard-wired inputs have two possibilities, they can simply be used to report the status of external (to
the actuator) contacts, or they can control the actuator. When selected for control the hard-wired
inputs take priority over the Foundation controls, but are subordinate to the local controls (except for
ESD). If there is a Foundation digital command is still present when a Local or Hard-wired command is
removed the Foundation command will re-assert itself. A Foundation analogue command will be
cancelled by the new control. A Foundation position command will only move the actuator if the digital
commands are set to ‘Stop’.
High Priority
Hard Wired ESD**
Foundation ESD
*
**
Low Priority
Local Stop
Local Close*
Local Open*
Hard Wired Stop
Hard Wired Close
Hard Wired Open
Foundation Stop
Foundation Close
Foundation Open
Foundation Position
Mechanically interlocked to prevent both at the same time
The IQ can be set so that Local Stop has a higher priority than ESD
The priority can be set in the actuator itself
Fig 9: Controls Priorities
5.1.2
The IQ ‘S’ contacts.
The standard IQ/IQT actuator has contact outputs that may be configured to report the status of the
actuator with signals such as Open Limit, Closed Limit etc. These outputs comprise two parts, the
logical signal from the main board and the physical relay itself. Normally these two are directly
connected but when a Foundation module is placed in the actuator the FF-01 module sits between the
logical signal (S) from the main board and the physical output (R) from the output board. This means
that the setting of the S value can be reported by the FF-01 module whilst the actual relays (R) can be
controlled by the FF-01 module.
3000 series IQ with output board fitted
Actuator Main Board
S1 - S4
S5 - S8
R1 - R4
FF-01
Module
R5 - R8
Output Board
Fig 10: Connecting to the IQ Actuator Outputs, IQT is the same
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The Actuator Input and Output Signals
5.2 Actuator Status Feedback (Foundation)
The FF-01 module is able to report a comprehensive data set relating to the status of the valve and
actuator as well as information relating to the status of the module itself. This information can be used
in the construction of the control scheme and any two variables can be connected to the Digital Input
blocks in the module for scheduled broadcast onto the highway. The recommended signals for
connection to the DI blocks and the usual connection for the AI blocks are listed in the manual section
on function blocks.
Valve and Actuator data is reported through the Transducer block and the instantiated function blocks.
The Transducer block in turn uses data from the Valve Codes list. The Valve Codes are set values
reported by the Transducer block that have values associated with the actual condition of the actuator
and valve. Some Transducer block indices report alarm data whilst others report status. The following
section describes the valve and actuator data that can be read from these Valve Codes and
Transducer block. Note that within the actual Transducer block data is combined into one index that
will cover a number of conditions on the actuator.
Status Feedback
IQ/IQT actuator
AQ actuator
Q actuator
Open
Close
Stop
Inhibited (Motion Inhibit Timer)
Local Override (Local)
Position Achieved
Torque Achieved
Moving
Aux Input 1 to 4
Interrupter Timer
Blinker
Interlock
Open/Close
The two internal position sensors in the actuator report the valve to be
in either end of travel position, or in mid stroke when they are not true.
These limit positions should be set within the actual valve stroke.
When a torque seating valve is closing, the actuator will stop when the
seat is reached and the rated torque has been delivered, independent
of the closed limit switch setting. The position limit switch must be set
slightly before the torque off position in order to ensure that the
position is correctly reported. The data relating to position is
maintained even though the position itself has been passed through.
When the actuator has reached the closed or open limit the respective
code will be set to be true.
Stop
Reported when the actuator is stationary in mid travel. Stop will
generally not be seen in isolation and in the reported data also
includes the Stop position of the Local/Stop/Remote control selector
on the actuator
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Inhibited
Indicates that the actuator motor has stopped during a valve analogue
positioning action whilst the Motion Inhibit Timer is running. This timer
is used to ensure that the motor does not exceed its rated number of
starts per hour. This bit is set after the analogue positioner reaches
the required position and has stopped. It stays active for the MIT time
during which the positioner outputs are disabled. In practice it will
most likely be the delay seen during positioning when the actuator has
overrun the desired position and needs to reverse direction to come
back to the desired set point.
Local Override
Indicates that the three-position local control selector on the actuator
is in the ‘Local’ position. In this position it is not possible to control the
actuator from the Foundation network or from remote hard wired
inputs. Note that to pass from ‘Local’ to ‘Remote’ the selector has to
pass through the ‘Local Stop’ position. If it is placed in Local Stop or
Local the ‘Control Not Available’ alarm is generated.
Position Achieved Indicates that the actuator has stopped in the desired place, fully
open, fully closed or in mid stroke, without generating excessive
torque.
Torque Achieved This always indicates that the actuator has developed the preset
torque maximum level. There are three possible positions the valve
can be in when Torque Achieved is generated. If this occurs in mid
travel between the open and closed positions it shows that there is an
obstruction in the valve preventing the completion of the desired
action. When this occurs at end of travel on travelling towards that
end, then the valve will have achieved a tight closure or opening
position. When this occurs on trying to operate the valve and move
away from the current open or close position it indicates that the valve
is jammed in the valve seat. This information is only available from an
IQ actuator. Since the torque will no longer be generated after the
motor stops the information is relayed from the last value measured.
This may alter slightly on each measurement and cause the signal to
fluctuate.
Moving
When the actuator is moving as detected by the centre column
rotating or the potentiometer value altering the actuator is reported as
‘moving’.
For the IQ/IQT actuator only, the following status information is also available
Aux Input 1 to 4
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The 4 hard wired inputs to the IQ or IQT actuator can be used to
report feedback data or to control the actuator as remote inputs. The
choice of function is made during the setting up of the module during
the commissioning of the system. The Aux Inputs can be individually
selected to control the actuator or monitor the input. When these
inputs are used for remote control they are allocated as
Aux 1 = Remote Open
Aux 2 = Remote Close
Aux 3 = Stop/maintain
Aux 4 = ESD
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The Actuator Input and Output Signals
A closed contact is used to initiate the action in remote control mode,
and reports a true signal in control or report only mode. These signals
report the state of the input contacts.
Interrupter Timer This is a specific IQ or IQT function where the motor drive can be
pulsed on for a period, then dwell for a period during valve travel. The
effect is to increase the valve stroke time to prevent shocks to the
process system as the valve opens or closes. The timer can be
configured to operate over a percentage of travel in the opening and
closing directions and the length of each ON and OFF pulse is
configurable in the range 1 to 99 seconds using the setting tool.
(Using a communicator, much wider timing range can be configured,
i.e. up to 4½ hours). These features are fully described in the IQ and
IQT actuator manuals.
The purpose of this input is to allow the Foundation system to be
aware that the timer is in use. If, for example, the interrupter timer has
been set and the actuator is travelling closed, during the periods when
the actuator is not moving due to the interrupter timer, this bit will be
true.
Blinker
The IQ and IQT actuators include a ‘flasher’ function on the internal
relay outputs (generally not associated with Foundation control). This
input reports the status of the flasher.
Interlock
Interlocks provide a means of inhibiting the control action of an AQ or
Q actuator from opening or closing, even when commanded to do so,
until a “safe to move” signal is applied via the interlock input. The
interlock can be initiated by a Foundation highway signal to DO4. DO4
needs to be driven, in addition to the control signal, before the
actuator moves in the required direction. This input will be true if the
Interlock signal is active. (IQ/IQT interlocks are provided by hard wired
inputs only)
5.3 Actuator Alarm Feedback (Foundation)
The actuator and FF-01 module are able to determine a comprehensive range of alarm situations for
the valve and actuator combination. This information is available to the Foundation network from the
Transducer block in the module and the Valve Codes in that block.
Alarm Status Feedback
IQ/IQT actuator
AQ actuator
Q actuator
ESD
Control Not Available
Low Battery
Stalled
Handwheel
Thermostat
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ESD
Emergency shut down active. If the actuator receives an ESD signal
from any source this signal will be true.
Control Not Available Otherwise known as the ‘Monitor Relay’. The actuator includes
a composite signal for some alarms referred to as the Monitor Relay.
This signal will be set true if the actuator selector is in Local or Local
Stop (not in Remote) or if the thermostat trips. In an IQ actuator the
mains supply is also monitored and if any phase is lost the monitor
relay bit is set. If a supply phase is lost communications with the
actuator will also be lost if the actuator is single phase, or if the phase
associated with the control circuits is lost on a three phase actuator.
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Low Battery
In the IQ and IQT actuator the status of the internal battery is
monitored and should it fall below a critical level this signal will
become true. The battery is used to power the circuits used to keep
track of the valve position when the actuator mains power is switched
off. This battery is used only when the actuator has no power feed and
the valve is actually moved.
Stalled
If the actuator is commanded to move and fails to do so within 4
seconds it is assumed that the motor has stalled. This signal will be
present under those conditions.
Handwheel
This signal is present if the actuator is moved manually by turning the
handwheel. The motion needs to change the position by 1% or before
it is detected.
Thermostat
On electric actuators the motor is protected by a thermostat, if the
temperature of the motor windings rises above the thermostat trip
value, the thermostat contact will open and this signal will be present.
There are no adjustments for the temperature at which the thermostat
trip operates. The motor will be stopped if the thermostat trips. Only
once the motor has cooled down and the thermostat has reset itself
can a new Remote, Host or Local command to move the actuator
Open or Closed be carried out. The ESD command may be set to
override the thermostat. The bit will remain set at logic 1 until the
motor cools down and the thermostat resets itself.
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The Actuator Input and Output Signals
5.4 Analogue Feedback Data (Foundation)
The FF-01 module includes two Analogue Input blocks that are used to report data from the actuator.
These blocks are connected to the Transducer block in the default configuration.
Analogue Feedback
IQ/IQT actuator
AQ actuator
Q actuator
Valve Position
Actuator Torque Output
Valve Position
The valve position is reported through Analogue Input block AI1. The
signal is ranged 0-100% where Close is 0% and Open 100% as
reported by the ‘end of travel’ position limit switch settings.
Actuator Torque When fitted to an IQ or IQT actuator the module reports the
instantaneous percentage torque value through the Analogue Input
block AI2. The signal is ranged 0-120%.
5.5 Actuator Feedback Data (Hard Wired)
With each actuator, there can be feedback data available from the internal switches and relays that is
independent of the Foundation network. In some installations, these signals are used in local
indication panels to show the actuator status.
Status and Alarm Feedback
IQ/IQT actuator
AQ actuator
Q actuator
Monitor Relay
Auxiliary Limit Switches OAS2/CAS2
S1 to S4 settable switches
*
*
Functions of S5 – S8 are fixed in IQ and IQT actuators.
Note:
For full details of these signals refer to the wiring diagram supplied with the actuator.
Monitor Relay
The actuator includes a composite signal for some alarms referred to
as the Monitor Relay. This signal will be set true if the actuator
selector is in Local or Local Stop (not in Remote) or if the thermostat
trips. In an IQ actuator the mains supply is also monitored and if any
phase is lost the monitor relay bit is set. If a supply phase is lost
communications with the actuator will also be lost if the actuator is
single phase, or if the phase associated with the control circuits is lost
on a three phase actuator.
Aux Limit Switches
Two additional adjustable limit switches can be included in the
actuator to allow for external indication of valve position. These
switches can be set anywhere in the valve’s travel and are usually set
for the open and closed position. These switches must be specified at
time of order.
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S1 to S4
Note:
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The IQ/IQT actuator has configurable contact outputs. The logical four
contacts S1 to S4 can be configured to make or break for one of the
following functions and will be reported as true when made;
Closed limit
Open limit
Intermediate position indication
Torque trip in mid travel
Actuator closing
Actuator opening
Actuator output rotating
Motor stalled
Battery low
Hand operation
Blinker
Torque trip opening
Torque trip closing
Torque trip any position
On IQ and IQT actuators the settings must be
S5 = Make at Torque Trip opening direction
S6 = Make at Torque Trip closing direction
S7 = Make at Torque Trip, mid travel
S8 = Don’t care
S1 to S4 provide contact outputs from R1 to R4 and are directly configured in the
actuator itself.
The output contacts available from R5 to R8 must be configured on the FF-01 module
blocks DO5 to DO8
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Function Blocks
6
FUNCTION BLOCKS
Function Blocks
2x Digital Input
8 x Digital Output
2 x Anaogue Input
1 x Analogue Output
PID*
Transducer
Resource
Data Link Layer
Fieldbus Access
Sublayer
Fieldbus Message
Specification
Data
Highway
* PID is not available in the ITK4 version of FF-01
Fig 11: Function Blocks within the FF-01 module
Function blocks provide the heart of the Foundation Fieldbus system. Each device on a network
includes at least one function block and a resource block to allow the equipment to be configured to
operate on the network.
The ITK4 version of the FF-01 module includes 16 blocks, of which one is the Resource block and one
is the Transducer block. The remaining 14 input and output blocks are used to control and collect data
from the actuator.
In order to make the FF-01 easier to use many of the parameters in the blocks are already defined.
Although they have default values assigned, a suitable configuration tool may alter some. Some of the
network communications link location data (VCR codings) are already defined as required by the
Foundation specifications. Publisher and Subscriber function blocks have VCR values assigned as
described in the DD file. The pre-assigned connections that are fixed include:
the allocation of the two AI blocks to the two analogue input variables in the actuator;
the AO block to the resident analogue output positioner in the actuator
the DO blocks to the digital outputs for controlling the open/close actions of the actuator
Many of the features of the function blocks are provided in order to allow the system to identify and
use the blocks. The Fieldbus specification (FF-890 to FF-892) defines all aspects of the function
blocks. In practice, the user needs to know very little about the internal workings of the blocks, as the
Capabilities file list all the available features. A suitable configuration tool such as that supplied by
SMAR or National Instruments is needed to set up all the tag names and operation of the blocks in the
complete system. The contents of the blocks can also be examined using a configuration tool.
Each block has its own unique tag name allocated during system configuration.
Note:
The PID function is not available in the ITK4 version of the Rotork FF-01 Foundation
Fieldbus card. It is available in the ITK3 version.
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6.1 Resource Block
Every device includes a resource block. This block contains data that is specific to the FF-01 itself.
There are no links to this block and there is no function schematic. The block includes data such as
the following, which is specific to the FF-01 module
Index
10
11
12
13
40*
Note:
Parameter Mnemonic
MANUFAC_ID
DEV_TYPE
DEV_REV
DD_REV
ITK version
FF-01 Value
65281
1
1
1
4
Parameter 40 is only included in the ITK4 version of the firmware, V1.10 or higher
6.2 Analogue Input Blocks
The FF-01 includes two Analogue Input (AI) blocks.
AI 1
Valve Current Position (analogue % value)
The % open value (position) of the valve. The range is 0-100% and
the end values relate to the close (0%) and open (100%) position limit
switches.
AI 2
Valve Current Torque Output (analogue % value) IQ only
The instantaneous % torque value through the valve stroke. The
range is 0-120%.
AI
Transducer
SIMULATE
XD_SCALE
LOW_CUT
PF_TIME
OUTPUT
Fig 12: Analogue Input Function Block
On installing the card the following settings will apply
The block is instantiated on delivery of the module.
The connections to the Transducer block are fixed and in place
The Mode control is standard.
The Alarms are disabled
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Out
Function Blocks
Item
AI 1 and AI 2
VCR
PV
CHANNEL
Description
Block Instantiation
Outputs set to publish the values
Output scaling
Channel 1 and 2
LOW_CUT
PV_FTIME
HI_HI_PRI
through
LO_LO_PRI
HI_HI_LIM,
HI_LIM
LO_LO_LIM,
LO_LIM
Low cut off value
Measurement filter time setting
Alarm priority
Default Value
Yes, instantiated
Already Configured
Set to XD_SCALE (linear)
Ch1 = AI 1 = Position,
Ch2 = AI 2 = Torque
0%
0 seconds, (no filtering)
All set to 0, no reporting
High Alarm set points
High high = +INF, High = + INF
Low Alarm set points
Low, low = -INF, Low = - INF
6.3 Digital Input Blocks
There are two Digital or Discrete Input Blocks (DI) included on the FF-01 module. These DI’s may be
configured to read back information from the valve codes listed in the Transducer Block.
DI 1
Valve Code 0 to 39
The input may be set to trigger from one of the valve codes 0-39 as
listed in the section on the transducer block. For example DI1 can
represent the valve fully open by linking its trigger event to code 9 in
the list.
DI 2
Valve Code 0 to 39
The input may be set to trigger from one of the valve codes 0-39 as
listed in the section on the transducer block. For example DI2 can
represent the valve fully closed by linking its trigger event to code 10
in the list.
DI
Transducer
Valve Codes
Table
SIMULATE
OPTIONAL
INVERT
PF_TIME
OUTPUT
Out
Fig 13: Digital Input Function Block
On installing the card the following settings will apply
The block is instantiated on delivery of the module.
The connections to the Transducer block are made through the ‘Valve Codes’ table
DI 1 is set to Valve Code 33, ‘Fail and ESD’
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DI 2 is set to Valve Code 34, ‘Fail and Control Not Available’
The Mode control is standard.
The Alarms are disabled
Item
DI 1 and DI 2
VCR
CHANNEL
Description
Block Instantiation
Outputs set to publish the values
Channel 1 and Channel 2
PV_FTIME
Measurement filter time setting
Default Value
Yes, instantiated
Already Configured
DI 1 = Channel 1 = Valve code 33,
DI 2 = Channel 2 = Valve code 34
0 seconds, (no filtering)
6.4 Analogue Output Block
There is one Analogue Output (AO) block in the FF-01 which is designed to allow the valve under
control to be positioned to a specific value over its position range of 0-100%.
A0 1
The % open value (position) of the valve. The range is 0-100% and
the end values relate to the close (0%) and open (100%) position limit
switches. Practical resolution is 1%.
BKCAL_OUT
RCAS_OUT
CAS_IN
SETPOINT
RCAS_IN
AO
Out Convert
XD_SCALE
PV Convert
XD_SCALE
OUTPUT
PV
Out
(Transducer)
SIMULATE
READBACK
Fig 14: Analogue Output Function Block
On installing the card the following settings will apply
The block is instantiated on delivery of the module.
The output connections to the Transducer block are fixed and in place
The Mode control is standard.
The Alarms are disabled
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Channel
Function Blocks
Item
AO 1
VCR
SP
PV
SP Rate
SP limits
Description
Block Instantiation
Inputs set to subscribe to values
Output convert
PV convert
SP_Rate_Dn and SP_Rate_Up
SP_Hi_Lim, SP_Lo_Lim
Scale
SP and PV and Readback
Default Value
Yes, instantiated
Already Configured
Set to XD_SCALE (linear)
Set to XD_SCALE (linear)
Both + INF
High limit = 100%
Low Limit = 0%
All 0-100%, 0% = closed
The AO block acts as a positioner for the valve and actuator. The positioning action is initiated by
sending a new desired position to the input (usually the Cascade input). Repeating the previous
position instruction will not cause the actuator to move. In order to initiate the position control algorithm
the setpoint requested must differ between each instruction.
Note:
The positioning algorithm will only take effect if the digital inputs for controlling the
valve are not present i.e. All set to Stop, and a position instruction is generated.
Note:
If the actuator is sent to 50% by an AO command, followed by a DO to close and then
requested to return to 50% it will remain closed. The AO setpoint must differ between
commands to achieve a position output.
6.5 Digital Output Blocks
There are 8 Digital Output (DO) blocks in the FF-01 which are designed to allow the valve under
control in a discrete manner. In addition, for the IQ and IQT actuator the internal relays R5 to R8 may
be controlled when the Relay Board option is fitted to the actuator. The DO channel to actuator
function relationship is predefined by the connections to the Transducer block, but in the case of the
open, stop and close commands these can effectively vary. The Transducer block contains a user
variable setting for the Control Source. This determines if DO1 or DO2 alone, or both DO1 and DO2
channels will be used to drive the valve open and closed and also which value causes the operation.
DO 1
The ‘open’ channel, depending on the mode selected this channel can
totally control the valve.
DO 2
The ‘close channel, depending on the mode selected this channel can
totally control the valve.
DO No. 1 and No. 2 have their action set in the Mode control in the Transducer block. These mode
settings are explained below.
DO 3
This channel is used to ESD the valve when the input is true
DO 4
This channel is used for the Interlock input and has 4 possibilities
DO 5 – DO 8
Applicable to IQ/IQT actuators, controls Relay 5 to 8 on the Relay
Board
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BKCAL_OUT_D
RCAS_OUT_D
CAS_IN_D
SETPOINT
RCAS_IN_D
DO
OPTIONAL
INVERT
OPTIONAL
INVERT
OUTPUT
Out_D
(Transducer)
SIMULATE
PV_D
Channel
READBACK_D
Fig 15: Digital Output Function Block
On installing the card the following settings will apply
The blocks are instantiated on delivery of the module.
The output connections to the Transducer block are fixed and in place
The Mode control is standard.
The Alarms are disabled
The Control Source for DO1 and DO2 are set to Mono Discrete 3
The inputs are inactive if not connected.
Item
DO 1 to DO 8
VCR
SP_D
PV_D
6.5.1
Description
Block Instantiation
Inputs set to subscribe to values
Optional Invert
Optional Invert
Default Value
Yes, instantiated
Already Configured
Set to no inversion
Set to no inversion
Control Source for DO1 and DO2
DO 1 and DO 2 are linked in the Transducer block to outputs described as ‘open’ and ‘close’. These
two channels used in combination or as individual channels control the full open, full close and stop
discrete digital actions on the actuator. These DO digital signals always override any analogue AO
signal unless the digital inputs are set to Stop in which case the AO signal, when refreshed by a new
or repeated value will move the valve.
The Control Source is set up in the Transducer block for these outputs and has 7 possible settings.
For each of these settings, the value written to the DO output will cause differing actions by the valve.
In some cases, the action requires that both DO1 and DO2 are set correctly. When there is a conflict
the priorities given in section 5 will be applied.
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Function Blocks
Control Source Setting
Action and Input to DO1 and DO2
0 – None
Actuator Local and Hardwired Controls (no control from Fieldbus)
1 – Mono Discrete 1
DO1 operates the valve,
0 = Stop,
1 = Open,
2 = Close
DO1 no action
2 – Mono Discrete 2
DO2 no action
3 – Dual Discrete
DO2 operates the valve,
0 = Stop,
1 = Close,
2 = Open
DO1 operates the valve,
DO2 operates the valve,
0 = Stop,
0 = Stop,
1 = Open,
1 = Close,
2 = Close
2 = Open
(If one input is set to open and one to close the actuator will stop)
4 – Local
Actuator Local and Hardwired Controls (no control from Fieldbus)
5 – Local Auxiliary
Actuator Local and Hardwired Controls (no control from Fieldbus)
6 – Mono Discrete 3
DO1 operates the valve,
0 = Close,
1 = Open,
2 = Stop
7 – Transducer Test
Not Used
6.5.2
DO2 no action
DO3, ESD Action
Input DO3 is used to operate the Fieldbus controlled ESD (Emergency Shut Down) action of the
actuator. The action on receipt of this control is set in the actuator itself and may be Open, Close or
Stay Put (do nothing). The connection between the Do block and the Transducer block is fixed and
when the DO 3 input is true the actuator will perform the set ESD action.
Input to DO3
Description
0
No ESD via Fieldbus
1
ESD action invoked (as set in the actuator)
6.5.3
DO4, Interlock (AQ/Q only)
It is possible to set a permissive interlock that must be false before the actuator will respond to an
input on DO1, DO2 or AO1. Whilst the interlock is any other value than zero the possible movement
by any input source is restricted. In an IQ/IQT this action can be achieved by changing an output relay
and wiring the contacts to the hard wired Interlock input. The Fieldbus DO4 must be set to ‘0’ for no
interlocking action.
Note:
The interlock control overrides the Local controls on the actuator
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Input to DO4
1 – No Open
Action
No interlock action (except the actuator hard wired interlocks where
present)
Interlock will prevent valve from opening
2 – No Close
Interlock will prevent valve from closing
3 – No Moving
Interlock will prevent valve from moving
0 – None
6.5.4
DO5 to DO8, Relay R5 to R8 outputs (IQ/IQT only)
On the IQ/IQT actuator, when a Relay Board is fitted, the relays on that board can be controlled
directly by the Fieldbus card. These are latching relays and will maintain the output contact status
even when the power is removed from the actuator. Their status cannot be changed unless the
actuator has power.
Input to DO5 – DO8
Action
0 – Reset
Relay contact will be opened and latched open
1 – Set
Relay contact will be closed and latched closed
6.6 PID Control Block – Not Available in ITK4 version 1.10 or higher
The actuator includes a standard three-term PID controller block for use in a control loop. The inputs
and outputs of this block are not directly linked to the actuator Transducer block that means the PID
controller can be used for controlling devices other than the actuator. With a PID function as long as
an error exists between the set point (desired value) and the measured value feedback (process
variable) the controller will change the output in a direction to reduce the error.
The way in which the output changes is influenced by the actual error value and the time it is present
and the rate of change it undergoes. The PID settings applied Integrate the error with respect to time
(RESET value), apply a proportional gain on the error (GAIN) and differentiate the rate of change in
the error (RATE); all these actions are combined to produce the OUTPUT.
PID
A stand-alone 3-term controller within the actuator.
On installing the card the following settings will apply
The block is instantiated on delivery of the module.
There are no connections to the Transducer block
The Mode control is standard.
The Alarms are disabled
The controller is in Manual mode
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Function Blocks
BKCAL_OUT
RCAS_OUT
PID
FF_VAL
CAS_IN
SETPOINT
BYPASS
SP
GAIN
RESET
BAL_TIME
RATE
BKCAL_IN
ROUT_IN
ROUT_OUT
RCAS_IN
IN
PV_TIME
FF_SCALE
FF_GAIN
PV
OUTPUT
TRK_IN_D
TRK_VAL
OUT
TRK_SCALE
Fig 16: PID Function Block
Item
PID
VCR
PV
GAIN
RESET
RATE
BAL-TIME
BYPASS
FF-SCALE
FF-GAIN
Description
Block Instantiation
Inputs set to subscribe to values
PV Filter
Control
Control
Control
Control
Bypass
Feed forward
Feed forward
Default Value
Yes, instantiated
Already Configured
0 sec
0
+ Inf
0 sec
0 sec
Off
Eng. Units, 0-100%
0
The PID block must be connected and set up before it can be used. It is the only block in the FF-01
module that is not pre-connected to any input or output of the actuator transducer block and may be
freely connected into a control loop. The scheduler is used to allocate a time slot for the control
algorithm to execute.
6.7 Transducer Block
The transducer block is the heart of the function blocks in the FF-01 module. It provides all the
connections to the actuator itself and contains within its parameters all the information about the
Foundation device, commands and data feedback. Links between the hardware and block are already
made to allow the user to access defined settings for the device.
Many of the links between the Transducer block and the Input/Output blocks are also defined and may
not be altered. Data may be read from the parameters but not all parameters permit write commands.
Writes are limited to the parameters used to set up the actuator control functions. The links between
the DI blocks and the Transducer block are not totally defined and these inputs select a source signal
from the valve status as reported in the tables within the Transducer block. These tables are referred
to as the Valve Codes.
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Some of the Transducer block parameters represent multiple conditions for the state of the actuator. In
order to determine the value in these parameters a second list is provided to define them. This list is
the Valve Codes list where multiple state conditions are described in a single parameter. The
parameters that draw their reporting value from this list include the Digital Input block inputs, the Valve
Status, the Stopping At and the Digital Output block source data for the relays in the IQ and IQT
actuator. The tables give a full list of the available parameters and the Valve Codes.
On installing the card the following settings will apply
The Transducer block is instantiated on delivery of the module.
The default values in the table will apply
The various settings must be made to allow control of the actuator
Table 1: Transducer Block Parameters
No
Parameter Mnemonic
Description
Valid Range
1
2
3
4
5
6
7
8
9
10
11
12
ST_REV
TAG_DESC
STRATEGY
ALERT_KEY
MODE_BLK
BLOCK_ERR
UPDATE_EVT
BLOCK_ALM
TRANSDUCER_DIRECTORY
TRANSDUCER_TYPE
XD_ERROR
COLLECTION_DIRECTORY
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
Positive
13
CONTROL_SOURCE
14
FINAL_VALUE
15
16
17
18
19
FINAL_VALUE _RANGE
FINAL_VALUE_HYSTERESIS
FINAL_VALUE _DEADBAND
FINAL_VALUE _CUTOFF_ HI
FINAL_VALUE _CUTOFF_ LO
20
FINAL_POSITION_VALUE
21
22
23
A0 1
PRIMARY_VALUE_POSITION
AI 1
PRIMARY_VALUE_TORQUE
AI 2
PRIMARY_VALUE_
TEMPERATURE
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Units
Class
none
na
none
none
na
na
na
none
E
none
none
RO
RW
RW
RW
RW
RO
RW
RO
RO
RO
RO
RO
none
RW
PVR
RO
PVR
%
%
FVR
FVR
RO
RW
RW
RW
RW
0 to 100%
%
RO
0 to 100%
%
RO
0 to 120%
%
RO
o
RO
1 to 255
100
0
Selects the Discrete output
channel, DO1, DO2 or
both, to open and close the
valve
Refer to the DO block
description for details
0 – None
1 – Fieldbus - Mono
Discrete Action 1
2 – Fieldbus - Mono
Discrete Action 2
3 – Fieldbus - Dual
Discrete Action
4 – Local
5 – Local Auxiliary
6 – Fieldbus - Mono
Discrete Action 3
7 – Transducer test
Analogue Output channel
AO 1 Write value
0 to 100%
0 to 100%
0 to 100%
0 to 100%
0 to +Inf
0 to -Inf
Analogue Output channel
AO 1 read back value
Analogue input AI No 1
(valve position) raw value
Analogue input AI No 2
(torque) raw value
Actuator Internal Ambient
temperature (No Analogue
input channel connected)
Initial
Default
Value
0
Null
0
0
O/S
o
0 to 100 C
Publication S179E Issue 07/03
2
(DO No 2
controls
the
actuator)
2
2
+Inf
-Inf
0
C
Function Blocks
No
Parameter Mnemonic
Description
Initial
Default
Value
Units
Class
0
none
RO
0
none
RO
2
none
RO
2
none
RO
0
none
RO
Valve Code Index 0 to 39
32
none
RW
0 – Inactive (false)
1 – Active (true)
0
none
RO
Valve Code Index 0 to 39
33
none
RW
0
none
RO
0
none
RW
0
Null
Null
0
Null
0
0
Null
0
Null
E
none
none
none
none
none
none
none
none
none
RO
RW
RW
RW
RW
RW
RW
RW
RW
RW
0
none
RO
0
none
RO
0 – Inactive (false)
1 – Active (true
0
none
RO
0 – No Interlock
1 – Inhibit Opening
2 – Inhibit Closing
3 – Inhibit Moving
3
none
RO
Valid Range
Mono 1
24
25
26
OPEN_FINAL_VALUE _D
Discrete Output channel
DO 1 DO 1 value
OPEN_LOCAL_FINAL_VALUE_
D
CLOSE_FINAL_VALUE_D
Discrete Output channel
DO 1 Read back
Discrete Output channel
DO 2 DO 2 value
27
CLOSE_LOCAL_FINAL_VALUE
_D
Discrete Output channel
DO 2 Read back
28
FINAL_POSITION_VALUE_D
Current Actuator
Open/Close command
29
PRIMARY_VALUE_D_1
_SOURCE
30
31
32
PRIMARY_VALUE_D_1
PRIMARY_VALUE_D_2
_SOURCE
PRIMARY_VALUE_D_2
33
ACT_FAIL_ACTION
34
35
36
37
38
39
40
41
42
43
ACT_MAN_ID
ACT_MODEL_NUM
ACT_SN
VALVE_MAN_ID
VALVE_MODEL_NUM
VALVE_SN
VALVE_TYPE
XD_CAL_LOC
XD_CAL_DATE
XD_CAL_WHO
ESD_FINAL_VALUE_D
44
45
46
47
Selectable Internal Value
event to set Discrete Input
channel DI 1 active
Discrete Input channel DI 1
DI 1 value
Selectable Internal Value
event to set Discrete Input
channel DI 2 active
Discrete Input channel DI 2
DI 2 value
Actuator action on loss of
communications signal
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
FF specific parameter
Discrete Output channel
DO 3 DO 3 value
Discrete Output channel
ESD_LOCAL_FINAL_VALUE_D
DO 3 Read back
Actual ESD condition
ESD_FINAL_POSITION_VALUE
inclusive of hardwired ESD
_D
input
ILOCK_FINAL_VALUE_D
DO 4
Discrete Output Channel
DO 4 value
0 – Stop
1 – Open
2 – Close
Mono 3
0 – Close
1 – Open
2 – Stop
Mono 1
0 – Stop
1 – Open
2 – Close
Mono 3
0 – Close
1 – Open
2 – Stop
Mono 2 or 3
0 – Stop
1 – Open
2 – Close
Mono 2 or 3
0 – Stop
1 – Open
2 – Close
0 – Stop
1 – Open
2 – Close
0 – Inactive (false)
1 – Active (true)
0 – Stop
1 – Close
2 – Open
3 – Stay at last position
0 – Inactive (false)
1 – Active (true
0 – Inactive (false)
1 – Active (true
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No
Parameter Mnemonic
Description
48
ILOCK_LOCAL_FINAL_VALUE_
D
Discrete Output Channel
DO 4 Read back
49
ILOCK_FINAL_POSITION
_VALUE_D
Actual Interlock condition
inclusive of hardwired
Interlock Inputs
50
VALVE_STATUS
51
INHIBITING_TIMER
52
STOPPING_AT
53
RELAYS_SOURCE
54
RELAYS_TRIGGER
55
56
57
58
RELAY5_FINAL_VALUE_D
DO 5
RELAY6_FINAL_VALUE_D
DO 6
RELAY7_FINAL_VALUE_D
DO 7
RELAY8_FINAL_VALUE_D
DO 8
Valve and actuator
condition indication
Actuator Motion Inhibit
Time (used in positioning)
Actuator position and
motion indication
Fieldbus (DO Block) or
internal actuator event
selector
(Each relay source may be
selected independently)
Internal actuator event
selection. (Each relay
trigger may be selected
independently)
Discrete Output Channel
DO 5 value
Discrete Output Channel
DO 6 value
Discrete Output Channel
DO 7 value
Discrete Output Channel
DO 8 value
RELAYS_VIEW
Current state of relays
(independently viewed)
60
AUX_FUNCTION
Control state of hardwired
actuator inputs. Monitor the
input or control the actuator
(Each input may be
independently set)
61
AUX_VIEW
Hardwired input current
state for Aux 1 to 4
62
ACTUATOR_CONTROL_STATE
Local Control selector
position report
59
Valid Range
0 – No Interlock
1 – Inhibit Opening
2 – Inhibit Closing
3 – Inhibit Moving
0 – No Interlock
1 – Opening Inhibited
2 – Closing Inhibited
3 – Moving Inhibited
Valve Code Index 4,
15,16, or Index 33 to 39
Initial
Default
Value
Units
Class
3
none
RO
3
none
RO
none
RO
0 to 255
0
Sec
R/W
Valve Code Index 0 to 3
or Index 5 to 14
0
none
RO
0 – Actuator controlled
1 – Fieldbus controlled
0
none
RW
Valve Code Index 0 to 39
0
none
RW
0
none
RO
0
none
RO
0
none
RO
0
none
RO
0
none
RO
0
none
RW
0
none
RO
none
RO
0 – Reset
1 – Set
0 – Reset
1 – Set
0 – Reset
1 – Set
0 – Reset
1 – Set
Relay 5 to 8
0 – Reset
1 – Set
Aux 1 (Open)
Aux 2 (Close)
Aux 3 (Stop/maintain)
Aux 4 (ESD)
Setting:
0 – Monitor
1 – Control
Aux 1to Aux 4 Condition:
0 – Inactive (false)
1 – Active (true)
0 – Local
1 – Local Stop
2 – Remote
The Parameter Mnemonic will appear in the Configuration Tool being used to set up the module. The
following explains the function of the Rotork specific parameters. References to Local refer to the
actuator local control knobs whilst references to Auxiliary inputs refer to the hard-wired contacts taken
to the actuator terminals. Not all the parameters are applicable to all the actuator types. Only IQ and
IQT actuators have the ability to use AI 2, the Torque reading, and the four relays DO 5 to DO 8.
13 – CONTROL_SOURCE
The actuator may be controlled from a number of alternate sources, DO1, DO2, or
AO1 or the local controls and hard wired inputs. If digital control DO1 and DO2 or
just DO1 or DO2 are to be used then this parameter must be set correctly to select
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the source. The list of choices includes some settings which are not applicable to
actuators and the actuator local controls and hard wired inputs are always
available for control (provided the hard wired inputs are set for ‘control’ and not
‘monitoring’). When analogue control is used, the digital control must be set to Stop
to allow the new desired position command to be active. A new digital command
will remove the actuator from analogue control. The section on DO blocks
describes the DO codes needed to move the actuator in a particular direction. It is
necessary to set up the CONTROL_SOURCE as well as direct the correct
command to the DO block to control the actuator digitally.
Value
Name
0
None
1
2
Mono Discrete 1
Mono Discrete 2
3
Dual Discrete
4
Local
5
Local Auxiliary
6
Mono Discrete 3
7
Transducer Test
Foundation
Digital and Analogue
commands will not move
the actuator
DO1 operates the actuator
DO2 operates the actuator
DO1 and DO2 operate the
actuator
Commands will not move
the actuator
Commands will not move
the actuator
DO1 operates the actuator
Commands will not move
the actuator
Remote hardwired
Local Controls
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
14 – FINAL_VALUE (AO1)
The current value of the valve desired analogue position may be read from this
Read Only parameter.
15 – FINAL_VALUE_RANGE
The analogue output signal is ranged 0-100%. This parameter may not be altered.
16 – FINAL_VALUE_HYSTERESIS
See also Parameter 17 and Parameter 51.
The position controller in the actuator that is used to move the valve to an
analogue position includes a hysteresis setting that, in combination with the
deadband, prevents hunting when positioning the actuator. The value of hysteresis
is set here. Hysteresis acts differently to deadband in that the hysteresis control
acts on the edge of the deadband. The controller will run the actuator towards the
setpoint, stopping the motor when the position is inside the deadband by an
amount equal to the hysteresis. The motor will not restart until the deadband is
exceeded.
17 – FINAL_VALUE_DEADBAND
See also Parameter 16 and Parameter 51
The position controller in the actuator runs the actuator in a direction towards the
analogue setpoint, then stops the actuator. Because of the valve and actuator
inertia there is a possibility that the desired position may be overrun and the
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controller will then reverse the direction to return to the setpoint. This is known as
hunting and the actuator may hunt around the control point if the inertia is high. To
prevent this from happening the actuator has three adjustable settings, Deadband,
Hysteresis (see parameter 16) and Inhibiting Timer (see parameter 51). The
deadband setting is the amount by which the actuator and valve must overrun the
setpoint before it is reversed. The motor will be stopped once the position
approaches the setpoint nearer than the deadband value minus the hysteresis
setting. The motor will restart if the overshoot is sufficient to make the position
deviate from the setpoint by an amount greater than the deadband alone.
18 – FINAL_VALUE_CUTOFF_HI
19 – FINAL_VALUE_CUTOFF_LO
These parameters should not be adjusted. They do not affect the actuator
operation.
20 – FINAL_POSITION_VALUE
Read back parameter showing the actual value sent as the setpoint for the valve
position controller.
21 – PRIMARY_VALUE_POSITION (AI1)
Read only parameter giving the valve position.
22 – PRIMARY_VALUE_TORQUE (AI2)
Read only parameter giving the current valve torque. This value latches when the
motor stops to show the last value read before the motor stopped.
23 – PRIMARY_VALUE_TEMPERATURE
Read only parameter from which the actuator internal temperature can be read.
(Note that this is not linked to an Analogue Input channel)
24- OPEN_FINAL_VALUE_D (DO1)
This parameter can be read to determine the current control action on the output of
DO1. The action will depend on the setting of the CONTROL_SOURCE parameter.
25 – OPEN_LOCAL_FINAL_VALUE_D
This is the read back parameter for DO1 from the transducer block. The action will
depend on the setting of the CONTROL_SOURCE parameter.
26 - CLOSE_FINAL_VALUE_D (DO2)
This parameter can be read to determine the current control action on the output of
DO2. The action will depend on the setting of the CONTROL_SOURCE parameter.
27 – CLOSE_LOCAL_FINAL_VALUE_D
This is the read back parameter for DO2 from the Transducer block. The action will
depend on the setting of the CONTROL_SOURCE parameter.
28 – FINAL_POSITION_VALUE_D
Once the Transducer block has determined the action to take depending on the
values of DO1 and DO2 and the CONTROL_SOURCE parameter a value is placed
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in this parameter of the actual demand on the actuator. This value also becomes
the read back for DO1 and DO2.
29 – PRIMARY_VALUE_D_1_SOURCE
Write to this parameter to select a Valve Code Index to be fed back by DI1. The
chosen Valve Code Index will be shown in this parameter.
30 – PRIMARY_VALUE_D_1 (DI1)
For the Valve Code Index selected this parameter shows if the status of the code is
true or false and hence if the actuator is in the selected state or not.
31 – PRIMARY_VALUE_D_2_SOURCE
Write to this parameter to select a Valve Code Index to be fed back by DI2. The
chosen Valve Code Index will be shown in this parameter.
32 – PRIMARY_VALUE_D_2 (DI2)
For the Valve Code Index selected this parameter shows if the status of the code is
true or false and hence if the actuator is in the selected state or not.
33 – ACT_FAIL_ACTION
The actuator can react itself to the loss of communication on the Foundation
highway. If no activity is detected the actuator may stop, close, open or remain in
its last position. The value written to this parameter determines the action taken. If
Option 3, Stay in Last Position is selected the actuator will complete any current in
progress. Local controls remain active when communications are absent.
44 – ESD_FINAL_VALUE_D (DO3)
This parameter can be read to determine the current control action on the output of
DO3. The action will depend on the setting of the actuator for an ESD input.
45 – ESD_LOCAL_FINAL_VALUE_D
This is the read back parameter for DO3 from the transducer block. The action will
depend on the setting of the actuator for an ESD input.
46 – ESD_FINAL_POSITION_VALUE_D
This parameter gives the actual condition of the actuator ESD signal, including the
ESD signal from a hard-wired remote input as well as from the Foundation
highway.
47 – ILOCK_FINAL_VALUE_D (DO4)
This parameter can be read to determine the current control action on the output of
the Interlock signal, DO4. If there is no interlock required DO4 must be set to zero.
48 – ILOCK_LOCAL_FINAL_VALUE_D
This is the read back parameter for DO4 from the Transducer block. The action will
depend on the setting of DO4.
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49 – ILOCK_FINAL_POSITION_VALUE_D
This parameter gives the actual condition of the actuator Interlock signal, or for the
IQ/IQT, the Interlock signal from a hard-wired remote input as well as from the
Foundation highway.
50 – VALVE_STATUS
This parameter allows the valve status with respect to the availability for control to
be examined. The value reported will be taken from the Valve Code list and will be
one of Index 4, index 16 or Index 33 to 39. If the condition of the actuator satisfies
more than one of the codes then the condition with the highest Index will be
reported. As the conditions changes the reported data will change. If the
51 – INHIBITING_TIMER
See also parameter 16 and parameter 17
The position controller in the actuator includes a setting to protect the motor from
exceeding the rated starts per hour and also assist in stabilising the process and
setpoint. Every time the actuator stops it will remain stationary for a period equal to
the Inhibiting Timer setting value set in this parameter.
52 – STOPPING_AT
This parameter allows the valve position (open, closed, moving etc.) to be
examined. The value reported will be taken from the Valve Code list and will be
one of Index 3 or Index 5 to 16. If the condition of the actuator satisfies more than
one of the codes then the condition with the highest index will be reported. As the
conditions changes the reported data will change.
53 – RELAYS_SOURCE
Applicable to IQ/IQT actuators only - the operation of the actuator relays 5 to 8 may
be selected from one of the Valve Codes (Actuator) or from another function block
or other signal through the DO block itself (Foundation). The choice between
Foundation or Internal control for each relay is made using this parameter.
54 – RELAYS_TRIGGER
IQ/IQT only - When the relay has been chosen to be activated by an Actuator
condition this parameter is used to select, for each relay, the Valve Code state that
will cause the relay to operate.
55 – RELAYS_FINAL_VALUE_D (DO5)
IQ/IQT only – Shows the current state of Relay 5
56 – RELAYS_FINAL_VALUE_D (DO6)
IQ/IQT only – Shows the current state of Relay 6
57 – RELAYS_FINAL_VALUE_D (DO7)
IQ/IQT only – Shows the current state of Relay 7
58 – RELAYS_FINAL_VALUE_D (DO8)
IQ/IQT only – Shows the current state of Relay 8
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59 _ RELAYS_VIEW
This parameter allows the status of each of Relays 5 to 8 to be viewed individually.
60 – AUX_FUNCTION
The actuator can accept remote hardwired contact inputs that may be used for
controlling the actuator position (Open, Closed, Stop, or ESD) or to report field data
such as a level switch or pressure switch contact state. This parameter allows (for
each of the four remote inputs) the action of these inputs to be set. It can be either
‘Monitor’ which simply reports the input status or ‘Control’ which reports the status
and also controls the actuator.
61 - AUX_VIEW
This parameter allows the state of the four hard-wired inputs to be examined.
62 – (FUTURE) ACTUATOR_CONTROL_STATE
The Local/Local Stop/Remote selector on the actuator must be in the Remote
position for the Foundation inputs to control the actuator. This parameter directly
reports the condition of the selector.
6.7.1 Valve Codes
In determining the condition f the actuator or connecting function blocks to various actuator states
(open, closed, moving etc.) the condition is reported in various parameters in the Transducer Block.
Some of these parameters directly reflect a single actuator condition as true or false whilst others have
multiple conditions. These multiple conditions are found in a table or list that comes from the Valve
Codes. The Valve Codes are a list of the possible conditions the actuator. If the actuator condition
satisfies more than one of the codes, for example Moving and Moving Open then the Transducer
parameter reporting the code will report the one with the higher index. If the parameter has a limited
range of codes to report and none are true it will report a code from lower in the table that is true.
Some of the possible codes are not used and some are allocated for internal use in the actuator.
Some of the codes are not available from AQ and Q actuators. Table 2 gives a full list of the Valve
Codes and a description of them follows.
Table 2 – Valve Codes
Valve
Code
No.
Identifier message
Available
as Trigger
Event
00
STOP
Y
01
OPEN
Y
02
CLOSE
Y
03
Motion Inhibited
Y
04
LOCAL OVERRIDE
Y
05
Position Achieved
Y
06
Torque Limit Achieved
Y
07
Moving
Y
Description
Stationary in Mid Travel or Local/Stop/Remote
selector in Stop position
Open and Open Limit switch or Open Torque
switch true, or actuator moving in open direction
Closed and Close Limit switch or Closed Torque
switch true, or actuator moving in closed direction
Motion Inhibit Timer Running
Local/Stop/Remote selector in Local or Stop
position
(assigned to actuator stationary at desired
position)
(assigned to at desired position and stopped on
torque)
Actuator in motion either opening or closing
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Applicable
Actuator Type
All
All
All
All
All
All
IQ/IQT
All
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Valve
Code
No.
Identifier message
Available
as Trigger
Event
Description
Applicable
Actuator Type
08
Stopped at Position Mid
N
09
10
11
12
13
14
15
Y
Y
Y
Y
Y
Y
Y
17
18
19
20
21
22
23
24
Opened at Position Lim
Closed at Position Lim
Opened at Torque Lim
Closed at Torque Lim
Opening
Closing
STOP and LOCAL OVERRIDE
Fail and Stopped at Position Mid
and at Torque Lim
Xcode not defined
Xcode nor defined
Aux Input 1
Aux Input 2
Aux Input 3
Aux Input 4
Interrupted Timer
Blinker
25
Interlock
Y
26
Xcode not defined
N
27
Interlock and None
Y
28
Interlock and OPEN
Y
29
Interlock and CLOSE
Y
30
Interlock and Both
Y
31
32
33
Xcode not defined
Xcode not defined
FAIL and ESD
N
N
Y
34
FAIL and control not available
N
35
36
37
38
39
40
FAIL and Battery Low
FAIL and Stalled
FAIL and Handwheel moving
FAIL and Hot
FAIL and Maintain
SAVING EEPOM
BATTERY LOW &
CONTROL_NOT_AVAILABLE
STALLED &
CONTROL_NOT_AVAILABLE
STALLED & BATTERY LOW &
CONTROL_NOT_AVAIABLE
HANDWHEEL &
CONTROL_NOT_AVAILABLE
HANDWHEEL & LOW BATTERY
HANDWHEEL & LOW BATTERY
& CONTROL_NOT_AVAILABLE
HOT &
CONTROL_NOT_AVAILABLE
HOT & BATTERY LOW
HOT & LOW &
CONTROL_NOT_AVAILABLE
Y
Y
Y
Y
N
N
(assigned to stopped in mid-travel at desired
position)
Valve Open Limit Switch reached
Valve Closed Limit Switch reached
Valve Open and opening Torque Switch tripped
Valve Closed and closing Torque Switch tripped
Travelling in Open Direction
Travelling in Close Direction
Local/Stop/Remote selector in Local Stop position
Valve Obstructed (actuator stopped in mid-travel
and torque switch tripped)
Reserved
Reserved
Auxiliary Input 1 Active
Auxiliary Input 2 Active
Auxiliary Input 3 Active
Auxiliary Input 4 Active
Interrupter Timer Running
Blinker On
Interlock Active (electrical movement not
permitted)
Reserved
(assigned to interlock active and mid travel
position)
(assigned to interlock active and actuator open
command received, valve cannot be opened)
(assigned to interlock active and actuator close
command receive, valve cannot be closed)
(assigned to interlock active and actuator cannot
be opened or closed)
Reserved
Reserved
ESD Command Issued
Monitor Relay (Local, Local Stop, or Thermostat
tripped) active
Low Battery
Valve Jammed
Manual Movement Detected
Thermostat Trip
Not implemented as trigger event
Not implemented as trigger event
N
(Battery Low and Control Not Available)
Future
N
(Stalled and Control Not Available)
Future
N
(Stalled, Battery Low and Control Not Available)
Future
N
(Hand Operation and Control Not Available)
Future
N
(Hand Operation and Battery Low)
(Hand Operation, Battery Low and Control Not
Available)
Future
N
(Thermostat Tripped and Control Not Available)
Future
N
(Thermostat Tripped and Battery Low)
Future
N
(Thermostat Tripped and Control Not Available)
Future
16
41
42
43
44
45
46
47
48
49
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N
N
N
Y
Y
Y
Y
Y
Y
N
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NA
All
All
IQ/IQT
IQ/IQT
All
All
All
IQ/IQT
NA
NA
All
All
All
All
IQ/IQT
IQ/IQT
All
NA
All
All
All
All
NA
NA
All
NA
IQ/IQT
IQ/IQT
All
All
NA
NA
Future
Function Blocks
Valve
Code
No.
50
51
52
53
54
55
56
57
Identifier message
HOT & STALLED
HOT & STALLED &
CONTROL_NOT_AVAILABLE
HOT & STALLED & LOW
BATTERY
HOT & STALLED & LOW
BATTERY &
CONTROL_NOT_AVAILABLE
HOT & HANDWHEEL
HOT & HANDWHEEL &
CONTROL_NOT_AVAILABLE
HOT & HANDWHEEL &
BATTERY LOW
HOT & HANDWHEEL &
BATTERY LOW &
CONTROL_NOT_AVAILABLE
Available
as Trigger
Event
N
Description
Applicable
Actuator Type
(Thermostat Tripped and Stalled)
(Thermostat Tripped and Stalled and Control Not
Available)
Future
N
(Thermostat Tripped and Battery Low)
Future
N
(Thermostat Tripped and Battery Low and Control
Not Available)
Future
N
N
N
N
N
(Thermostat Tripped and Hand Operation)
(Thermostat Tripped and Hand Operation and
Control Not Available)
(Thermostat Tripped and Hand Operation and
Battery Low)
(Thermostat Tripped and Hand Operation and
Control Not Available)
Future
Future
Future
Future
Future
Code 00 – STOP
This code indicates that the actuator Local/Stop/Remote selector is in the ‘Stop’
position, or that the actuator has stopped in mid-travel.
Code 01 – OPEN
This code indicates that the valve is in the fully open position or travelling in the
open direction. The open position is detected by the limit switch setting or the
torque switch depending on the type of valve and the actuator setting.
Code 02 – CLOSE
Similar to the OPEN indication this code indicates that the valve is in the fully
closed position or travelling in the closed direction. The closed position is detected
by the limit switch setting or the torque switch depending on the type of valve and
the actuator setting.
Code 03 – Motion Inhibited
This code indicates that the actuator motor has stopped during a valve analogue
positioning action whilst the Motion Inhibit Timer is running. This timer is used to
ensure that the motor does not exceed its rated number of starts per hour. In
practice, it will most likely be the delay seen during positioning when the actuator
has overrun the desired position and needs to reverse direction to come back to
the desired set point.
Code 04 – LOCAL OVERRIDE
When the Local/Stop/Remote selector is in either the Local or Stop position this
code will be valid.
Code 07 – Moving
If the actuator is moving due to either motor action or hand action this code will be
true.
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Code 09 – Open at Position Lim
When the actuator reaches the Open limit switch due to an open command, a
100% position command, is manually opened by the hand wheel, opened by the
local controls, or by a remote hardwired input this code will be true.
Code 10 – Closed at Position Lim
When the actuator reaches the Closed limit switch due to a close command, a 0%
position command, is manually closed by the hand wheel, closed by the local
controls, or by a remote hardwired input this code will be true.
Code 11 – Opened at Torque Lim
When the actuator reaches the Open torque trip switch due to an open command,
a100% position command, or is manually opened by the hand wheel, opened by
the local controls, or by a remote hardwired input and the torque setting is reached
or exceeded this code will be true.
Code 12 – Closed at Torque Lim
When the actuator reaches the Closed torque trip switch due to a close command,
a 0% position command, is manually closed by the hand wheel, closed by the local
controls, or by a remote hardwired input and the torque setting is reached or
exceeded this code will be true.
Code 13 - Opening
When the actuator is travelling in the open direction by motor or hand operation
this code will be true.
Code 14 - Closing
When the actuator is travelling in the close direction by motor or hand operation
this code will be true.
Code 15 – STOP and LOCAL OVERRIDE
This code indicates that the actuator Local/Stop/Remote selector is in the ‘Stop’
position and that control over the Foundation link is not possible.
Code 16 – Fail and Stopped at Position Mid and at Torque Lim
When the valve is jammed due to an obstruction it will torque trip in mid stroke and
stop moving. It will be necessary to reverse the direction of travel to release the
jam. When these conditions are met the code is true.
Code 19 to Code 22 – Aux 1 Input to Aux 4 Input
When the hard-wired inputs are active the appropriate input code will be set on
these bits.
Code 23 – Interrupted Timer
In an IQ or IQT when the Interrupter Timer (as used to slow down the speed of
travel) halts the motion of the actuator this code will be true.
Code 24 – Blinker
The IQ and IQT include a ‘flasher’ signal, this code follows the state of the flasher,
true when the flasher output is on.
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Function Blocks
Code 25 – Interlock
If the Interlock output (DO4) is active then this code will be true. Note that if the
interlock is active then the local controls do not operate.
Code 27 – Interlock and None
When the valve is in a mid position and the interlock (DO4) is set to prevent
moving (both opening and closing) this code will be true if a command to move the
actuator is issued.
Code 28 – Interlock and Open
When the valve is open and the interlock (DO4) is set to prevent it from closing this
code will be active if a close command is present.
Code 29 – Interlock and Close
When the valve is closed and the interlock (DO4) is set to prevent if from opening
this code will be active if an open command is present.
Code 30 – Interlock and Both
When the valve is at either end of travel and the interlock (DO4) is set to prevent
moving (both opening and closing) this code will be true if a command to move the
actuator is issued.
Code 33 – Fail and ESD
When a command is sent to the actuator, but it is in ESD mode this code will be
true. The command will be rejected because the ESD is present and take priority.
Code 35 – Fail and Battery Low
In an IQ if the Battery voltage falls below a critical level this code will be true.
Code 36 – Fail and Stalled
When the actuator encounters an obstruction in mid travel the torque trip
mechanism will operate and stop the actuator. This code will be true.
Code 37 – Fail and Handwheel moving
If the actuator is moved by means of the handwheel this code will be true.
Code 38 – Fail and Hot
If the motor thermostat trips this code will be true, the thermostat can trip on a
modulating duty if the rated number of starts per hour is exceeded. Setting the
motion inhibit timer (Parameter 51) to a longer period will overcome this.
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Link Active Scheduler
7
LINK ACTIVE SCHEDULER
Foundation devices may be either Basic or Link Master devices. Basic units do not have the ability to
hold the timing schedule for scanning the nodes and cannot act as system controllers. Every network
requires at least one Link Master to control the network communications. A Link Master that is in
control of the communications is known as a Link Active Scheduler.
All FF-01 modules are capable of acting as Link Masters and assuming network control by switching
automatically to become the Link Active Scheduler. The default value is for the unit to be in Basic
mode and the Link Master option must be switched on during system configuration. As many as are
required can be switched to this mode since only one will become the active device at any one time.
A3
A1
A5
T
Fieldbus
Power
Supply
+
-
T
LAS
A2
A4
A6
Fig 17: Link Active Scheduler – one per network
In order to change the FF-01 from a Basic unit to a Link Master a suitable configuration tool or
dialogue tool must be used. The setting is contained in the Management Information Base and the
data must first be opened using the dialogue tool.
The parameter to be altered resides in the MIB type of VFD. The class is called
BOOT_OPERAT_FUNCTIONAL_CLASS
This class can have two values,
01 = Basic Unit
02 = Link Master
Edit the value and download the setting to obtain the desired function. Units are shipped as ‘Basic’
modules.
The type of function available can also be read in the parameter
DLME_BASIC_CHARACTERISTICS
then the class
DL_OPERAT_FUNCTIONAL_DEVICE_CLASS
a value of 1 indicates a basic unit whilst a 2 indicates a Link Master.
Once the type has been selected the configuration tool can be used to download the system
configuration. The schedule will reside in all the Link Masters and be executed by the one that is
active, the Link Active Scheduler. Should the LAS fail then any of the remaining Link Master units is
able to take the role of LAS.
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When a system is being configured the Rotork devices on the network must be connected to the bus
after the configuration tool is started unless the devices are in Basic mode. If they are in Link Master
mode then the first one connected will become the LAS and the configuration tool will be unable to
gain full network control.
7.1 Creating a Schedule
Once a control strategy has been worked out the individual function blocks distributed across the
network have to be interconnected using a suitable configuration tool. The configuration process also
includes formatting the schedule for the execution of the function blocks. Many configuration tools
include the facility to create and alter the schedule, which is downloaded to the system during the
system download.
The individual function blocks each require a time slice of the total execution cycle in which to operate.
The execution times required for each block in the FF-01 module are as indicated in the table. The
data from the Transducer block does not need to be included in the schedule as it is recovered during
the probe node and compel data cycles of the Link Active Scheduler.
If the DI blocks are connected to trigger events in the Transducer block on the same actuator they
have a minimal execution time.
Function Block
Analogue Input (AI)
Analogue Output (AO)
Digital Input (DI)
Digital Output (DO)
Controller (PID)
Execution Time (mSec)
34
30
30
34
67
Make sure when creating a schedule that there are sufficient time gaps between the cycles to allow
the routine background tasks to perform correctly.
7.2 Connecting the Blocks
The function blocks used to execute the control strategy must be connected together as well as
configured to the Transducer block. The interconnection of the blocks requires the use of a suitable
Configuration tool. Such devices can be purchased from SMAR or National Instruments.
Since all the function blocks are instantiated on delivery there is no need to instantiate them when a
control scheme is designed.
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Setting Up the FF-01 Module
8.
SETTING UP THE FF-01 MODULE
When setting up the actuator to use the Foundation Fieldbus control there are a number of parameters
in the Transducer block that must be set to match the control system requirements. The method of
Foundation control of the actuator can be
Digital
Analogue
Mixed
using Open/Stop/Close commands,
using a position demand setpoint
using digital and positioning commands
The hard-wired inputs can be used for either monitoring or control
Hard-wired inputs monitor contact feedback signals
Hard-wired inputs control the actuator directly
The Foundation DI digital input blocks can report data from the values in the valve codes list.
Digital Input (DI)
selected from the valve codes
The condition of the actuator can be viewed by selecting the correct parameter.
Valve Status
gives the valve condition
Stopping At
gives the valve position (digital)
Primary Value Position gives the actual analogue position
Note:
the valve must be moved from fully closed to fully open with the fieldbus and actuator
power applied in order to scale this value correctly.
8.1 Setting Digital Control
The Transducer block parameter ‘CONTROL_SOURCE’ has to be set to a value suitable for the
control system to use. The three actuator commands (Open/Stop/Close) can be generated from one
or two DO blocks depending on the mode of control chosen. The ‘mode’ has four choices that affect
the Foundation control, Mono Discrete 1, Mono Discrete 2, Dual Discrete or Mono Discrete 3.
CONTROL_SOURCE
Value
Name
Foundation
Discrete Output
channel DO No 1
value
Discrete Output
channel DO No 2
value
0
None
Digital and Analogue commands will
not move the actuator
NA
NA
1
Mono Discrete 1
DO 1 operates the actuator
0 – Stop
1 – Open
2 – Close
NA
2
Mono Discrete 2
DO 2 operates the actuator
NA
3
Dual Discrete
DO1 and DO2 operate the actuator
0 – Stop
1 – Open
2 – Close
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0 – Stop
1 – Open
2 – Close
0 – Stop
1 – Open
2 – Close
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CONTROL_SOURCE
4
Local
5
Local Auxiliary
6
Mono Discrete 3
7
Transducer Test
Commands will not move the
actuator
Commands will not move the
actuator
NA
NA
NA
NA
DO 1 operates the actuator
0 – Close
1 – Open
2 – Stop
NA
Commands will not move the
actuator
NA
NA
With the chosen mode (Mono Discrete 1, 2 or 3, or Dual Discrete) the actuator is controlled for fully
open, fully closed or stop in mid travel using the DO channels, either DO1 or DO2, or both. Note that
in addition the state of the DO3 and DO4 channels must be considered.
If Channel DO4 (ESD) is active then the actuator will go to its ESD (Emergency Shut Down) position
and this will override controls from channels DO1 or DO2. Local controls will also be overridden. If
Channel DO3 (ILOCK) is active and the interlock facility will be active and this may prevent valve
movement in one, the other or both directions depending on the value written to the interlock output.
8.2 Setting Analogue Control
The Transducer block parameters for Motion Inhibit Timer, Deadband and Hysteresis must be set for
the particular valve for the internal analogue positioner to function correctly. The AO block controls the
actual output drive and is already instantiated to make it available. Settings for hysteresis and
deadband ensure the actuator does not hunt around the setpoint whilst the motion inhibit timer is used
to ensure the rated number of starts per hour is not exceeded.
Note:
If the fieldbus power is removed and restored the actuator will close to 0% as no signal
will have been applied whilst the power was removed.
FINAL_VALUE_HYSTERESIS
Set the motion hysteresis between 0-100% (typically 2%)
FINAL_VALUE_DEADBAND
Set the motion deadband between 0-100% (typically 2%)
INHIBITING_TIMER
Set the motion inhibit timer between 0-255 seconds (typically 20 sec)
8.3
Mixed Digital and Analogue Control
When using a mixed control strategy with both DO block control and AO block control it is necessary
to make sure the Digital control (DO blocks) are set to ‘Stop’ before an Analogue control of the
setpoint (DV) through the AO block will become effective. Digital controls (DO blocks) have a higher
priority than Analogue control (AO block).
Where the actuator has been sent an AO value and subsequently a DO instruction is issued to Open,
Close or Stop the valve any following AO value must differ from the initial value or no action will result.
Step 1
Issue Desired position value of ‘X’
Step 2
Issue a Close digital command (or open or stop)
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Setting Up the FF-01 Module
Step 3
Issue a Desired position value of ‘Y’
X and Y must be different, if not the command issued at step 3 will have no result and the valve will
remain in the position defined in stage 2.
8.2 Controlling Digital Inputs
The Digital Input blocks (DI1 and DI2) may be used to feed back information about the valve as
specific data. The status fed back will depend on the trigger values set in the Transducer block
parameters PRIMARY_VALUE_D1_SOURCE and PRIMARY_VALUE_D2_SOURCE.
The values set in these parameters are taken from the Valve Codes and any one of the codes 0 to 39
can be used for either DI block trigger source. The DI block input will then be true if the code is true.
Typically the value will be taken from one of the table below. Note that torque seating data is only
available from the IQ and IQT. In the case of the AQ and Q the valve always stops at the position limit
switch to prevent valve damage. There are other conditions which can be used to trigger the DI
functions and the full list can be found using a configuration tool or from the list in the section on the
Transducer block.
PRIMARY_VALUE_D1_SOURCE
One of the conditions in the Valve codes is used to set the input for the DI 1 block. D1 will be true if the Valve code is true
PRIMARY_VALUE_D2_SOURCE
One of the conditions in the Valve codes is used to set the input for the DI 2 block. D2 will be true if the Valve code is true
Valve Code
Applicable Actuator
Identifier message
Description
No.
Type
09
Opened at Position Lim
Valve Open Limit Switch reached
All
10
Closed at Position Lim
Valve Closed Limit Switch reached
All
11
Opened at Torque Lim
Valve Open and opening Torque Switch tripped
IQ/IQT
12
Closed at Torque Lim
Valve Closed and closing Torque Switch tripped
IQ/IQT
13
Opening
Travelling in Open Direction
All
14
Closing
Travelling in Close Direction
All
19
Aux Input 1
Auxiliary Input 1 Active
All
20
Aux Input 2
Auxiliary Input 2 Active
All
21
Aux Input 3
Auxiliary Input 3 Active
All
22
Aux Input 4
Auxiliary Input 4 Active
All
8.3 Controlling the IQ/IQT Actuator Relays (DO5 to DO8)
In the IQ/IQT actuator there are 4 relays R5-R8 that can be controlled by the Foundation network or by
the actuator itself. The normal IQ/IQT process of controlling the relays by the settings for the ‘S’ values
is suspended when a FF-01 module is fitted. The relays are then available for control either by a
network input to DO5 to DO8 or by a Valve code for the actuator condition.
8.3.1
Relay Source
The initial choice in setting up the FF-01 is to set the Transducer block to select the source for each
relay, either Fieldbus or Actuator. Fieldbus means controlling the relay by a DO signal whilst Actuator
means controlling the relay by a Valve code.
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RELAYS_SOURCE
Set the four relays individually to be operated either by a DO signal on the Foundation, or by an actuator event in the valve
Code list.
8.3.2
Relay Trigger
If the choice for the control source is to use an Actuator event then the Transducer block setting for
the actual event must be selected from the Valve code list. If the choice is to use a DO signal from the
network then the default value for the trigger can be left in place.
RELAYS_TRIGGER
For each relay, if the RELAYS_SOURCE is set to Actuator, set the relay to be operated by a valve code as listed in the
transducer block section. If set to Foundation leave at the default.
8.3.3
Relay View
The status of each relay can be seen by reading the Transducer block parameter RELAYS_VIEW.
This parameter reports the relay condition as either ‘set’ or ‘reset’.
8.4 Hard-wired Input Monitoring and Control
All the actuators can be controlled using direct contact inputs as well as the Foundation commands.
Alternately the hard-wired inputs can be used as a method of feeding back data either directly form the
Transducer block or through the two DI blocks. The selection for the function of these inputs is made
in the Transducer block.
8.4.1
Aux Input Function
The initial decision is to choose whether to use the hard-wired Auxiliary inputs as controls or simply for
monitoring. Selecting the mode in the AUX_FUNCTION parameter of the Transducer block determines
the action for each of the inputs. Note that the function for the inputs when they are used for control is
fixed.
AUX_FUNCTION
Aux 1
Aux 2
Aux 3
Aux 4
Control function = Open command
Control function = Close command
Control function = Stop/maintain command
Control function = ESD command
Setting: 0 = Monitor, 1 = Control
Setting: 0 = Monitor, 1 = Control
Setting: 0 = Monitor, 1 = Control
Setting: 0 = Monitor, 1 = Control
When the inputs are chosen for control they will override the Foundation signals and remain the only
method of control. The network will regain control only after all the settings are returned to ‘monitor’.
For IQ actuators a special version exists where the actuator may be controlled by both the network
and the hard wired inputs at the same time. If this option is required please contact Rotork.
8.4.2
Aux Input Condition
At any time the state of the hard-wired inputs can be viewed in the Transducer block parameter
AUX_VIEW. The data in this parameter shows if the input is active (closed circuit) or inactive (open
circuit).
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AUX_VIEW
Aux 1
Aux 2
Aux 3
Aux 4
Control function = Open command
Control function = Close command
Control function = Stop/maintain command
Control function = ESD command
0 = inactive, 1 = active
0 = inactive, 1 = active
0 = inactive, 1 = active
0 = inactive, 1 = active
8.5 Viewing the Actuator Status
The current status of the actuator position and control availability is reported in several parameters of
the transducer block. In some cases these parameters also reflect the state of the direct inputs as well
as the Foundation controls.
8.5.1
Analogue Position and Torque Data
Before the actuator can accurately report the position of the valve the actuator must be moved
between the fully open (100%) and fully closed positions whilst power is applied to the actuator and
fieldbus. The Transducer block parameters relating to analogue position control (AO) and analogue
feedback data (AI) are listed below.
FINAL_VALUE
Reports the setpoint (Desired Value) of the position controller associated with the AO block. The actuator will adopt this
position unless it has been followed by a digital command or it is in Local control
PRIMARY_VALUE_POSITION
Reports the actuator analogue position as a % signal where 0% = fully closed and 100% = fully open. This is the input to AI
channel 1.
PRIMARY_VALUE_TORQUE
Applicable to IQ actuators only, this is the value of torque currently generated by the actuator, or generated just before it
stopped if the actuator is stationary. The scale is 0-120% for zero to rated torque
8.5.2
Digital Command and Status Readback data
The status of the digital commands can be viewed in the read back signals from the Transducer block.
These parameters also include the condition of the hard-wired inputs when they are set for ‘control’.
FINAL_POSITION_VALUE_D
Reports the current actuator Open/Stop/Close command status demanded. This will be the position adopted by the actuator
unless it is in Local control or a subsequent analogue position has been sent over the network.
PRIMARY_VALUE_D1
Reports the status of the selected valve code for digital input (DI) channel 1. The signal will be true or false depending on the
state of the valve code.
PRIMARY_VALUE_D2
Reports the status of the selected valve code for digital input (DI) channel 2. The signal will be true or false depending on the
state of the valve code..
ESD_FINAL_POSITION_VALUE_D
Reports the current condition of the actuator Emergency Shut Down signal, inclusive of the hard-wired input..
ILOCK_FINAL_POSITION_VALUE_D
Reports the current condition of the actuator Interlock input signal, inclusive of the hard-wired input.
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8.5.3
Actuator Condition Report
The ‘Valve Status’ parameter in the Transducer block reports the condition of the actuator by taking
the highest listed Valve code that is true. If the actuator has a fault present (for example it is in Local
control and cannot be controlled over the network) then this parameter will report the fact. If there are
no faults on the actuator this parameter will report the next lowest condition in the Valve code list, from
codes 0 to 2 (Stop, Open, Close).
VALVE_STATUS
Reports one of the conditions from the Valve codes, the highest code is reported first.
Valve Code
No.
Identifier message
Description
33
LOCAL OVERRIDE
STOP and LOCAL OVERRIDE
Fail and Stopped at Position Mid and
at Torque Lim
FAIL and ESD
34
FAIL and control not available
35
36
37
38
39
FAIL and Battery Low
FAIL and Stalled
FAIL and Handwheel moving
FAIL and Hot
FAIL and Maintain
Local/Stop/Remote selector in Local or Stop position
Local/Stop/Remote selector in Local Stop position
Valve Obstructed (actuator stopped in mid-travel and
torque switch tripped)
ESD Command Issued
Monitor Relay (Local, Local Stop, or Thermostat
tripped) active
Low Battery
Valve Jammed
Manual Movement Detected
Thermostat Trip
Not implemented as trigger event
04
15
16
Applicable
Actuator
Type
All
All
IQ/IQT
All
NA
IQ/IQT
IQ/IQT
All
All
NA
In addition the position of the valve can be determined from the ‘Stopping At’ parameter in the
Transducer block. This parameter again reports data from the Valve codes, but the information is
limited to the valve position and does not include any alarm or failure conditions for the control system.
Where more than one code may be satisfied by the actuator condition the actual one reported will be
the highest code.
STOPPING_AT
Reports one of the position of actuator from the Valve codes, the highest code is reported first..
Valve Code
Applicable
Identifier message
Description
No.
Actuator Type
Stationary in Mid Travel or Local/Stop/Remote selector
00
STOP
All
in Stop position
Open and Open Limit switch or Open Torque switch
01
OPEN
All
true, or actuator moving in open direction
Closed and Close Limit switch or Closed Torque switch
02
CLOSE
All
true, or actuator moving in closed direction
03
Motion Inhibited
Motion Inhibit Timer Running
All
05
Position Achieved
(assigned to actuator stationary at desired position)
All
06
Torque Limit Achieved
(assigned to at desired position and stopped on torque) IQ/IQT
07
Moving
Actuator in motion either opening or closing
All
08
Stopped at Position Mid
(assigned to stopped in mid-travel at desired position)
NA
09
Opened at Position Lim
Valve Open Limit Switch reached
All
10
Closed at Position Lim
Valve Closed Limit Switch reached
All
11
Opened at Torque Lim
Valve Open and opening Torque Switch tripped
IQ/IQT
12
Closed at Torque Lim
Valve Closed and closing Torque Switch tripped
IQ/IQT
13
Opening
Travelling in Open Direction
All
14
Closing
Travelling in Close Direction
All
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Updating the FF-01 Firmware
9
UPDATING THE FF-01 FIRMWARE
Both sections of the FF-01 module have related firmware embedded in them. The roundcard firmware
can be updated by downloading new firmware from a PC to the roundcard using the SMAR FDI 302
programming tool. The interface firmware is updated by removing the COP8 microcontroller and
replacing it with a microcontroller that has been pre-programmed with the required version of firmware.
Both the round card firmware and microcontroller upgrade must be supplied by Rotork.
In order to carry out an upgrade the following tools will be required Computer with Windows 95, 98 or NT operating system, Pentium P120 processor, 32
Mbyte RAM and serial port
Anti-static mat and wristband.
Smar FBTools download software.
SMAR FDI 302:- Program Download Tool
Foundation Fieldbus power supply: (18V min to 24V max)
Fieldbus Power supply cable with suitable connector.
Microcontroller upgrade part: COP8 programmed with Rotork firmware.
Smar roundcard firmware upgrade disk with new (.abs) file.
9.1 Remove the FF-01 from the Actuator
In order to carry out the upgrade it is recommended to remove the module from the actuator and take
it to a clean workshop environment.
To gain access to the FF-01 module the actuator electrical cover should be removed to gain access to
the card. The connecting looms and screening can lid should be removed making a note of their
positions for subsequent re-assembly. The module should be removed from the actuator, taking care
to follow all necessary anti-static precautions. Once removed the module should be placed in an antistatic bag for transfer to a workshop area where it can be reprogrammed.
9.2 Connect the FF-01 to the PC and Power Supply
During programming, the FF-01module should be placed on an anti-static mat, in a clean workshop
area. The module must be connected to a Foundation Fieldbus power supply and to the PC running
the SMAR FBTools application.
A Foundation Fieldbus power supply must be used since the SMAR round card is powered from this
bus. Note that the 24V DC supply must include the correct filtering components to be suitable for this
task.
Attach the FDI 302 programming tool to the Fbboard round card using the attachment clip supplied.
The FDI 302 will only fit in the orientation shown. If the programming tool does not appear to fit, rotate
it through 180° and try again. Do not force the tool to fit the attachment holes as this could damage
both the tool and the Fbboard.
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Power and Network
connector
COP8 processor
with Rotork
firmware
Connection point for
program download
SMAR FDI 302
FBBOARD-5
smar
Fieldbus
Power
Supply
_
+
CN 2
Program download
connection point
To COM 1 on PC
Fig 18 FF-01 module programming connections
The 9 pin D type connector for the FDI 302 should be connected to the serial port of the PC. This can
be either the COM1 or COM2 but normally COM1 is used. Make a note of the port being used.
Connect the round card to the fieldbus power supply using the fieldbus power supply cable. This
power supply should have a filtered output and should have an output of between 18V min and 24V
max. To enable reprogramming the Fbboard must be powered by the fieldbus.
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Updating the FF-01 Firmware
FDI
302
Fig 19: Connecting the FDI 302 to the round card (shown with screening can removed).
9.3 Downloading the SMAR Firmware
The PC should be one that has had the SMAR FBTools software installed. Run the FBTools software,
the installation will have added an icon, which can be selected from the windows start list. Select the
FB302 as the device and click the finish button.
Fig 20: Select the download tool type to FB302
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Next the serial download window will appear. First the port should be set to match the serial port to
which the FDI 302 is connected
The firmware file to be downloaded is supplied on a floppy disk. Place this disk in the floppy disk drive
and select this as the file to download.
Fig 21: Serial Download Window
To select the file to download click the button next to the firmware text label, this is the button
indicated by … . Navigate to the floppy drive and reveal the list of files available for downloading to
the Fbboard.
Fig 22: Select the file to download
Be sure to have selected the file on the floppy disk drive containing the new firmware.
Select and open the latest file on the firmware upgrade disk, this will cause the display to return to the
previous window. Once the correct file and comm port have been selected then proceed to download
the file to the roundcard by clicking on the download button.
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Updating the FF-01 Firmware
If the Fbboard is both powered and the FDI 302 is correctly connected the selected firmware will be
downloaded to the Fbboard.
Fig 23: File downloading screen
Allow the download to complete. Remove the fieldbus power connection then remove the download
tool.
9.4 Updating the COP8 Firmware
To change the Rotork interface firmware remove the COP8 micro controller from its socket, using a
PLCC chip extraction tool, and replace it with the pre-programmed COP8 micro controller which has
been supplied as an upgrade.
The chip must be correctly orientated when placing it into the socket. This is achieved by lining up the
pin 1 indication marks and the locating chamfer on both the chip and the socket.
FBBOARD-5
smar
Locating Chamfer
Socket
COP8 Processor
Pin 1 Indication
Processor
Fig 24: Replacing the COP8 Processor
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9.5 Re-assemble the Actuator
Maintaining anti-static precautions the fieldbus card should be placed back in the actuator. The card
should be reconnected to the multipin connector and all looms to the FF-01 module should be
reconnected. Make sure that all looms are connected to the correct place before replacing the
electrical cover.
The actuator is now ready to use the upgraded firmware.
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10 DEVICE DESCRIPTION FILES
The Rotork FF-01 Foundation Fieldbus module requires certain device description files to be loaded
onto the host or configuration computer to allow the system to be set up. These files are not required
for the operation of the network. Configuration can only be achieved if the DD files are available to the
configuring software.
The Device Description files provide the Configuration tool with the information it needs to identify the
Function Blocks in the device and the text labels associated with each parameter.
When the FF-01 is connected to a host system such as a Fisher DeltaV or a Yokogawa Centum there
may be a need for an additional file used by the host system to allow it to recognise the Rotork device.
These files are maintained and supplied by the host system suppliers. Should a copy of any of these
files be needed they should be obtained from the host system manufacturer.
10.1 ITK3 DD Files
File
Firmware File
Capabilities File
Device Resource File
Symbol File
Device Description
Rotork Firmware
File Name
FB302-19-1-1-107.ABS
010101.CFF
0101.DRF
0101.SYM
0101.FFO
44596-01
ITK Version
3.0
3.0
3.0
3.0
3.0
3.0
For systems meeting the interoperability tests level ITK3 a .drf file is required. For later ITK versions
only the .sym, .cff and .ffo files are required.
10.2 ITK4 DD Files
File
Firmware File
Capabilities File
Symbol File
Device Description
Rotork Firmware
File Name
FB302-19-1-1-110.ABS
020101.CFF
0201.SYM
0201.FFO
44596-02
ITK Version
4.01
4.01
4.01
4.01
4.01
Whenever a system configuration is being made the DD files must be available in a folder on the
machine performing the configuration. Rotork supplies current versions of these files with the
hardware or from the Rotork web site.
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htpp://www.rotork.com
Rotork reserves the right to amend
and change specifications without
prior notice
Published data may be subject to
change.
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UK Head Office
USA Head Office
Rotork Controls Ltd
Bath
England
BA1 3JQ
Rotork Controls Inc
675 Mike Crossing Blvd
Rochester
New York 14624
USA
Tel: +44 (0) 1225 733 200
Fax: +44 (0) 1225 333 467
e-mail: [email protected]
Tel: +1 716 328 1550
Fax: +1 716 328 5848
e-mail: [email protected]
Publication S179E Issue 07/03
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