rotork CK Series Installation Manual
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rotork CK Series Installation Manual

rotork CK Series Installation Manual

Profibus actuator control, profibus dp option card for actuators
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CK
Range
Profibus Actuator Control
Profibus DP Option Card Installation Manual
Keeping the World Flowing

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  • Page 1 Range Profibus Actuator Control Profibus DP Option Card Installation Manual Keeping the World Flowing...

  • Page 2: Table Of Contents

    5.1.1 Controls Priority Abbreviations 5.1.2 Profibus Control using the ACTCON Register References 5.1.3 Profibus Control using the Notes for Rotork POS DV register 5.1.4 The Centronik ‘S’ contacts (Profibus DOs) 1 Introduction controlled by the O_STAT register 1.1 General 5.1.5 Profibus Network Control...
  • Page 3 Contents Section Page Section Page 7 Parameters 7.2 Parameters viewed and set by DP-V1 Communication 7.1 Parameters set by GSD and DP-V1 Communication 7.2.1 Actuator Tag Data (Parameter 20) 7.1.1 Limited Range Position Minimum 7.2.2 Software Versions and Maximum (Parameter 1 and 2) (Parameter 21 and 22) 7.1.2 Deadband and Hysteresis 7.2.3 Field Interface Type (Parameter 24)

  • Page 4: Table Of Figures

    Block Diagram 26 Rotork DTM running in the M&M FDT container 11 Typical Profibus DP cable specifications 27 Rotork EDD running in the Siemens PDM application 50 12 Single Highway 28 Insight 2 Software; connected to a CK actuator 13 Dual Highway SR Mode Connections...
  • Page 5 Note 2: interchangeable when talking about Profibus: this manual The information in this manual relates to the following refers to both. Centronik is the term applied to a Rotork firmware releases: actuator that has an optional electronic control system in it.

  • Page 6: Glossary Of Terms

    Profibus DP/FMS Profibus DP-V0 and DP-V1 Profibus Guideline 2.212 Specification Slave Redundancy The cyclic (V0) and acyclic (V1) versions of the protocol supported by the Rotork module. Profibus Guideline 2.152 Specification for Profibus Device Description and Device Integration – EDD Profibus Nutzerorganisation –...

  • Page 7: Introduction

    Introduction 1 Introduction The Rotork Profibus DP Actuator Control option card (PFU) The Profibus DP Module circuits do not impinge on the conforms to the PNO as compliant with specifications actuator control electronics; the actuator itself remains fully IEC61158 and EN50170. The card supports both Profibus self-protecting.

  • Page 8: General

    General 1.1 General The Profibus DP Module has three versions: Pro bus DP • Single Channel Profibus DP Highway 1 • Simple Dual Channel, independent isolated Profibus DP highways for redundant systems that do not support full RedCom Single Profibus DP Highway •...

  • Page 9: Profibus Dp Option Card Properties

    Profibus DP option card properties 2 PROFIBUS DP OPTION CARD PROPERTIES 2.2 Electrical Properties The PFU does not sit in the main control path for the actuator 2.1 Mechanical Properties and does not affect the actuator control integrity. The PFU module consists of a network interface card, which The Profibus DP fieldbus data highway connections are fully fits directly to the main actuator printed circuit board.

  • Page 10: Fitting The Profibus Dp Option Card

    The following table describes the wiring harnesses using Main PCB connection SK2. and their function in the Rotork actuator. The Interface card must be correctly profiled and loaded with the appropriate connectors to match the actuator. The illustration below shows the location of the cards in the Centronik unit.

  • Page 11: Replacing Or Fitting A Profibus Dp Option Card

    Once the module is fitted the actuator should be re- assembled and the battery reconnected (if applicable). If an option card is fitted into a Rotork after it has left the factory then the actuator needs to be set-up to use this card in the software, the card will not do anything until this has been done.

  • Page 12: Single And Dual Data Highway Configurations

    Single and Dual Data Highway Configurations 4 Single and Dual Data Highway Configurations 4.1 Profibus Data Highway The rules governing the installation and connection of a Profibus DP highway should be observed at all times to produce a successful installation. The highway does not allow power to be transferred and the Profibus module is powered from the actuator itself.

  • Page 13: Segmented Single Highway System

    Single and Dual Data Highway Configurations 4.2 Segmented Single Highway System Bus Master Segment 1 Repeater Powered Active Terminator Segment 2 Repeater Segment 3 Fig. 6: Profibus Single Channel Data Highway Topology The data highway may be connected as several segments coupled by repeaters.

  • Page 14: Redundant Systems - Simple Redundancy

    Single and Dual Data Highway Configurations 4.3 Redundant Systems – Simple Redundancy These two connection options allow for redundancy protection against either a failure of the highway (SR mode) The Simple Dual Channel Profibus DP Option Card version has or failure of the card interface channel (FR mode). Most dual two redundant communications channels.

  • Page 15: Flying Redundancy Slave To Master Connection

    Single and Dual Data Highway Configurations 4.3.1 Flying Redundancy Slave to Master Connection In the event of a failure of the Primary channel, the Backup automatically changes to use the Primary address. Hence for all control purposes the Master only uses the Primary address. Primary Master Backup Master First Master...

  • Page 16: System Redundancy Slave To Master Connection

    Single and Dual Data Highway Configurations 4.3.2 System Redundancy Slave to Master Connection In the event of a failure of the Primary channel the Backup automatically changes to become Primary and communication will be established with the Second master Backup Master First Master Second Master on the second highway.

  • Page 17: Redundant Systems - Redcom Redundancy

    Interface Card • FR – Flying Redundancy (Two slave addresses offset by 64) Actuator The Rotork Profibus DP RedCom Dual Channel Option Card obeys the Profibus REDCOM Redundant Slave Specification for Redundant Communications. This includes 3 bytes of Extended Diagnostics for Fig.

  • Page 18: Extended Diagnostic Messages For Redcom

    Single and Dual Data Highway Configurations 4.4.1 Extended Diagnostic Messages for RedCom The extended diagnostics is contained in 3 bytes in the diagnostic message and is reported by the Primary slave only: The Redundancy Extensions to the standard V1 protocol allow the two channels to communicate between themselves Description Comment...

  • Page 19: Cable Types

    Single and Dual Data Highway Configurations 4.5 Cable Types 4.6 Termination Network The network must be connected using a suitable cable for In order to operate correctly all Profibus segments must be Profibus DP applications. Two conductors plus a shield are terminated at each end in an active network termination required and there is a Profibus specification for the cable.

  • Page 20: Connecting To The Highway And Setting Up The Profibus Card

    4.7.1 Single Channel Highway Profibus Card With the single channel option the actuator is connected The Rotork Profibus variants allow for different highway to only one highway. The connection of the actuator to the connections. The ‘single channel’ can be used for simple highway uses terminals A and B (in and out terminals) and highways.

  • Page 21: Dual Highway

    Single and Dual Data Highway Configurations 4.7.2 Dual Highway The connection of the actuator to the highway uses terminals 1A /1B (in and out terminals) on highway 1 and 2A / 2B (in The most common application of the Dual channel card is for and out terminals) on highway 2, the terminal numbers Dual Highways in SR (System Redundancy) applications.

  • Page 22: Optional Ck Disconnect Module

    Single and Dual Data Highway Configurations 4.7.3 Optional CK disconnect module Disconnect Module Parking The CK range of actuators can be fitted with an optional Housing disconnect module, the purpose of which is to enable the Parking Housing removal of the actuator for service without disrupting the Cover network.

  • Page 23: The Actuator Cyclic Data Signals

    The Actuator Cyclic Data Signals 5 The Actuator Cyclic Data Signals The Profibus DP Module allows the actuator to be controlled Cyclic Data Exchange by, and to report data to, a suitable host device using Profibus Output Registers Input Registers DP protocol.

  • Page 24: Control Outputs

    The Actuator Cyclic Data Signals 5.1 Control Outputs The Profibus DP Module can be used to control the actuator Command & CK and position the valve. The valve may be moved fully closed, Profibus over the network fully open or to an intermediate position (requires DSM or MSM with optional potentiometer).
  • Page 25 (This feature requires the actuator to be fitted with a DSM or MSM with optional potentiometer). Most Rotork multi-turn actuators are set to open until the open limit switch is reached and close Relay Output DO-1 to DO-4...

  • Page 26: Controls Priority

    Hard-Wired Stop The hard-wired stop input acts as a change of state input. For the Rotork actuator, the remote control hard wired inputs If the actuator is moving, opening the Stop input will can be used as discrete input signals, to report the status of stop the actuator.

  • Page 27: Profibus Control Using The Actcon Register

    The Actuator Cyclic Data Signals 5.1.2 Profibus Control using the ACTCON Register A single register is provided to allow the digital control of the actuator. Writing to the individual bits in the register causes the actuator to open, close, stop, ESD, adopt Positioning mode or perform a Partial Stroke and at the same time cancels any other command set.

  • Page 28: The Centronik 'S' Contacts (Profibus Dos) Controlled By The O_Stat Register

    The Actuator Cyclic Data Signals 5.1.4 The Centronik ‘S’ contacts (Profibus DOs) controlled Actuator with Additional Relay Output Board tted by the O_STAT register The actuator has four ‘S’ contact outputs that may be Actuator S1-S4 configured to report the status of the actuator with signals Main Board such as Open Limit, Closed Limit etc.

  • Page 29: Digital Input Status Feedback

    The Actuator Cyclic Data Signals 5.2 Digital Input Status Feedback Register Name Status Feedback The Profibus DP Module cyclically reports over the network IDATA1/0 Register 0 Bit 0 Actuator Moving a comprehensive data set relating to the status of the valve, IDATA1/1 Register 0 Bit 1 Close Limit...

  • Page 30: Digital Inputs

    The Actuator Cyclic Data Signals 5.2.1 Digital Inputs A setting on the actuator main board allows the ESD command to override the thermostat. The bit will Actuator Moving remain set at logic 1 until the motor cools down and the Whenever the actuator position is changing due to the thermostat resets itself.
  • Page 31 The Actuator Cyclic Data Signals Valve Moving by Hand Digital Input DI-1 The manual movement of the valve is reported as true (1) This bit reports the status of the contact connected to if the actuator is moved by the handwheel away from the the actuator hard-wired Open terminals.

  • Page 32: Digital Inputs Reporting The Profibus Card Condition

    The Actuator Cyclic Data Signals 5.2.2 Digital Inputs Reporting the Profibus Backup or Primary Channel Card Condition This bit is used to indicate if the Profibus communication is to a channel on the card that is able to move the valve GSD Parameterisation Permitted (Primary) or to a channel that is prevented from operating If the actuator and card is being parameterised using...

  • Page 33: Actuator Analogue Input Feedback

    It can be connected to another piece any non-zero number to parameter 35. For more information of equipment near the actuator from which feedback is please consult the Rotork technical manual. required, such as level sensors, pressures sensors or flow rate sensors, etc.

  • Page 34: Profibus Dp Communication

    The address can be set using the Accent software directly Profibus DP Cyclic (V0) and Acyclic (V1) with the actuator (free from www.Rotork.com) or using communication the setting tool. The address can also be set over the highway using a Class 2 master.

  • Page 35: Dual Highway, Dual Channel - Sr Mode

    Accent software directly with between Primary and Secondary mode. The the actuator (free from www.Rotork.com) or using the switch over time increases with each change setting tool. The address can also be set over the highway to a maximum of 32 seconds.

  • Page 36: Single Highway Dual Channel - Fr Mode

    Accent software directly with the second switch over time until one channel actuator (free from www.Rotork.com) or using the setting receives PLC messages. The channel addresses tool. The address can also be set over the highway using a alternate at this point.

  • Page 37: Dual Channel Indication Leds

    Profibus DP Communication 6.6 Dual Channel Indication LEDs If the actuator cover is opened there are several LEDs on the circuit board that are used to indicate communication activity. These indicate both the communication between the Profibus highway and the card and the communication within the card’s two main processors.

  • Page 38: Basic Operation On Start Up

    Profibus DP Communication 6.7 Basic Operation on Start up Power On Whenever a field device is powered up and it is found by the PLC it will go through the standard Profibus procedure of Master sends DIAG_req Parameterisation and Configuration before commencing Data telegram to slave Exchange.
  • Page 39 Profibus DP Communication 7 Parameters After a successful Diagnostic Request the Set Parameterisation Telegram is sent from the PLC. The Set 7.1 Parameters set by GSD and DP-V1 Communication Parameter message contains the user defined Parameter Profibus defines a power on reset sequence for all devices as: Data Unit (DU) of a minimum of 7 bytes, max 244 bytes.
  • Page 40 Open and 300 secs 812C hex Bits 0-14 are time values in seconds for timeout Actuator Type 0 – Unknown (default), 23 – Rotork Reserved Note - On Redcom Dual Channel cards the default is 2 (0002 hex) These parameters set up the response the actuator will make to various control and network actions.

  • Page 41: Limited Range Position Minimum And Maximum (Parameter 1 And 2)

    Parameters 7.1.1 Limited Range Position Minimum and Maximum 7.1.2 Deadband and Hysteresis (Parameter 3 and 4) (Parameter 1 and 2) When using position control by sending a value to the These parameter registers are used to define the positions Actuator Position DV set-point there are a number of in the range of valve travel that will be reported as 0 to parameter registers used to tune the position controller and 100% if the whole travel from the closed position to the...

  • Page 42: Motion Inhibit Timer (Parameter 6)

    Parameters 7.1.3 Motion Inhibit Timer (Parameter 6) 7.1.6 Watchdog Timeout (Parameter 9) The Motion Inhibit Timer setting is the period that must If the watchdog trips to reset the processor the Watchdog elapse between consecutive starts of the actuator motor Recovery data bit is set.

  • Page 43: Auxiliary Input Mask (Parameter 13)

    Parameters 7.1.10 Auxiliary Input Mask (Parameter 13) Position Value Function This parameter relates to the auxiliary inputs (open, stop, Disable ESD input as command close, ESD) to be set to control the actuator or simply report Enable ESD input as command their status.

  • Page 44: Esd Di-4/Net Disable (Parameter 14)

    (set by parameter 16) closed irrespective of the Aux Mask setting. must be achieved if the test is successful. Please consult the Rotork manual for more information. Value Function 7.1.12 Redundancy FR/SR Mode and Simple/RedCom...

  • Page 45: Parameters Viewed And Set By Dp-V1 Communication

    Parameters 7.2 Parameters viewed and set by DP-V1 Communication The Profibus DP Module supports both these utilities. The list of parameters that can be accessed by these tools is as The Profibus DP Module supports V1 acyclic communication below. These tools will allow the actuator to be controlled as well as V0 cyclic messages.
  • Page 46 Parameters Parameter Read / Default Data Value / Range Write Value Function for Indication contact S1 0000 Bit 0: 0-Normally Open, Function for Indication contact S2 0001 1 – Normally Closed. Bits 1 to 15: See separate Function for Indication contact S3 0002 table ‘S contact functions’.

  • Page 47: Control Outputs (Parameter 26 To 29)

    Parameters Parameter Read / Default Data Value / Range Write Value ID Power 16 bytes ASCII ID Option1 16 bytes ASCII ID Option 2 16 bytes ASCII Reserved Reserved Manufacture notes 48 bytes ASCII General Notes 67 bytes ASCII Note - Only readable by V1 comms on Simple Dual and 7.2.4 Permit GSD Parameterisation (Parameter 25) RedCom Dual modules.
  • Page 48 Parameters 7.2.8 Function for indication Contacts S1 – S8 (Parameters 78-81 and 86-89) These parameters enable the indication contacts S1 to S8 to be set to trip to any one of the following functions. The contact can be set to Normally Open or Normally Closed using bit 0.

  • Page 49: Position Trip For Indication Contacts

    Parameters 7.2.9 Position Trip for indication Contacts S1 – S8 7.2.13 Interrupter Timer parameters (104 – 108) (Parameters 82-85 and 90-93) The interrupter timer enables pulsed ‘start / stop’ operation as These parameters select the position for the contact to trip a response to local or remote control commands.

  • Page 50: Setting Up And Maintaining The Profibus Module

    FDT container. A typical configuration screen is illustrated below. Fig. 27: Rotork EDD running in the Siemens PDM application. Fig. 26: Rotork DTM running in the M&M FDT container The settings for the parameters and the control and review of actuator information can all be carried out in the FDT container using the DTM.

  • Page 51: Setting Up The Network Address In The Pfu

    Centronik. It can be freely communication port for setting the network address for the downloaded from the Rotork website. It designed to be run actuator using the supplied setting tool. The software Accent from a Windows computer and connects to the actuator can also be used (requires Bluetooth).

  • Page 52: Setting Tool Menu Structure And Pfu Settable Parameters

    NORM.CLOS. ADDRESS OPEN OPTION-2 LOST.S.ACT. CLOSE GSD.PARAM. STOP POSITION TERMIN.1 S.LOSS.POS. PROFIBUS 100% TERMIN.2 Fig. 29: Setting tool menu structure and PFU settable parameters FLYING REDUNDCY. SYSTEM Refer to the Rotork installation manual for EXTD.DIAG. more details. Profibus Installation Manual...

  • Page 53: Setting Up The Remote Source In A Ck Actuator With The Setting Tool

    Setting Up and Maintaining the Profibus Module ® 8.5 Setting up the remote source in a CK actuator 8.6 Maintenance and Repair with the Setting Tool There is no periodic service requirement for the PFU. The actuator requires the remote source to be set up into the Repairs should not be attempted on the module.

  • Page 54: Records

    Setting Up and Maintaining the Profibus Module ® 8.7 Records In order that a replacement can be easily introduced in the event of a device failure it is very important to record and keep safe all the settings made for the variable registers. The table lists all the registers that must be checked and set up for each Profibus Module on a network.
  • Page 55 Keeping the World Flowing...
  • Page 56 As part of a process of on-going product development, Rotork reserves the right to amend and change specifications without prior notice. Published data may be subject to change. For the very latest version release, visit our website at www.rotork.com PUB111-011-00 The name Rotork is a registered trademark.

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