J metso automation

EFTA01216870 Dataset 9 52 pages Download original PDF
J metso automation PROFIBUS PA VALVE POSITIONER Series ND800PA rev1.0 USER'S GUIDE SIMATIC PDM EFTA01216870 Table of Contents Table of Contents 1 Introduction 4 1.1 Abbreviations 4 1.2 Referenced Documents 4 2 Quick start instructions 5 2.1 ND800PA basic setup 5 2.2 Fine tuning 5 3 Installation 6 3.1 GSD file 6 3.2 Simatic PDM driver 8 4 ND800PA GSD modules 11 5 Operation 14 5.1 Identification Group 15 5.1.1 Operation Unit 15 5.1.2 Device 15 5.1.2.1 Positioner 15 5.1.2.1.1 Static Revision No 15 5.1.2.2 Actuator 16 5.1.2.3 Valve 16 5.1.3 Batch Information 16 5.2 Settings Group 17 5.2.1 Assembly Related Configuration 17 5.2.2 Profibus Communication Fail Safe Action 17 5.2.3 Servo Controller 18 5.2.4 Valve Diagnostics 18 5.3 Input Group 19 5.3.1 Input value 19 5.3.2 Working Range 20 5.3.3 Travel Time 20 5.4 Human Interface Group 20 5.4.1 Maintenance 20 5.4.2 Simulation 20 5.5 Certificates and Approvals Group 21 5.6 Device menu 22 5.6.1 Operation 22 5.6.1.1 Page AUTO 22 5.6.1.2 Page Remote Cascade 23 5.6.1.3 Page MAN 24 5.6.1.4 Page Simulation 25 5.6.2 Flow characterization 26 5.6.3 Valve test 30 5.6.4 Write Protection 31 5.6.5 Calibration 33 5.6.5.1 Page Calibration 33 5.6.5.2 Page Position Sensor Temperature Compensation 34 5.6.6 Reset 35 5.6.6.1 Page Factory Reset 35 5.6.6.2 Page Reset Diagnostics 36 5.7 View menu 37 5.7.1 Display 37 5.7.1.1 Page Measured Value 37 5.7.1.2 Page Output 38 2(52) EFTA01216871 Table of Contents 5.7.2 Device Status 39 5.7.2.1 Page General 39 5.7.2.2 Page Profile 40 5.7.3 Valve Diagnostics 41 5.7.3.1 Page Measurements Trend 41 5.7.3.2 Page Travel Counters 43 5.7.3.3 Page Travel Deviation Trend 44 5.7.3.4 Page Actuator Load Factor Trend 45 5.7.3.5 Page Valve Travel vs. Time Trend 46 5.7.4 Event log 47 6 Appendix A. Parameter table. 48 7 Appendix B. Adding the ND800PA to the PDM project. 52 3(52) EFTA01216872 Quick start instructions 1 Introduction ND800PA is a PROFIBUS PA compatible valve positioner made by Metso Automation. Simatic PDM is a field device configurator software that supports PROFIBUS DP/PA and HART devices. The ND800PA documentation is provided in two manuals: • ND800PA Installation, Maintenance and Operation instructions /1/. This document describes the physical installation instructions and configuration using the Local User Interface. • ND800PA User's Guide. This document describes the functionality of the device in the Simatic PDM point of view. This device is designed according to the PROFIBUS-PA Profile for Process Control Devices Version 3.0 /2/. 1.1 Abbreviations OLE Object Linking and Embedding (Microsoft technology) OPC OLE for Process Control (Microsoft technology) DDE Dynamic Data Exchange (Microsoft technology) LUI Local User Interface PDM Process Device Manager 1.2 Referenced Documents /1/ ND800PA Installation, Maintenance and Operation instructions. /2/ PROFIBUS Nutzerorganisation, PROFIBUS-PA Profile for Process Control Devices Version 3.0, October 1999. 4(52) EFTA01216873 Quick start instructions 2 Quick start instructions 1. Install the PDM driver and the GSD file. See page 6. 2. Add the ND800PA to the Simatic PDM project. See Appendix B. 2.1 ND800PA basic setup 1. Set the Assembly related configuration. See page 17. 2. Set the Profibus Communication Fail Safe Action. See page 17. 3. Run the Automatic travel calibration. See page 33. 4. Set the Bus address from LUI or PDM. 5. Configure the GSD module. See page 11. 2.2 Fine tuning Some applications may require some of the following adjustments; • Direction • Travel Time limiting • Cutoff • Limits • Dead angle compensation • Flow characterization Diagnostic warning and alarm limits also may need adjustment as well as the supply pressure estimate. 5(52) EFTA01216874 Installation 3 Installation The ND800PA is shipped with one CD-ROM disc. The CD-ROM disc contents; • GSD file • Simatic PDM driver • Installation, Maintenance and Operation instructions (IMO) • Users Guide 3.1 GSD file GSD file is needed for the PROFIBUS master (class 1) to be able to configure the cyclic DP communication between the master and the slave. The Profibus master could be a DCS or PLC from any vendor. All of these systems have their own, separate configuration tools. All of these tools understand the ND800PA GSD file. The following example (figures 1-5) describes how to add the NEL_052D.GSD file to the Siemens Step 7 Hardware catalog as well as to the hardware project. IIW Conk) Conliour IIaide/ate ,Station LW yaw DIESIciLN Edt Catalog Prdias !Iodate Catalog Install Netiu • GSE Files CakAINE Instals new device database Pc in the system and tgdates the co:tents of the catalog Figure 1. Select "Install New ".GSE Files". Install Now A.GSE Hot Locke I A IZ .21 Filename: files of hope INel_052d 9.74 I• GSE Fies t• gss7) Open Cancel Figure 2. Browse to CD-ROM drive and select NEL_052D.GSD. 6(52) EFTA01216875 Installation ilw Cook, • ISIMAI1C 300 Station 1Cordiquiolionli• slave_diool MGM Alta:so Edi Intert PLC View Doom Window Hop DIta•I2-•I® gol r-10IUA 1 F5307 2A 2 ClltI2IS-2 ORB .1/47 Ao 3 1 a&s128i 5 6 I 8 9 10 11 Figu e 3. pRofiguisili tiP m.,3,,, yy.1,,f, a i BAD 'Standee FROFISUS DP - _j AddoonelFieldOeice: • ,_J I/0 __I Soon* _J NM% I Unvertal Moduh • J actimix 1 AO • —I VS710 • —I Gattway - J ClotekoopCcresollin - —I CooknoidSlotan - _J CP 3425.e OP Mesta DP/inSii I nP,PA Now the ND800PA appears on the hardware catalog. Drag and drop the ND800PA object to the hardware project. Selecting the Preset Configuration SP,CHECKBACK SP,READBACKPOS_D,CHECKBACK RCAS_IN.RCAS_0117 RCAS_INSCAS_OUT,CHECKBACK SPBB.RC_ISC 0.POS_D.00 (40)SP (4t 1SP READBACKPOS D OK Cancel I HelpA Figure 4. Select the module for the cyclic communication. In this case the module contains signals SP, READBACK and Properties PROEMS Node 140800RA Genera Panemelets adckesx 121 Tiansmission Hee 45 45 (31 25)Kbps Sttoei: DoPenks— OK Cancel I Help I Figure 5. Select the device slave address. This does not change the slave address but only tells to the S7 project that what the current address is. 7(52) EFTA01216876 Installation 3.2 Simatic PDM driver Simatic PDM driver adds the ND800PA device support to the Simatic PDM. This driver is tested with following PDM versions: • PDM v. 5.0.1 • PDM v. 5.0.1 SP3 • PDM v. 5.0.2 SP1 The driver installation is described in figures 6-11. Nd800pa (Z:) SO Ent File Edit Yew Help n7nd72en.pdf Devicelnstall exe DEVICEINSTALL.HLP ,211ND_HIpM.inc ND800PAdct mJ ND800PAddl ND 800 PA_ Users_Guidepcif OND800PAB.hlp ie Nel_052d.gsd Nel052dn.bmp j NELES.devices i PA_9710n.dib Lai PA139710.gsd Vobject(s) selected 13260 Figure 6. Browse to CD-ROM drive and start (double click) Devicelnstall. I Device Install for Simatic PDM E3 Device Install for Simatic PDM Version R 5.0.0.26-REL • installs or updates devices • installs service packs Copyright SIEMENS AG © 1997 - 1999 Next > Cancel Help Figure 7. Click Next. 8(52) EFTA01216877 Installation Device Install for Simatic PDM: Choose Location R Supplied devices or service packs r Diskette C Search in sirn_PDM1devices <Sack Next > Cancel I Help Figure 8. Select "Supplied devices or service packs" and click Next. a Device Instill lor Sonol. I >DM P i6ND800PA (EN Finish Cancel Help Figure 9. Click Finish. 9(52) EFTA01216878 Installation Device Install fur Simatic PDM. Dune ! El 6 files copied No update necessary for 2 files Thank you for using DeviceInstall for Simatic PDM I Close Help Figure 1O. Result of successful installation. SIMATIC PDM Device Selection El PA-Device Catalogue:139 entries (89 devices) - Actuators - Elecio-pneumobc - Metso Automation Profile 2 SAMSON AG + SIEMENS T- SMAR ± Converter • Discrete Output + Other . Sensors OK Cancel Help Catalogue-lmport .. I Qesciiplion. Electropneumatic valve positioner ND800PA Software Re•. 1.00. PA-Profile 3.0. Qrder No.: ND8sticcox< Figure 11. Now the ND8OOPA device should appear in the PA-Device Catalogue window. This window can be found by selecting the menu Insert / PDM / PFOFIBUS PA device in the Simatic Manager Process Device Network view. 1O(52) EFTA01216879 ND800PA GSD modules 4 ND800PA GSD modules The control communication is basically as follows; PLC/DCS writes the valve position setpoint to the ND800PA and reads the position measurement from the ND800PA. This communication is configured by the GSD modules. GSD module is a set of data, which the ND800PA and DCS/PLC exchanges cyclically until the end of the world. The GSD modules are listed in the GSD file. The ND800PA GSD file name is Nel_052d.gsd. During the DCS/PLC configuration, the configuration software, such as Siemens Simatic Step 7, reads the Nel_052d.gsd file and asks user, which GSD module should be used. The ND800PA has following GSD modules; • SP • SP,READBACK, • SP,CHECKBACK • SP,READBACK, CHECKBACK • RCAS _IN,RCAS_OUT • RCAS_IN,RCAS_OUT.CHECKBACK • SP,RB,RC_I,RC_O, CB Abbreviations; RB=READBACK, RC_I=RCAS_IN, RC_O=RCAS_OUT, CB=CHECKBACK For compatibility reasons the modules are represented in both Identifier Byte format and in Extended Identifier Format. SP is the valve position setpoint in the AUTO mode. The ND800PA Analog Output Block default target mode is AUTO. The range is 0-100%. READBACK is the valve position measurement. The range is 0-100%. contains the limit switch information. The values are: 1 = closed 2 = opened 3 = intermediate If the limit switches are not installed, the measurement sensor as follows: 1 = closed, Position <= 2% 2 = opened, Position >=98% 3 = intermediate, 2 < Position < 98 value is determined from the position RCAS_IN is the valve position setpoint in the Remote Cascade mode. Before this setpoint is used, the Analog Output Block (AO) actual mode has to be the RCAS mode. This requires as follows; • AO block target mode must be RCAS. • The DCS/PLC has to go through the remote cascade initialization sequence with the ND800PA. This is done by using the STATUS bytes of the RCAS_IN and RCAS_OUT signals. RCAS_OUT feeds back the SP or RCAS_IN, depending on the mode. CHECKBACK is a diagnostic signal. All control systems has their ways to convert this standard bit-information to human readable alert messages. See table 1. 11(52) EFTA01216880 ND800PA GSD modules Table 1. Byte Bit Description Indication Class 0 0 Field device in Fail safe active R 1 Request for local Operation R 2 Field device under local control. LOCKED OUT switch is in gear R 3 Emergency override active R 4 Actual position feedback different from expected position R 5 Indicates that the torque limit in OPEN direction is exceeded R 6 Indicates that the torque limit in CLOSE direction is exceeded R 7 Indicates status of travel monitoring equipment, if YES, travel time for actuator has exceeded. A 1 0 Actuator is moving towards open direction R 1 Actuator is moving towards close direction R 2 The alert generated by any change to the static data (Function and Transducer Block). A 3 Simulation of process values is enabled R 4 - - 5 Internal control loop disturbed R 6 Positioner inactive (OUT status = BAD) R 7 Device under selftest R 2 0 Indicates that total valve travel limit is exceeded R 1 Indicates that an additional input (i.e. for diagnostics) is activated R R Indication, remains active as long as the reason for the message exists. A Indication. will be automatically reset after 10s. CHECKBACK signal bit-enumeration. In addition to the actual value (IEEE-754 float), all GSD module signals (except CHECKBACK) have a status information (See table 2). The status tells the quality of the value. Example; READBACK status is bad, device failure, if the position measurement sensor is broken. Table 2. Status byte mapping. Status byte in case that the limit bits are zeros Quality Bits Additional information Bits Limit Bits Meaning 5 4 3 2 0x00 0 0_ 0 0 0 0 x x bad 0x04 0 0 0 0 0 1 x x bad. configuration error 0x08 0 0 0 0 1 0 x x bad. not connected 0x0C 0 0 0 0 1 1 x x bad. device failure 0x10 0 0 0 1 0 0 x x bad. sensor failure 0x14 0 0 0 1 0 1 x x bad. no communication (last usable value) 0x18 0 0 0 1 1 0 x x bad. no communication (no usable value) 0x1C 0 0 0 1 1 1 x x bad. outer service 0x40 0 1 0 0 0 0 x x uncertain 0x44 0 1 0 0 0 1 x x uncertain, last usable value 0x48 0 1 0 0 1 0 x x uncertain. substituted value 0x4C 0 1 0 0 1 1 x x uncertain. initial value 0x80 1 0 0 0 0 0 x x good 0x84 1 0 0 0 0 1 x x good. Update event (change of parameters) 0xA0 1 0 1 0 0 0 x x good. go into failsafe position (command) 0xA4 1 0 1 0 0 1 x x good. maintenance required OxC0 1 1 0 0 0 0 x x good (cascade) 0xC4 1 1 0 0 0 1 x x good (cascade). initialization confirmed 0xC8 1 1 0 0 1 0 x x good (cascade). initialization requested 0xCC 1 1 0 0 1 1 x x good (cascade). rcas mode not requested 0xD8 1 1 0 1 1 0 x x good (cascade). local operation has priority 0xE0 1 1 1 0 0 0 x x good (cascade). go into failsafe position (command) x x x x x x 0 0 value is not limited x x x x x x 0 1 value is low limited x x x x x x 1 0 value is high limited x x x x x x 1 1 value is constant x = could be any (0 o 1) 12(52) EFTA01216881 ND800PA GSD modules In addition to the CHECKBACK, the ND800PA has two more diagnostic signals. These signals are not included in the GSD modules. DIAGNOSIS contains standard diagnostic information (See table 3). This parameter is available to DCS/PLC if it supports a DP service called ddlm_slave_diag. The idea here is that this parameter is not polled cyclically, but whenever new information is available, the ND800PA rises a diagnostic flag (in cyclic communication). When DCS/PLC sees that flag, it reads the DIAGNOSIS parameter by using the ddlm_slave_diag service. DIAGNOSIS EXTENSION is manufacturer specific extension to the DIAGNOSIS (See table 4). This parameter is included in the ddlm_slave_diag service only if the PROFIBUS Ident Number is selected to be Manufacturer specific. Table 3. Byte Bit Indication Class Description 1 0 Hardware failure of the electronic R I Hardware failure mechanics R 2 Motor- temperature too high Ft 3 Electronic temperature too high R 4 Pile mory error R 5 Fa:ure in measurement Ft 6 Device not initialised (No selfcalibralion) Ft 7 Setfcabbration failed Ft 2 0 Zero pord error (limit position) Ft I Power supply failed (electrical. pneumatic) R 2 Configuration not valid R 3 New-start-up (wamtstart up) carried out. A 4 Re-start-up (coldstart up) carried out. A 5 Maintenance required Ft 6 Characterisation inva►d R 7 Set to 1 (one), if the (dent Number of the running cyclic data transfer and the value of Physical Block IDENT_NUMBER SELECTOR parameter are different. R 3 0 7 Reserved for use within the PNO 4 0 ... 6 Reserved for use within the PNO 4 7 More diagnoses information is available R Indication. remains active as long as the reason for the message exists. A Indication. will be automatically reset after 10s. Dia nosis Darameter bit-enumeration. Table 4. Byte Bit Description Indication Class 1 0 Pneumatic prestage valve 1 control failure R 1 Pneumatic prestage valve 2 control failure R 2 Position feedback ADC low limit failure R 3 Position feedback ADC high limit failure R 4 Pressure sensor failure R 5-7 - 2 0 EEPROM error R 1 RAM error R 2 ROM error R 3 Processor failure R 4 Board to board communication timeout Ft 5 Write was not successful R 6-7 - 3 0 VaNe bil strokes wameig omit exceeded Ft I Valve reversals warning limit exceeded R 2 Actuator full strokes warning limit exceeded R 3 Actuator reversals warning limit exceeded R 4 Deviation warning limit exceeded Ft 5 Load factor warning Ind exceeded Ft 6 Deviation alarm limit exceeded Ft 7 Load factor alarm limit exceeded R 4 0 Pneumatics problem R I Friction problem R 2 Travel deviation alert Ft 3 Load factor alert Ft 4-7 5 0-7 6 0-7 R Indication, remains active as long as the reason for the message oasts. A Indication. will be automatically reset after 10s. Dia nosis Extension Darameter bit-enumeration. 13(52) EFTA01216882 Operation 5 Operation The ND800PA Simatic PDM user interface is divided in three main categories. • Parameter groups. The static configuration parameters are grouped in logical groups. The parameters in the groups are presented in the parameter table. The parameter table can be saved to the Hard Disk. The saved parameter table can be compared with the parameters in the device. • Device menu. Device menu contains high-level device functions like Calibration. • View menu. Unlike the Device menu, the View menu contains only passive elements such as measured value displays. In the following paragraphs the ND800PA functionality is described in means of Parameter groups, Device menu and View menu. The Parameter groups are presented in figure 12. Pr SLMATIC PDM - Nd800pa File Device View Options km slalHelp ' P it Identification Operation Unit IS a Device IS S Positioner • CI Static Revision No. 11 Actuator I Valve ilatch Information flings Assembly Related Configuration Prof ibus Communication Fait Safe Action Servo Controller Valve Diagnostics Input Input Value Working Range al Travel Time '-• ' l-lumon Interface "clo intenance Simulation al Certificates and Approvals Figure 12. ND800PA Parameter Groups in Simatic PDM. 14(52) EFTA01216883 Operation 5.1 Identification Group 5.1.1 Operation Unit TAG Text; can be used in any way. A recommended use is as a unique label for a field device in the plant. Descriptor Text that is associated with the Field Device. This text can be used by the user in any way. There is no specific recommended use. Message Text that is associated with the Field Device. This text can be used by the user in any way. There is no recommended use. 5.1.2 Device 5.1.2.1 Positioner Manufacturer References a specific manufacturer, which is usually a company name, that is responsible for the manufacture of this Field Device. Device ID Uniquely identifies the Field Device when combined with the Manufacturer Identification and Device Type. Therefore, this variable cannot be modified by the Host user. Software Revision Device software revision number. Hardware Revision Device hardware (electronics) revision number. Serial Number Uniquely identifies the Field Device. Therefore, this variable cannot be modified by the Host. Device PCB Serial Number Device Printed Circuit Board serial number. Installation Date The Installation date of the device. Profile Revision Revision number of the profile relating to the block. PROFIBUS Ident Number Each PROFIBUS-DP device shall have an !dent Number provided by the PNO. There are profile specific Ident Numbers. A device may have a profile specific one and the manufacturer specific one. The user is able to choose one of both using this parameter. Selections are • Profile specific (0x9710) • Manufacturer specific (Ox052D) NOTE The Ident Number can be changed only when the cyclic communication is not active. 5.1.2.1.1 Static Revision No Physical Block, Transducer Block, Function Block The revision level of the static data associated with the block. The Static Revision No. is changed by the device each time a static parameter is changed in value. 15(52) EFTA01216884 Operation 5.1.2.2 Actuator Manufacturer References a specific manufacturer, which is usually a company name, that is responsible for the manufacture of this Field Device. Actuator Class Actuator class is electro-pneumatic. Actuator Type Actuator type indication. Options are • Undefined • Single acting actuator • Double acting actuator Actuator Fail Action Actuator fail safe position during LOSS OF SUPPLY PRESSURE. This parameter is informational only. • Not initialised • Opening (100%) • Closing (0%) • None (Double acting actuator) Serial Number Actuator serial number can be written here. 5.1.2.3 Valve Manufacturer References a specific manufacturer, which is usually a company name, that is responsible for the manufacture of this Field Device. Valve Type Valve type indication. Options are • Linear moving valve, sliding valve • Rotary moving valve, part-turn Serial Number Valve serial number can be written here. 5.1.3 Batch Information Batch ID Identifies a certain batch to allow assignment of equipment -related information (e.g. faults, alarms ...) to the batch. Batch Unit Identifies the active Control Recipe Unit Procedure or the related Unit (e.g. reactor, centrifuge, drier). Batch Operation Identifies the active Control Recipe Operation. Batch Phase Identifies the active Control Recipe Phase. 16(52) EFTA01216885 Operation 5.2 Settings Group 5.2.1 Assembly Related Configuration NOTE These parameters are valve assembly related; you should thus check that the control valve assembly conforms to the setting of these parameters ! Position Sensor Rotation Defines relationship between the position sensor rotation and the valve action. If the position sensor rotates clockwise when the valve closes, set Standard: clockwise to close. With inverse rotation set Nonstandard: counter-clockwise to close. See /1/ for more information of operation directions and air connections. Options are • Standard : Clockwise to close • Non-standard : Counter clockwise to close Actuator type Actuator type selection. Options are • Undefined • Single acting actuator • Double acting actuator Valve Type Valve type selection. Options are • Linear moving valve, sliding valve • Rotary moving valve, part-turn Positioner Fail Action Configuration of the action taken during the LOSS OF SUPPLY POWER (supply pressure is available). This action takes place ALSO when the positioner software notices a fatal device failure. In these both cases the spool valve feeds C1 (pneumatic connector) and releases C2 pressure. See /1/ how to set this parameter. Options are • Close • Open Actuator Fail Action Actuator fail safe position during LOSS OF SUPPLY PRESSURE. This parameter is informational only. • Not initialised • Opening (100%) • Closing (0%) • None (Double acting actuator) Dead Angle Compensation This adjustment is used to change the valve travel from fully closed to a desired travel with a small change in input signal near the 0% value of the input signal range. This can be used to compensate dead angle in a ball or segment valve such that it is equal to the ao adjustment in conventional Neles positioners. The ac, adjustment is used especially with small ball valves which require a turn of several degrees from the closed position before any flow through the valve is perceptible. Suitable ac, values for Neles segment and ball valves can be found in /1/. See figure 13. Limit switches This parameter defines either the limit switches are installed or not. Options are; • Not installed (default) • Installed 5.2.2 Profibus Communication Fail Safe Action Fail Safe Mode Defines reaction of device if communication fault is still detected after fail safe time. Options 17(52) EFTA01216886 Operation are • Fail Safe Value is used as control regulator input • Storing last valid setpoint • Positioner does Positioner Fail Action Fail Safe Time Time in seconds from detection of failure in output block up to the output action of the block output if the condition still exists. Fail Safe Default Value Default Value for the setpoint input if communication fault is detected. 5.2.3 Servo Controller Servo controller gain The servo controller gain value. This parameter is adjusted automatically during the Automatic Travel Calibration. After travel calibration the value is 1.0. For enhanced control use value 1.2. Servo controller parameter D Servo controller tuning parameter D. • 0.0 for double acting actuators (factory set) • 1.0 for single acting actuators (factory set) Servo controller parameter B Servo controller tuning parameter B. This parameter is adjusted automatically during the Automatic Travel Calibration. After travel calibration the value is 1.0. 5.2.4 Valve Diagnostics These settings are used to set limits for different diagnostics information to warn the user when the limits are exceeded. The limits should first be set to high values such that no unnecessary warnings are given. After gaining experience, the user can tune the limits to more accurate levels. When a particular limit is exceeded, it is reported in corresponding Diagnosis and Diagnosis extension status messages. Supply Pressure Set this parameter to the average value of the positioner supply pressure. Supply pressure is used to calculate the load factor. Travel Deviation Warning Limit Warning limit for the deviation between the setpoint and actual travel. Travel Deviation Alarm Limit Travel deviation alarm limit. Load Factor Warning Limit Load factor warning limit. In the case of a single acting actuator, the load factor shows the actuator load with respect to the present spring force, i.e., a load factor of 100% indicates that the actual load may exceed the spring force. For double acting actuators, the load factor shows the actuator load with respect to the user-given supply pressure level, i.e., a load factor of 100% indicates that the actual load may exceed maximum attainable pressure difference being equal to the supply pressure. A high load factor indicates the presence of high friction or an undersized actuator if the given supply pressure is equal to actual supply pressure level. Load Factor Alarm Limit Load factor alarm limit. Valve Full Strokes Warning Limit Warning limit for the distance the valve has traveled in full strokes. One full stroke means 18(52) EFTA01216887 Operation valve movement from 0 to 100%. E.g. if valve moves from 40% to 50% full strokes increases by 0.1. Valve Reversals Warning Limit Warning limit for the number of changes in valve movement direction. Actuator Full Strokes Warning Limit Warning limit for the distance the actuator has traveled in full strokes. Actuator Reversals Warning Limit Warning limit for the number of changes in actuator movement direction. 5.3 Input Group The input signal modifications accomplished using Dead Angle Compensation, Cut-Off and Limit functions are presented in figure 13. 100% OUTPUT Dead Angle Compensation Setpoint Cut-Off CLOSE Lower Limit Valve Position 14-INPUT 100% Setpoint Cut-Off OPEN Upper Limit Valve Position Figure 13. The input signal modifications accomplished using Dead Angle Compensation, Cut-Off and Limit functions. Note: Setpoint Cut-Off function overrides the Limit function. If Setpoint Cut-Off CLOSE is greater than 0%, the Lower Limit Valve Position is not applied (has value of 0%). Correspondingly, if Setpoint Cut-Off OPEN is smaller than 100%, the Upper Limit Valve Position is not applied (has value of 100%). 5.3.1 Input value Direction Direction of positioner. Options are • Rising (increasing of setpoint input results in opening of the valve) • Falling (increasing of setpoint input results in closing of the valve) Lower Value Defines the operational lower range value of the input value (0%) in engineering units. 19(52) EFTA01216888 Operation Upper Value Defines the operational upper range value of the input value (100%) in engineering units. Unit (Input) The engineering unit of the input value. Setpoint Cut•Off CLOSE When the servo setpoint goes below the defined percent of span, the valve is driven to the CLOSED position. See figure 13. Setpoint Cut•Off OPEN When the servo setpoint goes above the defined percent of span, the valve is driven to the OPEN position. See figure 13. 5.3.2 Working Range Lower Value Lower Value (Output Signal Range): Lower range value of the process variable (0%) in engineering units. Upper Value Upper Value (Output Signal Range): Upper range value of the process variable (100%) in engineering units. Unit (Output) The engineering unit that the output value is reported in. Lower Limit Valve Position Lower limit of the valve position in percent of travel span. Travel span corresponds to the Output Signal Range (Upper Value and Lower Value). See figure 13 Upper Limit Valve Position Upper limit of the valve position in percent of travel span. Travel span corresponds to the Output Signal Range (Upper Value and Lower Value). See figure 13. 5.3.3 Travel Time Travel Time CLOSE Setpoint for the time in seconds between the change of the state from OPEN to CLOSED. Travel Time OPEN Setpoint for the time in seconds between the change of the state from CLOSED to OPEN. 5.4 Human Interface Group 5.4.1 Maintenance Calibration Date Date of last calibration of the device. Configuration Date Date of last configuration of the device. Maintenance Date Date of last valve maintenance. 5.4.2 Simulation Simulation Enable or disable the simulation function. 20(52) EFTA01216889 Operation Simulation Value For commissioning and maintenance reasons, it is possible to simulate the Readback by defining the value and the status. This means that the Transducer Block and the Function Block will be disconnected. Quality Signal quality information. See table 2. Limit Signal limit information. See table 2 5.5 Certificates and Approvals Group Device Certification Certification of the device. 21(52) EFTA01216890 Operation 5.6 Device menu The items in the device menu are presented in figure 14. Pr SIMATIC PDM - Nd800po View Qptions Set Address... Load into Device Load into ?G/PC Operal ion Flow characterization Valve test Write Protection Calibration Reset H Ip lo. I Assembly Related Configuration - I Prof bus Communication Fail Safe Action Figure 14. Device menu items. 5.6.1 Operation 5.6.1.1 Page AUTO The page AUTO in the operation window is presented in figure 15. From this window it is possible to change the operating mode of the device and change the value of the auto-mode valve position setpoint (SP). Operation - r10800 PA (Online) AUTO I Remote Caned" (RCAS)114 5N I Simulesion Target Mode Actual Mode Setporit Setpoint Readback Value Readback Value Setpont Dewation Check Back IAJTO 3 50 50 61893 Quality Limit INot limned Ouality I brag I -0.6041745 Status OK Transfer 11 Close Figure 15. Operation / Auto. 22(52) EFTA01216891 Operation 5.6.1.2 Page Remote Cascade The page Remote Cascade in the operation window is presented in figure 16. From this window it is possible to change the operating mode of the device and change the value of the RCAS-mode valve position setpoint (RCAS_IN). OporoNon - NDSOOPA (OaIS) AUTO Remote Coscode (RCAS) imAN I Simulation' Target Mode Actual Mode RCAS RCAS IN RCAS OUT RCAS OUT Readback Value Readback Value Setpant Deviabon Check Back 'Remote Cascade (RCAS) 50 50 61024 Quality Limit Good (Cascade) in=sa4zation acknowledged INot limited Quaity IGood (Cascade) Limit INot limited Quay tOood omit It -it lir -0 6020203 Status OK J Transfer Close Figure 16. Operation / RCAS. 23(52) EFTA01216892 Operation 5.6.1.3 Page MAN The page MAN in the operation window is presented in figure 17. From this window it is possible to change the operating mode of the device and change the value of the manual- mode valve position setpoint (OUT). • • NO1100tin • IN AUTO I Remote Cascade (RCAS) I Simulation I Target Mode Actual Mode Output Output Value Readback Value Readback Value Setpoint Donation Check Back IMAM 50 5058864 Quality Limit Gocd Net kr ted Quality Limit I -0 7462425 Update Alert Transfer Close Figure 17. Operation / MAN. 24(52) EFTA01216893 Operation 5.6.1.4 Page Simulation The page Simulation in the operation window is presented in figure 18. From this window it is possible to enable/disable the simulation function and simulate the Readback value and status. When simulation is enabled, the Analog Output Block and the Tansducer Block are disconnected. The simulation value and status are copied to the AO Block Readback signal. Simulation is useful during the device commissioning and maintenance. Cperotion - NDS00PA (Online) AUTO I Remote Cascade (RCAS) I MAN Simulation Simulation Simulation Value Setpoint Deviation Check Back Simulation lEnabred 10 Quality IGood Lynn INOt limited -0.7350807 Simulation enabled. Close Figure 18. Operation / Simulation. 25(52) EFTA01216894 Operation 5.6.2 Flow characterization When optimizing process control loop performance a linear relationship between the flow and valve position setpoint signal should be established. This can be achieved by using this flow characterization design tool. Valve inherent flow characteristics curve tells the (normalized) valve capacity (effective flow cross-section) versus the valve position. This curve is specific to the physical valve design. Valve installed flow characteristics curve tells the (normalized) flow versus the valve position. This curve is the result of the inherent flow characteristics curve and the process pressure behavior. The flow characterization design tool changes the valve inherent flow characteristics curve to any desired curve. Current inherent characteristics table tells the flow characteristics without any signal modifications. Desired inherent characteristics table tells the desired characteristics. Based on this information, the tool calculates the required signal modification, Signal modification table, which is as well user editable. Current inherent characteristics table (Figure 19) This table tells the inherent flow characteristics without any signal modifications (flow characterization is off). The table values are the relative flow coefficients at corresponding valve openings. Desired inherent characteristics table (Figure 20) This table tells the desired inherent flow characteristics. The table values are the relative flow coefficients at corresponding valve openings. Fill table (Figures 19 & 20) • User defined - When this option is selected, the table can be entered by user. • Linear - Fills the table with linear characteristic values. • Equal percentage 1:25 - Fills the table with Equal percentage characteristic values. • Equal percentage 1:33 - Fills the table with Equal percentage characteristic values. • Equal percentage 1:50 • Quick opening (Equal percentage inverse 1:25) • Quick opening (Equal percentage inverse 1:33) • Quick opening (Equal percentage inverse 1:50) • Neles L1-series butterfly valve - Fills the table with Neles specific characteristic values. • Neles R-series segment valve - Fills the table with Neles specific characteristic values. • Neles M-series ball valve - Fills the table with Neles specific characteristic values. • Clear - Clears the table. Signal modification table (Figure 21) Signal modification table. The table values are inputs at corresponding outputs. Characterization (Figure 21) This parameter controls the characterization. Options are: • Off - Shows the active state or turns the characterization off. • On - Shows the active state or turns the characterization on. • Calculate new Signal mod table from CURRENT and DESIRED tables • Clear Signal mod table • Enable new Signal mod table using all table values • Enable new Signal mod table using every second table value. This option fills the missing points using linear interpolation. 26(52) EFTA01216895 Operation NOTE: If the installed flow characteristics curve is known, this tool can ALTERNATIVELY be used to modify the installed characteristics. In this case all the words INHERENT in the tool must be understood as INSTALLED. The installed curve can be found by a simple process test or it can be calculated by the Nelprof software. NOTE: The dead angle compensation is done before the characterization. Flow chorootorizotion - 140800e4 (Online) Curren( inherent characteristic-alai:4e I Dwslredmhoront chanadensics table I Signal modOrention !able I Curse 0% Rel flow 55% Rd flow 60% Rd flow 65% Rel flow 70% Rd flow 75% Rd flow 80% Rd flow 85% Rel flow 90% Rd flow 95% Rel flow 100% Rd flow Fill table 0 177 Rd flow Rd flow Rd flow Rel flow Rd flow Rel flew Rd flow Rd flow Rd flow Rd flow 5% 0 0358 0 2166 10% 0 0127 0 2638 15% 0 0209 0 32 20% 0 03)7 0 3869 25% 0 0423 0 4666 30% 0 0562 0 5616 35% 0 0727 0 6746 40% 0 0924 0 8093 45% 0 1159 50% 0 1438 'Equal percentage 133 B Transfer Close Figure 19. Current inherent characteristics table. 27(52) EFTA01216896 Operation Flow characterization - ND800PA Online Omani inherent chatactneislics tab,* Dewed inherent characienshcs iabie I signal modecabon liable I Curves I 0% 0 Rd flow 55% 0 5500001 Rd flow RN flow 60% Rel flow 5% 005 0 6000001 Rd flow 65% Rel flow 10% 01 0.6500001 Rel flow 70% Rel flow 15% 0 15 0.7000001 Rel flow 75% Rel flow 20% 0 0 7500001 Rd flow 80% Rel how 25% 0 25 0 8000001 RN flow 85% Rel flow 30% 03 0 8500001 Rd flow 90% Rel flow 35% 0 35 0 9000002 Rd flOw 95% Rel flow 40% 04 0 9500002 Rd flow 100% Reiman 45% 045 Rd flow Fill table 50% U ,ITAILI1 'Lineal Itansfer Close Figure 20. Desired inherent characteristics table. Flan characterization - I4b800PA (Online) El Cured inherent chreactansbcs table I [Petted inherent thatactensbet table signal mociaicabon table I Calves I 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% 50% % 55% % 80% % 65% % 70% % 75% % 80% % 85% % 90% % 95% % MO% % Characterization 84 38902 27 76779 86 89898 41 61634 88 91118 50 93346 90 94279 57 90331 92 79863 63 5374 94 65448 68 22008 96 06708 72 24183 97 37798 75 82175 98 68887 78 95811 100 81 75772 Transfer Close Figure 21. Signal modification table. 28(52) EFTA01216897 Operation The page "Curves" shows the Current. Desired and the signal modification tables in graphical format. Flow characterization - FJ0H00PA (Online) Curzenlinhereal chemaclanslics table Desired inherent chtuacierislics table Signal mcialicabon fable ;Surma 0 - 8I OO on O O O I I 0 10 20 1 1 11111 1 30 40 50 60 70 80 inpuVvah(e position IN Close Figure 22. Curves. 29(52) EFTA01216898 Operation 5.6.3 Valve test To ensure that the control valves are working properly they can be tested with the Testing function. Two control valve performance tests, the Hysteresis loop and Step response, can be run with the device. The Step response test tells how rapidly the valve reacts to the input sig- nal, while the Hysteresis loop test tells how large is the dynamic hysteresis + dead band, which indicates friction quantity. The control valve test results can be used to diagnose the condition of the control valve, thus showing the need for possible future maintenance work. Running control valve tests is, therefore, very important predictive maintenance work and en- sures optimal performance of the control valve in every situation. Note that control valve test- ing affects process control by driving the control valve independently of the input signal from the control system ! The valve test control page is presented in figure 23. Before starting the test, adjust the test settings. Test can be started by pressing the button "Start test". Test can also be cancelled any time by pressing the button "Cancel test". The dialog "Test state" shows the current sate of the test procedure. The graphic window shows the on-line measurements; Positioning value and Feedback value. The window axis can be adjusted by double clicking the window. The purpose of this window is just for monitoring the test execution. This window is not intented to be used to examine the test results, since the sampling time is too long and not constant. After successful' test, the test results can be found from the pages Step response test results (fig 24) and Hysteresis test results (fig 25). The data for these graphs is collected by the device itself. The data size is 50 measurement points. Shah,. lest I Sep reset-detettretell I11yaereststest meals I Test tetanal Test type Test starbng stout Loop or step size Test duratron Test control Test State Start test Iklysterests loop test :J 0 100 100 Cancel test 96 Valve test. 0 e 0 P Figure 23. 30(52) EFTA01216899 Operation Valve test - HOODOPA (Online) El V k. kit Step *sows kS s I Hyoranos IN mar I Last lost stamps TeS1POS Teststarting seeponi Loop or stop we Tes1clursOon 20 40 ±Ig • oo •-• 0 m E !so0 £o • 0 CI O 000.1 02 0.3 04 0.5 06 0.7 0.8 09 10 Time Is) NJ close Figure 24. Page Step response test results. VIM IP I S1gworm 111thrluit HY204*1 teN MUM LOU lest selling: Test Ape Test staling spooro LOOP or am site Test cluralm a 100 100 ilg — at 0 0 £O si F- mop 0 E 0 a co oleo N O O 0 10 20 30 40 50 60 Position setpon [96) 70 80 90 100 close Help Figure 25. Page Hysteresis test results. 5.6.4 Write Protection The window Write Protection is presented in figure 26. From this window it is possible to configure three different write protection options • HW Write Protection. Indicates the position of a hardware jumper which protects all acyclic write access to all writeable parameters of a device. • SW Write Locking. Protects all acyclic write access to all writeable parameters of a device except this SW Write Locking one. Selections are On and Off. • Local Operation. Enables/Disables the local operation of the device. The operation of the host has higher priority then the local terminal one. If communication fails for a time greater 30 sec, local operation will be enabled automatically. Communication failure is defined here as absence of cyclic and acyclic communication for the specified time period. If Local Operation parameter is disabled and the communication is working again, then the device switch back to remote operation. 31(52) EFTA01216900 Operation Write Protection - NbS00PA (Online) El Write Protection HW Write Protection' SW Write Locking I Off Transfer Local Operation 'Enable° Close Figure 26. Write Protection. 32(52) EFTA01216901 Operation 5.6.5 Calibration 5.6.5.1 Page Calibration The page Calibration in the Calibration window is presented in figure 27. From this window it is possible to run following calibration routines • Automatic Travel Calibration. This calibration calibrates the position sensor range and tunes the servo control tuning parameters. This calibration must be done during the device commissioning. • Position Sensor Calibration. This calibration is needed only when the position sensor module is replaced. Position sensor is factory calibrated. • Pressure Sensor Calibration. This calibration is needed only when the pressure sensor module is replaced. Pressure sensor is factory calibrated. • Temperature Measurement Calibration. This calibration calibrates the on-board temperature measurement. Temperature measurement is factory calibrated. Each calibration routine prompts and advises the user via dialog boxes. Calibnrtion - NDB00PA (Online) User delined table, pad 1 Calibration Automatic Travel Calibration Operation Status User defined table, part 2 Position Sensor Temperature Compensation Module Calibration Start Position Sensor Calibration Start Pressure Sensor Calibration Start Temperature Measurement Calibration Cancel Close Figure 27. Calibration. 33(52) EFTA01216902 Operation 5.6.5.2 Page Position Sensor Temperature Compensation The page Position Sensor Temperature Compensation in the Calibration window is presented in figure 28. From this window it is possible to configure the position sensor temperature compensation. Options are • Compensation off. This selection turns the compensation off. • Compensation on, User defined table. This selection turns the compensation on and uses the User defined table. User defined table (part 1 of 2) is presented in figure 29. • Compensation on, Default table. This selection turns the compensation on and uses the default compensation table stored in the device memory (permanently). The position sensor temperature compensation is factory configured. The configuration is needed only when the position sensor module is replaced. Calibration - Nb800PA (Online) El !I-- Position Sensor Serial Number Temperature Compensation User defined table, part 1 User defined table, part 2 Calibration Position Sensor Temperature Compensation 11 Compensation on; Default table Compensation off Compensation on. User defined table Compensation on Default tat:I: Transfer Close Figure 28. Position Sensor Temperature Compensation. 34(52) EFTA01216903 Operation Calibration - NDSOOPA (Online) Calibration User Position defined table, patt 1 Sensor Temperature User Compensation defined table, part 2 Min -40°C 43 4576 % Max-40°C 522259 Min -35°C % Max-35°C 43 4576 52.6243 Min -30°C % Max-30°C 43 4576 52.9817 Min -25°C % Max -25°C 43 4576 53.2993 Min -20°C % Max-20°C 43 4576 53.5789 Min-15°C % Max-15°C 43 4576 53.8219 Min-10°C % Max-10°C 43 4576 54.0307 Min-5°C % Max-5°C 43 4576 54.2074 Min 0°C % Max 0°C 43 4576 54.354 Min 5°C % Max 5°C 43 4576 54.4728 Min 10°C % Max 10°C 43 4576 54.5659 Min 15°C % Max 15°C 43 4576 54.6353 Min 20°C % Max 20°C % 43 4576 54.6828 Transfer Close Figure 29. 5.6.6 Reset 5.6.6.1 Page Factory Reset User defined temperature compensation table, part 1. The page Factory Reset in the Reset window is presented in figure 30. From this window it is possible to carry out three different reset functions • Factory Reset resets device parameters to default values. The bus address remains the same. • Warmstart of the device. All parametrisation remains unchanged. • Reset the bus address to value 126. 35(52) EFTA01216904 Operation Reset - N0800P A (Online) Factory Reset I Reset Diagnostics Factory Reset Check Back Diagnosis Diagnosis Extension Factory Reset No function Factor/ Reset Warmstart Reset Address to '126' Power supply failed. More information available. - I J Pneumatics problem Transfer close Figure 30. Factory Reset. 5.6.6.2 Page Reset Diagnostics The page Reset Diagnostics in the Reset window is presented in figure 31. From this window it is possible reset following diagnostic trends • Event history • Travel Deviation trend • Valve travel vs. time trend • Load Factor trend • Valve travel counters • Actuator travel counters Factory Reset Reset Diagnostics I Reset Diagnostics Valve travel counters None Event history Travel deviation trend Valve travel vs time trend Load factor trend Actuator travel counters Transfer Close Figure 31. Reset Diagnostics. 36(52) EFTA01216905 Operation 5.7 View menu The items in the view menu are presented in the figure 32. F' SIMATIC P DM - Nd800po elle Device lid id ti_14 Qptions yelp Display Device Status 'dent Valve Diagnostics of Event Log R D. Ioolbar A fa atatus bar Update F5 I e - I Batch Information Figure 32. View menu. 5.7.1 Display 5.7.1.1 Page Measured Value The page Measured Value of the window Display is presented in the figure 33. This window monitors the Setpoint, Readback value and related information. toispkoy - t4P800Pe (Online) Measured Value I Output I Readback value 50.49236 % 0% Readback Value Readback Value Segura Setpoint Valve Position Selpoint De Cation Check Back 6049236 sci 60% 100% Quality I J Limit I 'ite ouamy Limit ►' 30 28838 Status OK Close Figure 33. Display I Measured Value. 37(52) EFTA01216906 Operation 5.7.1.2 Page Output The page Output of the window Display is presented in the figure 33. This window monitors the AO Block Output and Positioning value. The signal modifications presented in figure 13 and characterization impact between these two signals. Positioning value is the final servo control setpoint after all signal modifications. Display - ell)800PA (Online) MeoswedVdue °ItPul Output Wet* 50 % 0% Output Value Output Value Positioning Value 50 60% 100 % A% Quaky I Limit I ted 80.80146 % 0% Positioning Value Postponing Value Check Back 80 80146 60% 100% % Ouatity IbuuJ Limit Status OK Close I HO) I Figure 34. Display I Output. 38(52) EFTA01216907 Operation 5.7.2 Device Status 5.7.2.1 Page General The page General of the window Device Status is presented in the figure 35. This window has first some identification parameters and the last three ones are diagnostic parameters. Device Status - Nb800PA (Online) General I profile I TAG Manufacturer Device ID Serial Number Software Revision Hardware Revision Installation Date Check Back Diagnosis Diagnosis Extension NDBOOPA NDBOOPA 2000390016 1.00 0.20 01.01.2000 Status OK Power supply failed. More inforrnabon available. Pneumatcs problem a Close Help Figure 35. Device Status \ General. Parameters Checkback, Diagnosis and Diagnosis Extension report the device diagnostic status messages. These parameters are explained in tables 1, 3 and 4, correspondingly. 39(52) EFTA01216908 Operation 5.7.2.2 Page Profile The page Profile of the window Device Status is presented in the figure 36. This window monitors the revision level of the static data associated with the three blocks. The Static Revision No. is changed by the device each time a static parameter has changed in value. Device Status - N0800PA Online General Profile Profile Profile Revision I —Static Revision No. Physical Block Transducer Block Function Block 11 4 23 Close I Help I Figure 36. Device Status 1 Profile. 40(52) EFTA01216909 Operation 5.7.3 Valve Diagnostics The ND800