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rotork Paksan P3F Technical Manual

rotork Paksan P3F Technical Manual

Field mount master station
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P3F - PAKSCAN FIELD MOUNT
MASTER STATION
TECHNICAL MANUAL
Publication S703E V1.1
Issue 06/09

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  • Page 1 P3F - PAKSCAN FIELD MOUNT MASTER STATION TECHNICAL MANUAL Publication S703E V1.1 Issue 06/09...

  • Page 2: Know Your Master Station

    P3F - Pakscan Master Station Technical Manual KNOW YOUR MASTER STATION Mounting Brackets Future Power option slot Connector Current Loop option Module Power Supply Host Ethernet Port 3 Host Ethernet Port 4 Service Current Ethernet Loop Port Connector Alarm and Terminals DIN Rail Earth...

  • Page 3: Table Of Contents

    Contents Contents: KNOW YOUR MASTER STATION ................2 INTRODUCTION ......................5 MOUNTING AND CONNECTING THE MASTER STATION ......7 Mechanical Fixing ........................7 Serial Comms Connections ....................8 Ethernet Comms Connections ....................8 Power Connector and Fuse....................8 ESD and Alarm Output Connector ..................9 Current Loop Connections.....................9 THE FIELD NETWORK ..................11 Loop Checks..........................11 Loop Checks..........................12...
  • Page 4 P3F - Pakscan Master Station Technical Manual 5.5.8 Option Card Event Logger..................36 5.5.9 FCU Menu ......................37 5.5.10 FCU Control - IQ/IQT Actuator ................38 5.5.11 FCU Control - Integral Actuator ................43 5.5.12 FCU Control - Flowpak Actuator.................47 5.5.13 FCU Control - General Purpose Field Unit............49 5.5.14 FCU Control - Other Field Units .................52 5.5.15...

  • Page 5: Introduction

    32 actuators or other field units. Most types of Rotork actuator can be connected to the Pakscan current loop provided they are fitted with the necessary field unit. Information on the respective actuator field units can be found in the appropriate manuals.
  • Page 6 P3F - Pakscan Master Station Technical Manual (This page is intentionally blank) 6 of 82 Publication S703E V1.1 Issue 06/09...

  • Page 7: Mounting And Connecting The Master Station

    Mounting the Master Station MOUNTING AND CONNECTING THE MASTER STATION Before fixing the master station in its permanent location, it may be more convenient to set the comms link switches as discussed in section 3. The Pakscan P3F master station provides front access for all the user connections including power feed and the field loop wires to the Current Loop module (PS720).

  • Page 8: Serial Comms Connections

    P3F - Pakscan Master Station Technical Manual Room should be left around the enclosure for all the connections and cables, allowing for suitable bending radius on each lead. Power wiring should be suitably fused or protected with a miniature circuit breaker (MCB) external to the master station. The master station should be mounted on a flat surface using the mounting brackets provided.

  • Page 9: Esd And Alarm Output Connector

    Mounting the Master Station Terminal ac Connection dc Connection (85-265V ac) (18-36V dc) Power (Neutral) (Line) 24 V (Earth) Earth Fig 4: Power connector terminal functions 1.5 ESD and Alarm Output Connector There is a removable screw terminal connector plugged into the main circuit board of the P3F master station for the connection of ESD hard-wired inputs and for connection to the internal alarm relay contacts, when required.
  • Page 10 P3F - Pakscan Master Station Technical Manual Power Fuse Connector Ethernet Ports Current Loop Hard Wired Serial Ports Fig 7: View of the Pakscan P3F master station showing the Connectors and Fuse 10 of 82 Publication S703E V1.1 Issue 06/09...

  • Page 11: The Field Network

    Field Network THE FIELD NETWORK The Pakscan current loop field network must be correctly cabled and connected to the master station. The values of the field loop resistance and capacitance must be known to determine the loop speed that can be used. If these are not known then the LOWEST loop speed must be set in each actuator and the master station to ensure some field network connectivity.

  • Page 12: Loop Checks

    P3F - Pakscan Master Station Technical Manual 2.1 Loop Checks The most common errors in installing the system occur on the field wiring. Loop Continuity With all the field units connected, but none of them powered up, check the continuity of the 2 cores of the cable and measure its resistance.
  • Page 13 Field Network MAINS SUPPLY 1 2 3 POWER SUPPLY EMERGENCY SERIAL SHUTDOWN PORT 1 PROCESSORS SERIAL COMMUNICATIONS PORT 2 ALARM ETHERNET ETHERNET PORT 5 PORT 3 (CONFIGURATION) ETHERNET PORT 4 Actuator Terminals Screen Port A OUT Port A IN PS 720 MODULE SIGNAL EARTH BAR (CURRENT LOOP If there is a signal earth bar, connect the...
  • Page 14 P3F - Pakscan Master Station Technical Manual (This page is intentionally blank) 14 of 82 Publication S703E V1.1 Issue 06/09...

  • Page 15: Sorting Out The Serial Comms Links

    Serial Comms Links SORTING OUT THE SERIAL COMMS LINKS The Pakscan P3F CPU module has two serial ports. Each of these is configurable for RS232 or RS485. Where redundant communications to the host system using serial comms is required, then two RS485 connections are often used.
  • Page 16 P3F - Pakscan Master Station Technical Manual Port Function The two DIP switches allow each port to be selected between RS232 and RS485. For RS485 slide the appropriate Port switch up, for RS232 they should be down. Each of the two ports may be set independently. Fig 11: Port Function Switches shown in RS232 position Port Termination Resistors...

  • Page 17: When To Use Rs232

    Serial Comms Links 3.2 When to Use RS232 Pakscan P3F Master Station Pakscan rotork Highway 1 – RS232 Highway 2 – RS232 Fig 13: RS232, dual highway, from P3F master station to PLC When the host PLC or DCS is located near to the Pakscan P3F master station, RS232 comms can be used with single point to point links.
  • Page 18 P3F - Pakscan Master Station Technical Manual the master station make this simple to achieve. When a multi-drop connection is made, care must be taken to ensure that the cable is not broken if a master station is disconnected. The master station supplies port termination resistors for each port, which can be enabled where required.

  • Page 19: Using Ethernet Host Comms

    DCS to access data and control the actuators on the field network. The IP address is already set and can be changed during setting up the master station Pakscan 3F Master Stations Pakscan P3F Master Stations Pakscan Pakscan rotork rotork Port 3 Port 4 Port 3 Port 4...
  • Page 20 P3F - Pakscan Master Station Technical Manual The recommended highway organisation is: Use two main data highway bus’s, each of which connects to all the master stations. The master is left with a Static DHCP port setting. The master station can serve up to 10 simultaneous host connections. With this arrangement either PLC port can always communicate with the master station and the devices on the loop.

  • Page 21: The Internal Web

    The Web Browser THE INTERNAL WEB PAGES The P3F master station includes a set of Web pages that may be remotely accessed via Ethernet. They can be used for setting up the system, examining the system for any faults or alarms and also for controlling the actuators on the network (provided the Interlock permission is set to allow this feature).

  • Page 22: Adjusting The Network Settings Of The Laptop / Pc

    P3F - Pakscan Master Station Technical Manual 5.3 Adjusting the Network Settings of the Laptop / PC Ensure nothing is connected to the Ethernet port of the laptop / PC. Open the Control Panel and select Network Connections. In the ‘Network Connections’ window, double-click on the ‘LAN or High Speed Internet’ icon and the ‘Local Area Connection Status’...

  • Page 23: Web

    The Web Browser Start the browser and enter the IP address of the master station. The default address is 10.200.1.1, so the address is http://10.200.1.1. The browser will then access the master station and bring up the opening page of the master station. In order to log in as a verified user, enter a username of admin and a password of admin.
  • Page 24 P3F - Pakscan Master Station Technical Manual Log In Masterstation View Configuration System Master Station Diagnostics datalogger Host Analyser Network Option Diagnostics Diagnostics Option Event Log FCU 1 to 32 control FCU Menu and data Admin* Users * requires Admin level log in Master station and Option Configuration Host Port...

  • Page 25: The Web Pages In Detail

    The Web Browser 5.5 The Web Pages in Detail 5.5.1 Log In Screen Fig 19: Log In Screen The first screen is the Log In screen on which the user must enter a Username and Password. Username - a case sensitive identification for an individual or group used to give access to the system.

  • Page 26: Master Station

    P3F - Pakscan Master Station Technical Manual 5.5.2 Master Station Site Name Tag Name Status Option Card 1 Status Controls Fig 21: Master Station Overview Page This screen is accessible to Read, Write and Administration user levels. The screen reports the current status of the master station and the option cards fitted. The coloured lights show the condition of the associated parameter.
  • Page 27 The Web Browser Auto Loopback : If a fault occurs on the network and an automatic reconfiguration of the loop occurs, a yellow light is shown here. Common Field : A red light shows if any field unit on the network has an alarm bit present. Unit Alarm Common : A red light shows if any actuator on the network is unavailable due to its...

  • Page 28: View Configuration

    P3F - Pakscan Master Station Technical Manual 5.5.3 View Configuration Fig 22: System Configuration Overview Page This screen is accessible to Read, Write and Administration user levels. The screen shows the settings for the control of the option card network and the CPU control capability, software fitted and various options selected.

  • Page 29: System Diagnostics

    The Web Browser 5.5.4 System Diagnostics Master Station CPU Status Controls Option Card 1 Controls Fig 23: System Diagnostics Page This screen is accessible to Read, Write and Administration user levels. The System Diagnostics screen shows an overview of the status of the fitted module and also provides access to further information.

  • Page 30: Master Station Data Logger

    P3F - Pakscan Master Station Technical Manual 5.5.5 Master Station Data Logger Close pop up Master Station Events Controls Fig 24: Master Station Data Logger This screen is accessible to Read, Write and Administration user levels. The data logger displays Modbus instructions received by the master station to carry out commands such Alarm Accept or commands to move a valve.
  • Page 31 The Web Browser Controls - Available to all user levels Print : Prints the logger to a printer attached to the PC. Save : Saves the logger data to a file on the PC. The saved file is of the type cmdlog.log and can be opened in the Notepad on the PC.

  • Page 32: Master Station Host Analyser

    P3F - Pakscan Master Station Technical Manual 5.5.6 Master Station Host Analyser Close pop up Analyser Events Controls Fig 27: Host Analyser Screen This screen may be used by Administration user level only. The Host Analyser is a real time system analyser that can be used with either a Modbus RTU serial data control source acting through one of the serial data ports (Port 1 or 2), or a Modbus TCP Ethernet control source acting through the Ethernet port.

  • Page 33: Pakscan 2 Loop Diagnostics

    The Web Browser 5.5.7 Pakscan 2 Loop Diagnostics Network Controls Network FCU Map Fig 28: Pakscan 2 Loop Diagnostics This screen is accessible to Read, Write and Administration user levels. The Pakscan 2 Loop Diagnostics screen gives diagnostic information on the two-wire loop option card and the network connected to it.
  • Page 34 P3F - Pakscan Master Station Technical Manual During configuration the following sequence can be displayed - 1. Wait for Loopbacks 1 (first wait for loopbacks to come on) 2. Find FCUs on Port A (finding FCUs on port A) 3. Test Loop (testing for complete loop) 4.
  • Page 35 The Web Browser Network), the network will continue to operate and miss out the faulty field units. Loop Baud Rate : Shows the current speed selected. The speed can be 110, 300, 600, 1200, or 2400 baud. No. Of FCUs : This is the total number of field units connected to the option card Port A On Side A and communicating via Port A.

  • Page 36: Option Card Event Logger

    P3F - Pakscan Master Station Technical Manual 5.5.8 Option Card Event Logger Close pop up Event Log Controls Fig 29: Option Card Event Logger This screen is accessible to Read, Write and Administration user levels. The event logger shows the last occurrence of the listed events and in the case of the ESD source, where the signal originated.

  • Page 37: Fcu Menu

    The Web Browser 5.5.9 FCU Menu Network Controls Fig 30: FCU Menu This screen is accessible to Read, Write and Administration user levels. The FCU Menu lists all the field units in address order (which may not be the same as the order in which they connected together on the loop).

  • Page 38: Fcu Control - Iq/Iqt Actuator

    P3F - Pakscan Master Station Technical Manual 5.5.10 FCU Control - IQ/IQT Actuator Navigation Actuator picture Controls Fig 31: IQ and IQT actuator FCU Control This screen is accessible to Read, Write and Administration user levels. The IQ and IQT control screens are similar and show a picture to identify the actual type of actuator at this FCU address.
  • Page 39 The Web Browser Identification Tag name : Identification tag given for this device. Address : Network address. Type : Shows the identified actuator type as IQ (IQT on the IQT screen). Network : The network to which this device is connected (Pakscan 2 for two-wire loop).
  • Page 40 P3F - Pakscan Master Station Technical Manual Pop-up screen shows the settings for all the parameters relating to the IQ actuator field unit. For users with Administration level rights the values can be edited and for the latest version field units, the type of actuator can be modified.
  • Page 41 The Web Browser Event Log - Available to all user levels Close pop up Controls Fig 35: IQ FCU Event Log (IQT Event Log similar) Pop-up screen showing a log of the last occasion on which the various control and alarm events occurred.
  • Page 42 P3F - Pakscan Master Station Technical Manual Controls Print : Prints the datalogger to a printer available to the PC. Save : Saves the logger data to a file on the PC. Actuator Controls - Available to Write and Administration user levels only Open : command to open the valve fully.

  • Page 43: Fcu Control - Integral Actuator

    The Web Browser 5.5.11 FCU Control - Integral Actuator Navigation Actuator picture Controls Fig 36: Q actuator FCU Control This screen is accessible to Read, Write and Administration user levels. The Integral actuator FCU Control screen shows a control and status page for a Q type actuator. The screen has information relating to the device, its current condition and system parameters.
  • Page 44 P3F - Pakscan Master Station Technical Manual Current Status The real time status of the actuator is listed in this pane on the screen. External Input : Active or Inactive shows the status of the input. Valve Position : Current position, closed, open or stopped mid position. Actuator : Moving or stationary.
  • Page 45 The Web Browser Pop-up screen shows the alarms on the actuator as red lights, grey is no alarm. Additional information on the meaning of these alarms is contained in the individual field unit manuals. Event Log - Available to all user levels Close pop up Controls Fig 39:...
  • Page 46 P3F - Pakscan Master Station Technical Manual Network ESD - ESD instruction over the control network. Position / Time - last position control event. Position / Time - last but one position control event. Position / Time - last but two position control event. Controls Print : Prints the datalogger to a printer attached to the PC.

  • Page 47: Fcu Control - Flowpak Actuator

    The Web Browser 5.5.12 FCU Control - Flowpak Actuator Navigation Actuator picture Controls Fig 40: Flowpak actuator FCU Control This screen is accessible to Read, Write and Administration user levels. The Flowpak actuator FCU Control screen shows a control and status page for a Flowpak type actuator.
  • Page 48 P3F - Pakscan Master Station Technical Manual Current Status The real time status of the actuator is listed in this pane on the screen. Valve Position : Current position, closed, open or stopped mid position. Actuator : Moving or stationary. Running Direction : Opening or closing.

  • Page 49: Fcu Control - General Purpose Field Unit

    The Web Browser 5.5.13 FCU Control - General Purpose Field Unit Navigation Device picture Controls Fig 42: GP FCU Control This screen is accessible to Read, Write and Administration user levels. The GP FCU Control screen shows a control and status page for a general purpose field unit. The screen has information relating to the device, its current condition and system parameters.
  • Page 50 P3F - Pakscan Master Station Technical Manual Address : Network address. Type : Shows the identified device type as GPFCU-GP. Network : The network to which this device is connected (Pakscan 2 for two wire loop). Current Status The real time status of the actuator is listed in this pane on the screen. Digital # 1 to # 8 : Digital input signal status, active or Inactive.
  • Page 51 The Web Browser Event Log - Available to all user levels Close pop-up Controls Fig 45: GP FCU Event Log Pop-up screen showing a log of the last occasion on which the various alarms, input and output events occurred. For commands the source of the command is also given. Comms Failed - loss of communication with the field unit.

  • Page 52: Fcu Control - Other Field Units

    P3F - Pakscan Master Station Technical Manual 5.5.14 FCU Control - Other Field Units In addition to the field units described above there are other types that can be connected to the Pakscan network. The controls and displays available are all similar to those used on the FCU already explained.
  • Page 53 The Web Browser Fig 48: EH Actuator FCU Control The EH electro-hydraulic actuator is also fitted with a field unit similar to a standard IQ actuator. The controls available include the event log and ability to set the parameters of the field unit. 53 of 82 Publication S703E V1.1 Issue 06/09...

  • Page 54: Admin

    P3F - Pakscan Master Station Technical Manual 5.5.15 Admin Admin button Fig 49: Administration Level This screen is only accessible to Administration user levels. When logged in at Administrator level the top of the screen menu list includes the Admin button. Clicking on this button gives entry to the Administrator level screens.
  • Page 55 The Web Browser Name Name of the current user, displayed on the top bar. User ID Secret identification used to gain entry to the system, shown in user list. Secret code of letters (and numbers) used to gain entry to the system. Not Password shown on the system.
  • Page 56 P3F - Pakscan Master Station Technical Manual Alarm User : Select ‘Yes’ or ‘No’ for the choice of sending E-mails and Text messages to this user. Language : Select the language to be used on the screens. Choices are English, French, German, Spanish, and Italian.

  • Page 57: Masterstation Config

    The Web Browser 5.5.17 Masterstation Config Master Station Drop-Down boxes Controls Option Card Controls Fig 53: Master Station Configuration This screen is only accessible to Administration user levels. The master station configuration page is used to set the parameters required for successful operation of the system and the parameters for the option cards fitted.
  • Page 58 P3F - Pakscan Master Station Technical Manual The Option card settings relate to the option card fitted in the option 1 slot. The Pakscan 2 Loop option card may only be fitted in this slot and must not be fitted in slot 2. It controls the actuators and field units over a two wire cable wired in a ring or loop, visiting each actuator in turn.
  • Page 59 The Web Browser scanning up to the highest address. All the addresses in the selected range should be used and gaps in the address range should be avoided. Gaps or unused addresses cause the system to run more slowly as the unused addresses are still checked.
  • Page 60 P3F - Pakscan Master Station Technical Manual hosts see all the alarms. When the alarms are linked, accepting an alarm on one port accepts the alarm on all the other ports as well. Linking the port alarm operations is useful in dual redundant serial link configurations between the master station and the host computer Controls Save Settings...

  • Page 61: Host Port Configuration

    The Web Browser 5.5.18 Host Port Configuration Drop Down boxes Fig 54: Host Port Configuration This screen is only accessible to Administration user levels. Controls The host port configuration page allows the settings for the serial and Ethernet ports to be made. The two serial ports (ports 1 and 2) are independent from one another, whilst the Ethernet ports (ports 3 and 4) are linked together.
  • Page 62 P3F - Pakscan Master Station Technical Manual Ethernet Port IP Authentication : The two IP addresses that can be set here relate to system access permission. When controlling the system via Ethernet and Modbus TCP, it is possible to increase the system security and only permit access from specified IP locations.
  • Page 63 The Web Browser Modbus Message Response Address : The address of the responding system, it will match the query address. Function Code : Modbus function code to read or write register, discrete or coil. Data : Modbus data reply, without a CRC. There will be no spaces in the data field.

  • Page 64: Alarms

    P3F - Pakscan Master Station Technical Manual 5.5.19 Alarms Controls Controls Fig 56: Alarm Reporting This screen is only accessible to Administration user levels. This page is used to set up the e-mail alarm reporting from the system to the dedicated recipients, as specified in the user setup screen.
  • Page 65 The Web Browser generated and the specifying of a suitable SMTP server, whilst the second specifies which events will cause messages to be sent. Alarm Email Settings Email Alarm : Set to Enable or Disable the whole process. SMTP Server : Specifies the server that the master station will use for forwarding e-mails.

  • Page 66: Time

    P3F - Pakscan Master Station Technical Manual 5.5.20 Time Controls Fig 57: Time Settings This screen is only accessible to Administration user levels. The master station keeps track of time and date in order to correctly make events in the logs and timestamp the e-mails sent.

  • Page 67: General

    The Web Browser 5.5.21 General Fig 58: General Housekeeping This screen is only accessible to Administration user levels. The General screen contains facilities for upgrading and maintaining the master station. General Clear Command : The Master Station data logger (which can be found under System Diagnostics, ms datalogger) creates a file for all the recorded events.

  • Page 68: Network

    P3F - Pakscan Master Station Technical Manual Language File : To update the language files, browse to the location of the new file and Update click on ‘load’. Firmware Update : To update the firmware, browse to the location of the new file and click on ‘load’.
  • Page 69 The Web Browser IP Address : The IP address that uniquely identifies this master station. This will generally be allocated by the network system administrator. Netmask : The netmask is allocated by the system administrator and set here. Gateway : When the master station is connected to a gateway or router onto the internet, the gateway IP address is entered here so that the master station and gateway can exchange data.

  • Page 70: Setting Up The Master Station Configuration Using The Web

    P3F - Pakscan Master Station Technical Manual 5.6 Setting Up the Master station Configuration Using the Web Pages In order to set up the system by the web pages it is necessary to access the system from a PC. This can either be directly connected, as described earlier, or via an Internet connection.
  • Page 71 The Web Browser Because the system and browser remembers visited pages, either the Users page will come up, or one of the previously visited Admin level pages will appear. Click on Masterstation Config to enter the main system configuration page. Fig 62: Master station Set-up page Modify this page to set up the master station parameters by using the drop-down menus on each...

  • Page 72: Option Module Set-Up (Including Host Comms Protocols)

    P3F - Pakscan Master Station Technical Manual 5.6.2 Option Module Set-up (including host comms protocols) The master station set-up page is also used for setting up the Pakscan 2 Current Loop Option card. Set the loop performance parameters in accordance with the data recorded earlier. Make sure the loop speed is compatible with the setting for the loop capacitance.

  • Page 73: Setting The Ip Address

    The Web Browser The port type is determined by the DIP switch settings on the back plane pcb and the setting is reflected in the message on the screen. The description changes to reflect the setting when the port is set to RS232.
  • Page 74 P3F - Pakscan Master Station Technical Manual value becomes active in the master station. The web browser must be restarted and directed to the new IP address. Re-establishing Ethernet Communication with a new IP address: Because most PCs associate a MAC ID to each IP address, the chances are that the PC will not be able to re-establish communication with the master station until the PC has been rebooted through a complete power cycle.

  • Page 75: Making The System Work

    Commissioning and Control MAKING THE SYSTEM WORK ALWAYS ENSURE THE PLANT IS IN A SAFE CONDITION AND ALL THE ACTUATOR CONTROLS ARE PLACED IN LOCAL BEFORE COMMENCING ANY COMMISSIONING OR FAULT FINDING ON THE SYSTEM 6.1 Commissioning the System The current loop needs to be commissioned to enable the system to locate and identify every actuator. The master station and laptop PC can be used to perform the commissioning.

  • Page 76: Monitoring And Controlling The Actuators

    P3F - Pakscan Master Station Technical Manual Fig 65: Pakscan 2 Option Card (Loop Card) Diagnostics page showing complete loop. Reset the network (current loop) by clicking the reset network button. The status information will change and show the configuration stages. Once complete, the actuator furthest from port A should be shown on the Network Map.
  • Page 77 Commissioning and Control Fig 66: List of Connected Field Units This screen lists the FCUs in address order, their type and current condition. The FCU Control button will bring up the page showing the information in more detail. Fig 67: Detailed Actuator Condition page.
  • Page 78 P3F - Pakscan Master Station Technical Manual The actuator can be moved by the Open and Close buttons and any alarms present displayed by clicking Show Alarms. The page will automatically refresh if the valve is moved and the buttons at the top of the page can be used to move to the next or previous actuator on the network.

  • Page 79: General Safety Information

    If such excess is applied, the product should be returned to Rotork or otherwise checked by a competent person before re-use, even if no damage is immediately evident. Use only the specified fuse type and rating as replacements.
  • Page 80 Reliability predictions, (including failure mode and effect analysis), are calculated by Rotork using statistical methods and the resulting figures should only be used for statistical purposes. These predictions are only valid if the maintenance procedures and maintenance intervals stated in Rotork documentation are observed.
  • Page 81 Safety (This page is intentionally blank) 81 of 82 Publication S703E V1.1 Issue 06/09...
  • Page 82 675 Mile Crossing Blvd England Rochester BA1 3JQ New York 14624 Rotork reserves the right to amend and change specifications without prior notice. Tel: +44 (0) 1225 733 200 Tel: +1 585 247 2304 Fax: +44 (0) 1225 333 467...

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