


10/22/14 TECH-488/D.W.O. 21089 of 28

Revision History Revision 22 Oct, 2014 Initial release Westlock Controls Offices

USA Westlock Controls Corp. 280 North Midland Ave. Ste 258, Saddle Brook, NJ 07663 Phone: (201) 794-7650 •Fax: (201) 794-0913 Email: [email protected] Internet http://westlockcontrols.com Europe Westlock Controls UK 22 Chapman Way, Tunbridge Wells Kent, England TN2 3EF Phone: 011-44-189-251-6277 •Fax: 011-44-189-251-6279 Email: [email protected] Internet: Error! Hyperlink reference not valid. South America Westlock Equipamentos de Controle Ltda. Sales: Al. Araguaia, 2044 – Sl. 1101, Bloco B Edifício CEA – Alphaville Barueri – São Paulo – Brasil 06455-000 Tel: + 55 11 2588-1400 Fax: + 55 11 2588-1410 Email: [email protected] Internet: Error! Hyperlink reference not valid.

Operations: Av. Antonio Bardella, 3000 Galpões 2A e 2B – Alto da Boa Vista Sorocaba – São Paulo – Brasil 18085-852 Tel: + 55 15 2102-7400 Fax: + 55 15 2102-7400

Asia Westlock Controls Singapore Sales: King's Centre #04-01 390 Havelock Road Singapore 169662 Phone: +65 676 858 00 •Fax: 011-441-892-516279 Email: [email protected] Internet: http://www.westlockuk.com




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Table of Contents

1. Introduction ................................................................................................ 5

1.1. Product Certification ............................................................................ 5

1.2. Warnings............................................................................................... 5

1.3. Description ........................................................................................... 6

1.4. Principles of Operation ......................................................................... 6

1.5. Features ................................................................................................ 6

1.6. Specifications ........................................................................................ 7

2. Order Guide ................................................................................................. 7

3. Installation .................................................................................................. 8

3.1. Limit Switch Adjustment ...................................................................... 9

3.2. Operating Instructions for Falcon Solenoid ......................................... 9

3.2.1. Standard Valve Specifications ...................................................... 9

3.2.2. Installation/Connection of FalconV Directional Control Valve ..... 10

3.2.3. Usage Instructions for Option Valves ......................................... 11

3.2.4. Plumbing and Air Supply Considerations ................................... 11

4. Field Wiring ............................................................................................... 13

5. Maintenance and Repair ........................................................................ 15

6. Hardware Configuration ............................................................................ 16

6.1. Setting the Profibus Slave Address..................................................... 16

6.2. Output Configuration ......................................................................... 17

6.2.1. Fail Safe Condition ..................................................................... 17

6.2.2. Double Acting Fail Safe Conditions ............................................. 17

6.2.3. Single Acting Spring Return Fail Safe Conditions ......................... 17

6.3. Potentiometer Calibration ................................................................. 18

7. Connection Options ................................................................................... 18

8. Module Data Configuration........................................................................ 18

9. Parameters ................................................................................................ 19

9.1. Instantaneous Reversal Time (1 Byte) ................................................ 19

9.2. Travel Timeout (1 Byte) ...................................................................... 19

9.3. Hold Control (1 Byte) .......................................................................... 19

9.4. ESD Action (1 Byte) ............................................................................. 19

9.5. Service Count Limit (2 bytes) .............................................................. 19

10. Slave Input Data (received from Master Out Data) ................................... 20

11. Input Bit Description................................................................................ 20

11.1. CL-CMD Bit for OUT-CL Output (0 x 00 01) ...................................... 20

11.1.1. OUT-CL Output when Hold Control is set to 1 ........................... 20

11.1.2. OUT-CL Output when Hold Control is set to 0 ........................... 20

11.2. OP-CMD Bit for OUT-OP Output (0 x 00 02)..................................... 21

11.2.1. OUT-OP Output when Hold Control is set to 1 .......................... 21

11.2.2. OUT-OP Output when Hold Control is set to 0 .......................... 21

11.3. Stop (0 x 00 04) ................................................................................. 21

11.4. ESD (0 x 00 08) .................................................................................. 21




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11.5. Potentiometer Calibration (0 x 01 00 & 0 x 02 00) .......................... 22

11.6. Reset Counter (0 x 04 00) ................................................................. 22

11.7. Set Diagnostic Flag (0 x 08 00) .......................................................... 22

12. Slave Output Data (sent to Master In Data) .............................................. 23

13. Output Bit Description ............................................................................. 23

13.1. Lower Limit Switch (Closed) (Byte-0 Bit-0, 0 x 00 00 00 01) ............ 23

13.2. Upper Limit (Open) (Byte-0 Bit-1, 0 x 00 00 00 02) .......................... 23

13.3. Closed Command Travel (Byte-0 Bit-2, 0 x 00 00 00 04) .................. 23

13.4. Open Command Travel (Byte-0 Bit-3, 0 x 00 00 00 08) .................... 23

13.5. ESD Active (Byte-0 Bit-4, 0 x 00 00 00 10) ........................................ 24

13.6. Auxiliary Inputs (Byte-1 Bit-0 to Bit-3, 0 x 00 00 01 00, 0 x 00 00

02 00, 0 x 00 00 04 00 and 0 x 00 00 08 00) .................................. 24

13.7. Position Feedback (Byte-2 and Byte-3, 0x FF FF 00 00) ................... 24

14. Diagnostic Data ....................................................................................... 25

15. Diagnostic Data Bit Description ................................................................ 25

15.1. Fail to Close Alarm (Byte 0, Bit 0) ..................................................... 25

15.2. Fail to Open Alarm (Byte 0, Bit 1) ..................................................... 26

15.3. Limit Switch Alarm (Byte 0, Bit 2) ..................................................... 26

15.4. Service Count Exceeded (Byte 0, Bit 3) ............................................ 26

15.5. Position Sensor Failure (Byte 0, Bit 4) .............................................. 26

15.6. Cycle counter (Bytes 1, 2, 3 & 4) ...................................................... 26

15.7. Average Close Time (Bytes 5 & 6) .................................................... 26

15.8. Average Open Time (Bytes 7 & 8) .................................................... 26

15.9. Parameters (Bytes 9 through 14) ..................................................... 26

15.10. Potentiometer Raw A-D Bits 0% (Bytes 15) ................................... 26

15.11. Potentiometer Raw A-D Bits 100% (Bytes 16) ............................... 26

16. Profibus Slave Address Table ................................................................... 27

17. Appendix (Air Filtration and Lubrication) ................................................. 28

18. Bibliography ............................................................................................ 28




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1. Introduction

1.1. Product Certification

72XX PROFIBUS Network Valve Monitor NI / I / 2 ABCD; S / II, III / 2 / FG / T4 Ta = 60°C; Type 4X *NI / I / 2 ABCD /T4 Ta = 60°; TYPE 4X *Pin Connecter only

7279 PROFIBUS XP / I / 1 / CD T6 Ta = 60°C; NI / I / 2 / ABCD / T5 Ta = 60°C; DIP / II, III / 1 / EFG T6 Ta = 60°C; Type 4, 4X

1.2. Warnings

• Never remove enclosure cover or make/break electrical connections with power connected to the unit.

• Perform all wiring in accordance with site and local codes and the National Electric Code ANSI-NFPA-70 (US) or the Canadian Electric Code Part I (Canada) for the appropriate area classifications.

• Confirm that the Profibus model being installed is approved for the hazardous area (consult unit identification label).

• Confirm that power supplied to network is within rated specifications listed on the unit identification label and is allowed for that network type.

• Protect the unit from exposure to aggressive substances or atmospheres to ensure that hazard rating is not compromised.

• Disconnect power and the inlet air supply before conducting any valve service or maintenance. Avoid the introduction of any contaminants into the valve.




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1.3. Description

The Profibus Pneumatic Actuator Controller (PPAC) is an actuator control module designed to meet the specific performance requirements of all pneumatic and electric actuators. The module can be an integral part of electric actuators and is installed inside the actuator housings. The PPAC provides actuator Open/Stop/Close control, Emergency Shutdown (ESD), and actuator status information including position feedback via the Profibus DP network protocol.

Profibus DP started as a joint Fieldbus project in 1987 between several companies (Siemens, Klockner- Moeller, Bosch, and 10 other Manufactures), The Profibus User Organization (PNO) was founded in 1989. The PNO oversees the Profibus specification and conformance testing of Profibus products. It is open to any manufacturer or user of this protocol with a worldwide membership of over 1100 companies. By the end of 2001, Profibus already had more than 5 million installed devices, over 2,000 available products, more than 550,000 applications worth more than $5.8B, and User Groups in 23 countries. Profibus is a powerful networking solution that reduces the cost and time required to install and wire industrial automation devices. A single Profibus AVID System will accommodate up to 126 stations, typically 124 slaves with 992 discrete I/O points and 124 analog points. Profibus has the capability to interconnect complex and simple devices from multiple vendors on the same network.

1.4. Principles of Operation

Westlock Profibus DP Module is a six discrete input, single analog resistive input, and two-output network monitor. Inputs 0 and 1 are internal Hall Effect sensors that are activated by the shaft trigger assembly magnets (south pole). Inputs 2 thru 5 are active low (activated by pulling the input to ground) for use with dry contact type sensors. Outputs are FET (field effect transistor) open drain active low with diode protection. Position feedback is an analog value developed via an external potentiometer returned as a value in the range 0 to 1000, representing the position in 0.1% increments. For data exchange to occur, each station, master or slave, connected to the Profibus network must be programmed with a unique address, numbered between 0 and 125. It is possible to exchange or add devices to the network during normal operations without interfering with communications to other nodes.

1.5. Features

• Open/Close limit switch indication. • Analog position feed back • Configurable - Drive Open/Drive Close/Stayput Emergency Shut Down command via the

Profibus Network. • LED status indicators for local diagnostics • Configurable address via the on-board DIP switch • Plug in style electrical terminal blocks




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1.6. Specifications

Topology Zero drop/daisy chain, no spurs Max. Bus Length 1200meters/segment Max. # of Segments 10 Max. Spur Length If unavoidable, 0.3m DATA RATE 9.6, 19.2, 93.75, 187.5, 500, 1500, 12000 kbps

Module Specifications: Max. Power Consumption (inputs and outputs energized)

7.5 W

Current Consumption (no load) 60 mA at 24V – typical Current Consumption with Solenoid

310 mA max (larger solenoids), 80 mA (with 20mA solenoid)

Input Voltage (from bus) 11 - 25 VDC (for PAC module, solenoid may require different voltage range)

Operating Temperature Range -40°C to +85°C Storage Temperature Range -40°C to +90°C Physical I/O 2 Hall Effect inputs (Close and Open Limit Switches)

4 Dry Contact General Purpose Inputs (Auxiliary Inputs) 2 Open Drain Outputs (Solenoid Outputs are powered

from Input Voltage from bus which is typical 24VDC). Each output has overload protection (maximum current per output is 100mA)

Analog Position Feedback Option Visual Indication Module and Network diagnostics

Closed Limit Switch (CL, Yellow LED) Open Limit Switch (OP, Yellow LED) General Input 1 (GI1, Yellow LED) General Input 2 (GI2, Yellow LED) General Input 3 (GI3, Yellow LED) General Input 4 (GI4, Yellow LED) Close Command Output (CL-CMD, Yellow LED) Open Command Output 1 (OP-CMD, Yellow LED)

2. Order Guide Ordering guides for all Profibus product series covered by this IOM are available through a local Westlock distributor, the current Westlock Controls catalog literature or the Westlock Controls website at www.westlockcontrols.com. Spare parts lists for refurbishments or repairs are also available for common Profibus models.




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3. Installation

Important: If valve monitor is in the field already mounted on an actuator and valve, please follow the field wiring instructions.

Warning: The valve monitor should always be handled with care when the cover is removed and wired to an electrical power source.

1. Attach the proper mounting bracket and adapter to the valve monitor housing with the hardware provided.

2. Operate the actuator to the fully closed position.

3. Attach the valve monitor and mounting bracket to

the actuator.

4. Remove the housing cover (by loosening all the cover screws) to gain access to the Limit Switches.

5. Adjust the Limit Switches as outlined in the Limit

Switch Adjustment section 3.1.

6. Before replacing the housing cover, note the position of the actuator and valve. Replace the cover and confirm that the Beacon position is properly aligned to the current valve position, as shown below. If it is not correct remove the four screws on the Beacon cover, rotate the Beacon 90 degrees and replace the screws.

Valve Monitor Housing

Mounting Bracket

Actuator




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3.1. Limit Switch Adjustment

Note: Switches are factory set. If you need to adjust them for any reason follow the instructions below. Switch actuation can be confirmed using a 24 VDC power supply or a Profibus DP network applied to J1 pin-1 (24V IN+) and J1 pin-2 (24V IN-). Use CL LED to show lower switch activation and OP LED to show upper switch activation. Adjust cams by hand by pushing/pulling the cam against the shaft spring to disengage from the mating spline, rotating to adjust and re-engaging firmly onto spline.

1. Remove unit cover as follows: loosen (but do not remove) cover captive screws, rotate top cover slightly to grip corners, pull top cover firmly away from bottom housing. DO NOT PRY COVER WITH TOOLS.

2. With valve in the closed position, adjust bottom cam until the bottom switch actuates as indicated by the CL LED.

3. Stroke valve to the open position, adjust top cam until the top switch actuates as indicated by the OP LED.

4. Cycle actuator several times to confirm proper switch indication at each end of stoke. Finely adjust cams if necessary.

5. Replace unit cover, applying approximately 20 in-lbs. of torque to cover screws.

3.2. Operating Instructions for Falcon Solenoid

3.2.1. Standard Valve Specifications

NOTE: ALWAYS consult the Quantum product ID label for coil electrical specifications

and for pressure and temperature specifications for each unit, as they will vary with area classification, valve options and other factors.

Solenoid Specifications Operating Pressure: 30-120 PSIG for single-coil valves; 20-120 PSIG for dual coil valves. Solenoid Operating Media: Lubricated or dry air, filtered to 40 microns. If air line lubricators

are used, please see Appendix for information or lubricating oils and suggested brands.




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Solenoid Operating Temperature:

Solenoid Type Temperature Range General purpose and non-Incendive coils:

-40° C to +75° C (-40° F to +167° F), except 125 VDC which is -40° C to +90° C (-40° F to +194° F)

Intrinsically safe coils: -40° C to +85° C

Standard valve bodies with Viton Seals: -20° C to +93° C (-5° F to +200° F)

Low temperature valve bodies with low temperature Buna Seals:

-48° C to +93° C (-55° F to +200° F).

(Agency approvals may not encompass full operating temperature range). For operating specifications of legacy Falcon Valves, see Tech-132.

3.2.2. Installation/Connection of FalconV Directional Control Valve

NOTES - For Dual Coil Valves 1. The valve may be in either position upon installation. Refer to the Air Flow Diagrams (Fig. 2)

and energize the appropriate coil (with supply air present) to reset valve to the desired position.

2. Dual coil valves require both an electrical signal and appropriate air pressure to operate. If either or both (electrical/air inputs) are lost the valve will remain in its current position.

3. Both coils should never be energized simultaneously. 4. If using manual overrides on a dual coil valve, the coils must be de-energized.

Porting Designation 1/4” NPT air ports for inlet, outlet, and exhaust (4.3 Cv FalconV valve has 1/2” NPT air ports)

Spring Return 3-Way (3/2) Valve Description of Operation: Solenoid De-energized -

air flows from Outlet Port 2 to Exhaust Port 3. Solenoid Energized - air flows from Inlet Port 1 to

Outlet Port 2.

Spring Return 4-way (5/2) Valve Description of Operation: Solenoid De-energized - air

flows from Inlet Port 1 to Outlet Port 2 and exhausts from Port 4 to Port 5. Solenoid Energized - air flows from Inlet Port 1 to Outlet Port 4 and exhausts from Port 2 to Port 3.

Dual Coil 4 -way (5/2) Valve Description of Operation: Coil B Energized - air flows from

Inlet Port 1 to Outlet Port 2 and exhausts from Port 4 to Port 5. Coil A Energized - air flows from Inlet Port 1 to Outlet Port 4

and exhausts from Port 2 to Port 3.

Note: The valve will not change state until the energized coil is de-energized and the opposite coil is energized in that order.

Fig. 2 Air Flow Diagrams

A B




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3.2.3. Usage Instructions for Option Valves

N – Manual Reset (Latching) Use palm button to manually shift valve position. Hold down latch button, then release palm button to latch in the shifted position. Latched position will be sustained and latch will automatically disengage when air and voltage are applied. When the coil is de-energized, the valve will return to its original position. See Fig. 3 R - Manual Reset (Non-Latching) With the coil first energized, and inlet air signal present, use palm button to manually shift valve position. Shifted position will be sustained as in normal use until coil is de-energized or inlet air is lost. When the coil is de-energized, the palm button automatically returns to its original position. See Fig. 4 L - Locking Manual Override Manually depress palm button and rotate clockwise for maintained condition; must manually disengage to return to original position. See Fig. 5 Coils must be de-energized before operating manual override. M - Momentary Manual Override Manually depress palm button to shift valve and manually hold to sustain shifted position. See Fig. 5 Coils must be de-energized before operating manual override E - External Pilot Provide auxiliary pressurized air supply to the external pilot connection of the valve. Supply a pressure signal to this auxiliary port in conjunction with electrical signal to solenoid to shift the valve. This feature should be used when the pressure supplied to inlet port 1 is below the minimum operating pressure. D/C - Dual Coil Option Four way valves are available with solenoid actuators on both ends of the Falcon valve, coil “A” and coil “B”, for fail-last logic. When only coil “A” is energized, the valve will shift as a standard 4-way does. If coil “A” is then de-energized, the valve will remain in this last position. The valve will not return to the original state until coil “A” is de-energized and coil “B” i s energized . The process is the same for coil “B”.

3.2.4. Plumbing and Air Supply Considerations

Fig. 3

Fig. 4

Fig. 5




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Air mains and lines should be large enough to avoid excessive pressure loss under conditions of maximum flow. Air lines should be installed with as few restrictions as possible if the cost of compressed air is to be kept to a minimum. Sharp turns in piping should be avoided for more efficient air flow and economical air power. It is advisable to pitch the mains in the direction of air flow so that both gravity and air flow will carry the water to traps or water legs located at frequent intervals.

To help in preventing condensed moisture from reaching the point of usage, down pipes should never be taken directly from the bottom of air pipes or mains. Connection should be made at the top of the main and a long radius return bend used.

The importance of proper filtration (40 Micron) of the air supply to pneumatic equipment can never be over-emphasized as a means of preventing wear due to abrasive solids being present in the air supply. Provide pneumatic equipment with serviced air by including suitable air line filters, and pressure regulators in the installation at minimum. If lubricators are used in the air line, use appropriate oil grades, such as ISO and UNI FD22. The performance and life of pneumatic valves may be affected by air supply conditioning methods. AIR FLOW Pipe sizes are normally determined on semi empirical lines, the basis for selection being an acceptable pressure drop (e.g. not more than 10% of the applied pressure). In sizing pipes, consideration should be given to likely future demands, as a system will be inefficient if the demand outgrows the supply. It is always better to over size mains as this will reduce air velocity and make water separation more effective. TUBES AND FITTINGS The use of copper, stainless steel, nylon or polyethylene tube is recommended for piping up air circuits and equipment. As a general rule, pipe threaded fittings should not be assembled to a specific torque because the torque required for a reliable joint varies with thread quality, port and fitting materials, sealant used, and other factors. The suggested method of assembling pipe threaded connections is to assemble them finger tight and then wrench tighten further to a specified number of turns from finger tight. The assembly procedure given below is for reference only; the fitting should not be over tightened for this will lead to distortion and most likely, complete valve failure.

1. Inspect port and connectors to ensure that the threads on both are free of dirt, burrs and

excessive nicks. 2. Apply sealant/lubricant or Teflon tape to the male pipe threads. With any sealant or

tape, the first one or two threads should be left u ncovered and care must be taken to avoid the application of excessive sealant media to avoid system contamination.

3. Screw the connector into the port to the finger tight position. 4. Using wrench tighten the connector approximately 1 - 2 turns (to seal) from finger tight.

Again this is for reference only - the fitting should NOT be over tightened.




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4. Field Wiring

1. The Wiring options for 7244 & 7279ME or XE are shown in Fig. 1 and 2 below. The proper wiring diagram for your unit is shown on the inside of the 7279ME or XE covers.

2. All wiring must be in accordance with National Electrical Code (ANSI-NFPA-70) for area classifications. The valve monitors are approved as explosion proof for Class I, Division 1, Groups C and D; non-incendive for Class I, Division 2, Groups A,B,C and D; dust-ignition proof for Class II/III, Division 1, Groups E,F and G hazardous (classified) locations; indoor/outdoor (NEMA type 4, 4X).

Always check the nameplate to make sure the agency approval ratings coincide with the application.

Caution: To Prevent Ignition of Hazardous Atmospheres, Replace Cover Before Actuating the Electrical Circuits. Keep Cover Tightly Closed When in Operation.

3. Replace the electronics housing cover or junction housing cover.

4. Unit is now ready for automatic operation. If any assistance is required, please call Westlock Controls at (201) 794-7650

Model 7244

1 2 3 4 5 6 7 8

ON

J9J2 J4

CL-CMDGI1 GI2 GI3 GI4 OP-CMD

DAX

OP

NET

CL

MOD

OUT-OP+ –

OUT-CL+ –J5PROG POT

MODADDRESS

CAL

S1

Figure 1




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5. Maintenance and Repair

Maintenance or repair of Westlock equipment must only be done by Westlock Controls or by qualified personnel that are knowledgeable about the installation of electromechanical equipment in hazardous areas. All parts needed for repairs or maintenance must be purchased through a Westlock Controls authorized distributor to maintain warrantee and to ensure the safety and compliance of the equipment.

No routine maintenance of Westlock Profibus units is recommended when units are installed in environments for which they are designed. Severe environments may warrant regular replacement of field units every two to five years for maximum performance and safety.

Troubleshooting Problem: No Power

• Check that power supply to the loop is functioning correctly and adequate to power all devices on the loop;

• Check that power wiring is in the correct location (device is polarity sensitive); • Check that power being supplied to unit is within the rated specifications; • Check wiring integrity immediately at the connection to the control device; • Check field wiring coming into the Profibus terminal strip for proper connection

and good wire preparation practices (approximately ¼” of insulation removed and all strands intact);

• Check that field wiring is no larger than 12AWG for proper fit in terminal strip and compliance with terminal strip rating.

Problem: Device does not appear on network

• Check address and make sure another unit is not using the same address. Problem: Beacon does not display the correct flow path

• Reset Beacon per the Beacon Adjustment section under Calibration. Problem: Unit appears to be binding during valve stroke or unit shaft has broken

• Carefully measure and adjust axial alignment of unit shaft, coupler and actuator shaft to eliminate lifting or twisting of the coupler during travel.

Problem: Unit has signs of moisture ingress • Check torque on cover screws • Check gaskets and sealing surfaces for debris and clean if necessary • Check that conduit connections are properly sealed, including gland fittings and

quick-disconnect receptacles • Check that conduit pipes are properly pitched to direct condensing moisture away

from units • Check that all unused conduit entries are properly sealed with suitably certified

plugs having an ingress protection rating of IP67 or better.




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6. Hardware Configuration

1 2 3 4 5 6 7 8

ON

J9J2 J4


DAX

OP

NET

CL

MOD

OUT-OP+ –

OUT-CL+ –J5PROG POT

MODADDRESS

CAL

S1

HS2

HS1CL-LS

OP-LS

J21 2 3 4 5

1 2 3 4 5 6 7

J1

J41 2 3 4

1 2 3 4 5 6 7 8

ON

J9


DAX

OP

NET

CL

MOD

J5PROG POT

MODADDRESS

CAL

S1

GI2GI1 GI3 GI4 COM+ – + –

OUT-OP OUT-CL

CL-LS

OP-LS

1 2 3 4 5 6 7

J1 HS2

HS1CL-LS

OP-LS

Figure 3 Figure 4

6.1. Setting the Profibus Slave Address

The Profibus slave address is configured by setting the binary address on selector switch S1 (See Figure 3 or Figure 4 above). Examples are shown below.

Slave Address 3 Slave Address 4 Slave Address 8 Slave Address 25

Switch position 8 serves to override the Solenoid Output fail state upon loss of communication. With S1-8 in the Off position the Solenoid outputs will go to the ESD state (see section 9.4) if communication is lost for more than 10 seconds. With S1-8 in the On position the Solenoid Outputs will remain as they are if communication is lost.

ON

1 2 3 4 5 6 7 8

ON

1 2 3 4 5 6 7 8

ON

1 2 3 4 5 6 7 8

ON

1 2 3 4 5 6 7 8




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6.2. Output Configuration

There are two outputs available to drive the actuator, one labeled OUT-OP and the other labeled OUT-CL. The OUT-OP would be connected to the solenoid that will drive the valve toward the Open position and the OUT_CL would be connected to the solenoid that will drive the valve toward the Closed position. Typically this will be used with a double acting actuator where one solenoid (connected to OUT-OP) will drive the actuator to the Open position and the other solenoid (connected to OUT-CL) will drive the actuator to the closed position. It can also be used with a spring return actuator where the configuration is arranged so the spring forces the actuator to the fail safe position. Then one solenoid is used to drive the actuator to the opposite position. In this case if fail safe is the Closed position then the solenoid is connected to OUT-OP, if fail safe is the Open position then the solenoid is connected to OUT-CL.

6.2.1. Fail Safe Condition

Fail safe condition is the position that the valve is to go to, upon a failure that will be the safest for the process. There are typically three areas of failure that should be considered, Failure Of Power, Failure Of Supply Air and Failure Of Network Communication. It is best practice to have all 3 of these fail in the same state of valve position. You can choose the state that the Profibus PAC will set its Solenoid outputs upon loss of network communication. This is done with a combination of S1-8 (part of address switch) and the ESD parameter. With S1-8 in the Off position the Solenoid outputs will go to the ESD state (see section 9.4) if communication is lost for more than 10 seconds. With S1-8 in the On position the Solenoid Outputs will remain in the state they currently are when communication is lost. Power must be available to the Profibus PAC for it to set the Solenoid outputs and for the outputs to supply to the solenoids. During failure of power or failure of network communication to the PAC the host system cannot determine the actual state of the valve position. This is one of the reasons for having the fail state the same for loss of power and loss of communication.

6.2.2. Double Acting Fail Safe Conditions

A double acting actuator is typically used when the fail safe condition is to keep the actuator at the current position upon failure. The piping of the air and the connection of the PAC Solenoid outputs will determine valve direction. Upon loss of air the actuator will not have any air available to cause movement. This will normally keep the vale in the current position but some valves and actuators may have some movement due to factors such as rate of change of the pressure as air is being lost, the process flow in the vale causing valve movement when both the actuators chambers have no air.

6.2.3. Single Acting Spring Return Fail Safe Conditions

A single acting spring return actuator is typically used when the fail safe condition is to have the valve go to the Closed or Open position upon a failure. Activating a solenoid to supply the air to the actuator chamber will drive the actuator in the opposite direction of the spring action. When the solenoid is turned off or air fails the spring will return the actuator to the fail safe position. The air pressure to move the actuator must be sufficient to overcome the force of the spring.




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6.3. Potentiometer Calibration

The position feedback potentiometer can be calibrated by either software or hardware. The software procedure is outlined in the following section entitled ‘Input Bits Potentiometer Calibration section 11.5’ The calibration can also be performed as follows:

1. Move the actuator to the close limit so that the Close Limit LED is illuminated.

2. To set the close position, press and hold the CAL button for 3 Seconds.

3. The Close LED will flash for 3 seconds, and then stop confirming the position has been set.

4. Move the actuator to the open limit, until Open Limit LED is illuminated.

5. To set the open position, press and hold the CAL button for 3 Seconds. The Open LED will flash for 3 seconds, and then stop confirming the position has been set.

7. Connection Options

Profibus DP supports a zero drop topology. Stubs less than or equal 0.3m are permitted if unavoidable.

Each segment can have a maximum of 32 devices attached (i.e. slaves, masters, repeaters, couplers, diagnostic tools etc). Each segment must not be longer than the specified maximum, which is dependent on bit-rate

BAUDBAUDBAUDBAUD raterateraterate Maximum SegmentMaximum SegmentMaximum SegmentMaximum Segment lengthlengthlengthlength

(When using best quality PROFIBUS RS485 (Type A) cable)(When using best quality PROFIBUS RS485 (Type A) cable)(When using best quality PROFIBUS RS485 (Type A) cable)(When using best quality PROFIBUS RS485 (Type A) cable)

9.6 Kbit/s 19.2 Kbit/s 45.45 Kbit/s 93.75 Kbit/s 187.5 Kbit/s

1000m

500 Kbit/s 400m 1500 KBit/s 200m 3000 Kbit/s 6000 Kbit/s

12000 KBit/s 100m

8. Module Data Configuration The unit can be configured as a 2 byte Input/2 byte Output module standard discrete Output (no analog position feedback used) or a 2 byte Input/4 byte Output module for use with analog position feedback.

0.3m stub

DP

Master Slave

Slave Slave Slave




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9. Parameters The following parameters are configurable using the appropriate network management tools or from the GSD file.

9.1. Instantaneous Reversal Time (1 Byte)

The Instantaneous Reversal Time Delay is configurable from 0.5 to 255 seconds in 100 ms increments. The Instantaneous Reversal Time prevents the action of instantaneously energizing the opposite output by delaying it for a preset amount of time.

9.2. Travel Timeout (1 Byte)

The Travel Timeout parameter sets the maximum allowable time from a command being received by the actuator to the corresponding limit switch activating. If the time to complete an actuator stroke is greater than the value set for this attribute the appropriate Fail to Open or Fail to Close alarm will be set (the travel will not stop it just sets an alarm). The Travel Timeout value is configurable between 0 to 255 seconds in increments of 1 second. A setting of 0 will disable this feature. Suggested time-out for pneumatic actuators is 15 seconds.

9.3. Hold Control (1 Byte)

If this parameter is set to 1 the PPAC will hold actuator at the target position i.e. if the actuator has received an Open/Close command, the actuator outputs will remain energized preventing movement from the full open/close position. A Stop command will de energize the output. Setting the Hold Control parameter to 0 will cause the actuator to de energize its outputs on completion of a command (as indicated by the activation of the limit switch of the commanded position). For pneumatic actuators it should be set to 1. See OP-CMD, CL-CMD and Stop commands in the Input Bit Description section 11 for more detailed information regarding the interaction with each command.

9.4. ESD Action (1 Byte)

The following values determine the ESD Action.

Parameter Value - ESD Action 0 - StayPut (Both Solenoid Outputs De-energized)

1 - Drive Close

2 - Drive Open

9.5. Service Count Limit (2 bytes)

The value of this parameter determines the number of cycles x 1000, after which the service request alarm is set (See Diagnostic Data Bit Description section 15.4). Setting a value greater than the value stored in the cycle counter will reset the alarm; alternatively setting this value to zero will disable the service count alarm.




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10. Slave Input Data (received from Master Out Data) The slave will accept two bytes of input data defined in the following table, a more detailed description of each function can be found in the sections to follow. The Input data consists of two bytes: - Byte 0, Runtime Inputs and Byte 1. Commissioning Inputs. Under normal operation 0x00 should always be written to Byte 1

Bit Hex Mask Description

BY

TE

0

0 0x00 01 CL-CMD (OUT-CL Output) 1 0x00 02 OP-CMD (OUT-OP Output) 2 0x00 04 Stop (deactivate OUT-CL & OUT-OP) 3 0x00 08 ESD 4 0x00 10 Not Used 5 0x00 20 Not Used 6 0x00 40 Not Used 7 0x00 80 Not Used

BY

TE

1

0 0x01 00 Set Close (0)% 1 0x02 00 Set Open (100)% 2 0x04 00 Reset 3 0x08 00 Set Diagnostic Flag 4 0x10 00 Not Used 5 0x20 00 Not Used 6 0x40 00 Not Used 7 0x80 00 Not Used

Only one bit of Byte 0 should be set at any one time. In the case of more than one bit being set, the following priority of commands will apply:

1. ESD 2. Stop 3. Drive Close 4. Drive Open

11. Input Bit Description

11.1. CL-CMD Bit for OUT-CL Output (0 x 00 01)

A transition of this bit from 0 to 1 will cause the OUT-CL Output to energize. Clearing the bit while the actuator is moving will have no effect. Only a Stop command will halt the actuator. Once the close position is reached, the action is dependent on the value of the parameter Hold Control as follows:

11.1.1. OUT-CL Output when Hold Control is set to 1

When the end of travel limit is reached, the OUT-CL Output will remain active, independent of the value of the CL-CMD Bit (i.e. the close output will remain energized if the drive close bit is set or is cleared). A Stop command will clear the CL-CMD command and turn off the OUT-CL Output.

11.1.2. OUT-CL Output when Hold Control is set to 0

When the end of travel limit is reached the OUT-CL Output will be deactivated, independent of the value of the CL-CMD Bit. (i.e. the close output will remain de-




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energized if the CL-CMD Bit is set or is cleared). If the actuator is manually moved from the Close Position, only a transition of the CL-CMD Bit from 0 to 1 will re-initiate the OUT-CL Output. To ensure that the actuator will properly respond to the next Close command, it is recommended that this bit be cleared after use.

11.2. OP-CMD Bit for OUT-OP Output (0 x 00 02)

A transition of this bit from 0 to 1 will cause OUT-OP Output to energize. Clearing the bit while the actuator is moving will have no effect. Only a Stop command will halt the actuator. Once the opened position is reached, the action is dependent on the value of the parameter Hold Control as follows:

11.2.1. OUT-OP Output when Hold Control is set to 1

When the end of travel limit is reached, the OUT-OP Output will remain active, independent of the value of the OP-CMD Bit (i.e. the open output will remain energized if the drive open bit is set or is cleared). A Stop command will clear the OUT-OP Output.

11.2.2. OUT-OP Output when Hold Control is set to 0

When the end of travel limit is reached the OUT-OP Output will be deactivated, independent of the value of the OP-CMD Bit (i.e. the open output will remain de-energized if the OP-CMD Bit is set or is cleared). If the actuator is manually moved from the Open Position, only a transition of the OP-CMD Bit from 0 to 1 will re-initiate the OUT-OP Output To ensure that the actuator will properly respond to the next Open command, it is recommended that this bit be cleared after use.

11.3. Stop (0 x 00 04)

Setting this bit stops the actuator at its current position. This turns off both the OUT-CL Output and the OUT-OP Output

Note: In the case of a pneumatic actuator with a single coil, two-position solenoid, the result of issuing a Stop command will be to de-energize the solenoid coil, returning the actuator to the de-energized position. (See Parameters section 9 for more information).

11.4. ESD (0 x 00 08)

When this variable is set to 1 the actuator will move to the Emergency Shut Down (ESD) position as set via the ESD parameter (See Parameters section 9.4 for more information).




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11.5. Potentiometer Calibration (0 x 01 00 & 0 x 02 00)

Setting bit 0 & 1 of byte 1 will calibrate the potentiometer feedback. Whenever a bit is written, the current potentiometer value (Actuator Position) will be recorded as follows:

− 0% set when bit 0 is set − 100%set when bit 1 is set.

The values will be calibrated on the 0 to 1 transition of the bit. Each bit should be reset to 0 after calibration is completed.

The following procedure can be used to calibrate the potentiometer remotely:

1. Command the actuator to close (Slave In Data = 00 01) 2. Wait for Close Limit indication (Slave Out Data = xx yy 00 21) 3. Calibrate close position (Slave In Data = 01 00) 4. Confirm set (Slave Out Data = 00 00 00 21) 5. Clear Calibrate close bit (Slave In Data = 00 00) 6. Command the actuator to open (Slave In Data = 00 02) 7. Wait for Open Limit indication (Slave Out Data = xx yy 00 22) 8. Calibrate open position (Slave In Data = 02 00) 9. Confirm set (Slave Out Data = 03 E8 00 22) 10. Clear Calibrate open bit (Slave In Data = 00 00)

Notes: xx yy = un-specified value, xx yy, where xx = most significant bits, yy = least significant bits

When confirming limits, the actual value of position may be different from above.

11.6. Reset Counter (0 x 04 00)

The Reset function will reset the cycle counter to zero, see section 15.6.

11.7. Set Diagnostic Flag (0 x 08 00)

This bit will force the slave state from “Ready” to “Ready+Diagnostics”. Under normal operation the slave state changes from “Ready” to “Ready+Diagnostics” only when an alarm bit is set (Byte 0 of the Diagnostic Data). Only when the slave state is “Ready+Diagnostics” will the contents of the diagnostics be current (See Diagnostic Data, section 14 for further information).




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12. Slave Output Data (sent to Master In Data) There are up to 4 bytes of output data.

Bit HEX MASK Description

BY

TE 0

0 0x00 00 00 01 Closed Limit (Lower) 1 0x00 00 00 02 Open Limit (Upper) 2 0x00 00 00 04 CL-CMD Travel (Valve Closing) 3 0x00 00 00 08 OP-CMD Travel (Valve Opening) 4 0x00 00 00 10 ESD Active 5 0x00 00 00 20 Reserved 6 0x00 00 00 40 Reserved 7 0x00 00 00 80 Reserved

BY

TE

1

0 0x00 00 01 00 Aux. Input 0 1 0x00 00 02 00 Aux. Input 1 2 0x00 00 04 00 Aux. Input 2 3 0x00 00 08 00 Aux. Input 3 4 0x00 00 10 00 Reserved 5 0x00 00 20 00 Reserved 6 0x00 00 40 00 Reserved 7 0x00 00 80 00 Reserved

Byte 2 * 0-7 0x00 FF 00 00 Position Low Byte

Byte 3* 0-7 0xFF 00 00 00 Position High Byte

* In 4 Byte Output Mode Only

13. Output Bit Description

13.1. Lower Limit Switch (Closed) (Byte-0 Bit-0, 0 x 00 00 00 01)

This bit will be set when the Lower limit switch contacts are activated indicating the valve is in the closed position.

13.2. Upper Limit (Open) (Byte-0 Bit-1, 0 x 00 00 00 02)

This bit will be set when the Lower limit switch contacts are activated indicating the valve is in the open position.

13.3. Closed Command Travel (Byte-0 Bit-2, 0 x 00 00 00 04)

This bit will be set when a valid CL-CMD command has been received.

13.4. Open Command Travel (Byte-0 Bit-3, 0 x 00 00 00 08)

This bit will be set when a valid OP-CMD command has been received.




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13.5. ESD Active (Byte-0 Bit-4, 0 x 00 00 00 10)

This variable reflects the ESD state. When value is 1 the ESD command is active, i.e. the actuator is at the ESD position (or traveling to the ESD position) and all other Runtime Input commands are disabled.

13.6. Auxiliary Inputs (Byte-1 Bit-0 to Bit-3, 0 x 00 00 01 00, 0 x 00 00 02 00,

0 x 00 00 04 00 and 0 x 00 00 08 00)

Byte 1, bits 0-3 report the status of the external auxiliary (or general purpose) inputs connected to J2. The corresponding bit will be set to 1 when the dry contact type switch connected to that input is closed.

13.7. Position Feedback (Byte-2 and Byte-3, 0x FF FF 00 00)

Bytes 2 and 3 contain the position feedback from the actuator calibrated as per the calibration procedure detailed in sections 6.3 and 11.5. The value returned is in the range 0 (0x00 00) to 1000 (0x03 E8), representing the position 0.0% to 100.0% in 0.1% increments.




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14. Diagnostic Data The following diagnostic data is available from the device. Only changes in Byte 0 will result in a DPN_SLV_READY_DIAG being returned. Since the diagnostic data buffer is only updated when DPN_SLV_READY_DIAG state is returned, the state must be forced in order to retrieve bytes 1 through 16. The DPN_SLV_READY_DIAG state can be forced by writing 0x0800 to the slave input.

Bit Description

BY

TE 0

0 CL-CMD Timeout 1 OP-CMD Timeout 2 Limit Switch Alarm 3 Service Count Exceeded 4 Position Sensor Failure 5 Reserved 6 Reserved 7 Reserved

Byte1 0-7 Cycle Counter LSB

Byte 2 0-7 Cycle Counter

Byte 3 0-7 Cycle Counter

Byte 4 0-7 Cycle Counter MSB

Byte 5 0-7 Average Close Time LSB

Byte 6 0-7 Average Close Time MSB

Byte 7 0-7 Average Open Time LSB

Byte 8 0-7 Average Open Time MSB

Byte 9 0-7 Reversal Time

Byte 10 0-7 Travel Time

Byte 11 0-7 Hold Control

Byte 12 0-7 ESD

Byte 13 0-7 Service Count Limit LSB

Byte 14 0-7 Service Count Limit MSB

Byte 15 0-7 Potentiometer Raw A-D Bits 0%

Byte 16 0-7 Potentiometer Raw A-D Bits 100%

15. Diagnostic Data Bit Description

15.1. Fail to Close Alarm (Byte 0, Bit 0)

The Fail to Close Alarm will be set if the time between a “Drive Close Command” being received and a Close Limit switch closure being detected exceeds the value set by the parameter Travel Timeout. The alarm will be reset after the close cycle completed within the Travel Timeout value.




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15.2. Fail to Open Alarm (Byte 0, Bit 1)

The Fail to Open Alarm will be set if the time between a “Drive Open Command” being received and an Open Limit switch closure being detected exceeds the value set by the parameter Travel Timeout. The alarm will be reset after the open cycle completed within the Travel Timeout value.

15.3. Limit Switch Alarm (Byte 0, Bit 2)

This bit will be set if both limit switches are activated at the same time. Correcting the fault will clear this alarm.

15.4. Service Count Exceeded (Byte 0, Bit 3)

Should the value of the cycle counter exceed the value of the parameter configured by the Service Count parameter, the Service Count Exceeded bit will be set and the slave state will be changed to DPN_SLV_READY_DIAG. Setting the Service Count Parameter to 0 will disable this feature.

15.5. Position Sensor Failure (Byte 0, Bit 4)

Should the Position Feedback value be out of normal operating values the Position Sensor Failure alarm is set.. Correcting the fault will clear this alarm.

15.6. Cycle counter (Bytes 1, 2, 3 & 4)

This shows the current valve of the valve cycle counter. The cycle counter is incremented each time the Close or Open outputs are energized. The counter can be cleared by writing to Reset (see section 11.6).

15.7. Average Close Time (Bytes 5 & 6)

The average close time is the average time of the last 10 complete close strokes. A complete close stroke time is recorded each time the actuator moves from the full open position, with open limit set, to the full close position, and the close limit is set. Partial strokes are not recorded.

15.8. Average Open Time (Bytes 7 & 8)

The average open time is the average time of the last 10 complete open strokes. A complete open stroke time is recorded each time the actuator moves from the full close position, with close limit set, to the full open position, and the open limit is set. Partial strokes are not recorded.

15.9. Parameters (Bytes 9 through 14)

These bytes reflect the parameter values downloaded from the master at start up (see section 9).

15.10. Potentiometer Raw A-D Bits 0% (Bytes 15) This byte reflects the raw (un-scaled) Analog to Digital converter reading of the potentiometer at J5 that is used for the calibrated 0.0% position.

15.11. Potentiometer Raw A-D Bits 100% (Bytes 16)

This byte reflects the raw (un-scaled) Analog to Digital converter reading of the potentiometer at J5 that is used for the calibrated 100.0% position.




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16. Profibus Slave

Address Table The table to the right shows the entire list of Profibus network addresses. Typically address 0 and addresses 126 and 127 are reserved for special functions. S1 position 8 serves to override the Solenoid Output fail state upon loss of communication. With S1-8 in the Off position the Solenoid outputs will go to the ESD state if communication is lost for more than 10 seconds. With S1-8 in the On position the Solenoid Outputs will remain as they are if communication is lost.




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17. Appendix (Air Filtration and Lubrication)

Airline Filtration

The importance of proper filtration (40 Micron) of the air supply to pneumatic equipment can never

be over-emphasized as a means of preventing wear due to abrasive solids being present in the air

supply. Provide pneumatic equipment with serviced air by including suitable air line filters, and

pressure regulators in the installation at minimum. If lubricators are used in the air line, see section

below. The performance and life of pneumatic valves may be affected by air supply conditioning

methods.

Airline Lubricator Oils

Many brand name oils may be suitable for valve lubrication if they have a paraffin base and aniline

point in the range of 200° - 220°F (95° - 105°C). Oils must be thin enough to atomize in the

lubricator. Users should be advised not to use penetrating oils or detergent type oils, as they will

damage the seals, thicken in cold weather and wash out assembly grease. Thick oils do not atomize

sufficiently.

At temperatures below 32°F (0°C) use pure ethylene glycol as a lubricant.

Listed below is a representative group of commercially available light (turbine type) oils which are

recommended for valves. They are compatible with the seals normally used [FKM (fluorocarbon

and low-temperature Buna)].

Manufacturer Lubricant

Chevron Oil Co. GST Oil 32

CITGO Pacemaker T-32

Exxon Teresstic 32

Gulf Oil Corp. Harmony 32

Mobil Oil Corp. DTE Light

Shell Oil Co. Turbo 32

Sun Oil Co. Sunvis 932

Texaco Inc. Regal Oil R & O 32

18. Bibliography Profibus Specification (FMS, DP, PA), Version 1.0 Test Specifications for Profibus DP-Slaves, Version 2.0 Profibus-DP Extensions, Version 2.0 Specification for Profibus Device Description and Device Integration, Volume1: GSD Specification, Version 4.1

intellis profibus dp network monitor operating...

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