Westlock ICOT 5400 Technical Manual Download

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WESTLOCK CONTROLS CORPORATION

280 N MIDLAND AVENUE STE 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913

www.westlockcontrols.com

5/12/2017

TECH-538/D.W.O. 23160

Page 1 of 189

ICOT 5400 AND ICOT 6400

(REVISION 4)

FOUNDATION FIELDBUS

INTELLIGENT VALVE POSITIONER

TECHNICAL MANUAL

IOM:

TECH538

Revision:

Prepared By:

William Ferraz

Date:

02/27/2017

Drafting Work Order:

23160

ECN:

Reviewed By:

Frank Oster; Chris Irwin;

Leiser de Souza; Rogerio da

Mata; Raj Patel

Date:

03/23/2017

Approved By:

Jason

Moorehead

Date:

11/01/2017

This document contains confidential information and is issued in confidence on the condition that it be returned on demand and not be copied,

reproduced, disclosed to others or used in manufacture of the subject matter thereof without the written consent of Westlock Controls

Summary of Contents for ICOT 5400

Page 1: ...8 Revision Prepared By William Ferraz Date 02 27 2017 Drafting Work Order 23160 ECN Reviewed By Frank Oster Chris Irwin Leiser de Souza Rogerio da Mata Raj Patel Date 03 23 2017 Approved By Jason Moor...

Page 2: ...TECH 538 D W O 23160 Page 2 of 189 Revision History Revision 12 05 2017 Initial release Westlock Controls Locations USA Phone 201 794 7650 Fax 201 794 0913 Europe Phone 011 44 189 251 6277 Fax 011 44...

Page 3: ...Mount ICoT 6400 36 7 Setting of switches on a rotary ICoT 5400 only 38 8 System Integration and Operation 39 9 Maintenance and Repair 105 10 Appendix A ICoT 6000 Series Local Display Menu Tree 128 11...

Page 4: ...nection pins Electrical connection 31 Figure 4 3 Example of ICoT 6400 Foundation Fieldbus network topology 32 Figure 4 4 Example of ICoT 5400 Foundation Fieldbus network topology 33 Figure 5 1 Diagram...

Page 5: ...racterization function 84 Figure 8 39 Deviation Deadband function 85 Figure 8 40 Final Value function 86 Figure 8 41 Final Value Hi Lo Cutoff function 87 Figure 8 42 STEP1 Select the positioner 89 Fig...

Page 6: ...5 Westlock ICoT FF EDD Folder 166 Figure 11 6 ICoT FF registration page at FF 167 Figure 11 7 Unzipped ICoT EDD Files in Windows Explorer 168 Figure 11 8 Add Device Type command in DeltaV Explorer 168...

Page 7: ...ide further diagnostic and quick information about communication status and other errors What this document contains In the following pages of this document basic information about four different proc...

Page 8: ...fer different options of manifolds which make available different flow capacities or CV The manifold material can also be in Aluminum or Stainless Steel See section 1 7 The physical dimensions of both...

Page 9: ...Tamb 40 C to 80 C FM09 ATEX 0028 Ex ia IIC T4 II 1 G Ta 40 C to 80 C II3 DT 75 C FM Project ID 3017233 IS I II III 1 ABCDEFG T4 Ta 80 C WD 11704 Entity Type 4X I 0 AEx ia IIC T4 Ta 80 C WD 11704 Entit...

Page 10: ...ticky frozen pneumatic spool at low temperatures or corrosive liquids gasses contaminating gaskets seals filters or spools Contact Westlock for tips and actions that may help is such situations Also C...

Page 11: ...ICoT Positioner High Flow manifold design is suitable for actuator swept volumes of a minimum 200 inch3 3 2 liters to a maximum of 1000 inch3 16 30 liters for proper Auto Calibration functionality Ag...

Page 12: ...arity insensitive o Maximum current consumption from the bus 12 5 mA Real Time Clock o Adjusted using Diagnostic Transducer Block o Back up Supercapacitor o Back up life 7 days 20o C 68o F Optional po...

Page 13: ...etic Compatibility EMC Table 1 ICoT 5000 Series EMC Immunity Test Immunity Test Standard Level Class5 Electrostatic Discharge ESD IEC 61000 4 2 Direct 4kV air 8kV A Electric Fast Transient Burst EFTB...

Page 14: ...o Maximum current consumption from the bus 12 5 mA Real Time Clock o Adjusted using Diagnostic Transducer Block o Back up Supercapacitor o Back up life 7 days 20o C 68o F Optional potentiometer sensor...

Page 15: ...6000 Series EMC Immunity Test Immunity Test Standard Level Class8 Electrostatic Discharge ESD IEC 61000 4 2 Direct 4kV air 8kV A Electric Fast Transient Burst EFTB IEC 61000 4 4 2kV A Lightning Surge...

Page 16: ...c valve The ICoT FF is also a two wire polarity insensitive instrument that receives both signal and power from the bus Current consumption of the ICoT FF is 12 5mA with an operating voltage of 9 32 V...

Page 17: ...ever 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...

Page 18: ...s like the actuator and other accessories attached to them Please follow the following instruction carefully Rotary Actuator Direct Mounting Step 1 Mount the bracket and inner beacon coupler on the ac...

Page 19: ...s with reference to the positioner manifold Condition 1 Actuator fails in a clockwise direction Spring Return Output Port 2 is plugged Output Port 1 is piped to turn the actuator counter clockwise Dou...

Page 20: ...ockwise Double Acting Output Port 2 is piped to turn the actuator counter clockwise Output Port 1 is piped to turn the actuator clockwise Magnet position with actuator in counter clockwise position Pl...

Page 21: ...he Transmitter is mounted in a fashion that properly orients it with respect to the inner beacon If the 3 steps are followed correctly the final assembly should be similar to the following picture Not...

Page 22: ...g Step 3 Mount the position sensor to the bracket As stated in Step 2 make sure that the position sensor is mounted in a fashion that properly orients it with respect to the inner beacon Step 4 Mount...

Page 23: ...189 Condition 2 Actuator fails in a counter clockwise direction Magnet Position in relation to remote conduit with actuator in counter clockwise position Placed at 9 00 left side Placed at 6 00 botto...

Page 24: ...actuator normally the sequence below should be followed Step 1 Assemble the linear magnet assembly on the magnet mounting bracket Step 2 Assemble the magnet assembly with the bracket on the actuator...

Page 25: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 25 of 189 Figure 3 9 Linear Actuator Assembly Drawings IcoT 6000...

Page 26: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 26 of 189 Figure 3 10 Linear Actuator Assembly Drawings IcoT 5000...

Page 27: ...bracket to the actuator as described before for a linear actuator Step 2 Mount the position sensor housing so that the conduit entry faces away from the actuator diaphragm or cylinder See Figure 3 11...

Page 28: ...al transducer and should be specified accordingly As mentioned before important information is the flow capacity needed by the actuator The Westlock ICoT 6000 can be ordered with different flow capaci...

Page 29: ...piped to drive the actuator away from the fail position increasing setpoint signal causes pressure to increase in Outlet Port 1 of the positioner and pressure to decrease in Outlet Port 2 of the posit...

Page 30: ...ed by the means of an Allen Head Cap Screw which secures to the underside of the cover when turned in the CCW direction preventing the covers from unintentional opening See figure below for reference...

Page 31: ...onsumption 12 5 mA ICoT 6400 Connector J1 pins 1 and 2 Grounding J1 pin 5 cable shield not connected Operating voltage 9 to 32 VDC Max 35 VDC Power consumption 12 5 mA ICoT FF Electrical Connections F...

Page 32: ...nce coupler between the power supply and the network Make sure that the electrical installation of the remaining parts of the network also complies with FF specifications For more information refer to...

Page 33: ...ARTCAl FF UI Vmax 17 5V Ii Imax 380mA PI Pmax 5 32W Ci 5nF Li 10uH Temperature Classification T4 ICOT 5400 AVID SMARTCAl FF UI Vmax 17 5V Ii Imax 380mA PI Pmax 5 32W Ci 5nF Li 10uH Temperature Classif...

Page 34: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 34 of 189 Figure 4 3 Electrical Connections ICoT 5400...

Page 35: ...le plug as shown below connect as in Detail A 5 Run the remote cable through positioner conduit entry use proper gland fitting for IP66 rating for 0 162 O D cable 6 Locate the actuator mounted Positio...

Page 36: ...closure conduit entry as shown in Figure 6 4 use proper conduit fitting or gland fitting for IP66 rating for 0 162 O D cable 5 Replace the terminal strip board and replace the terminal board mounting...

Page 37: ...12 2017 TECH 538 D W O 23160 Page 37 of 189 Figure 6 3 J3 J4 connectors on the bottom of terminal board Figure 6 4 Diagram of the connection between the ICoT 6400 junction box and the actuator mounted...

Page 38: ...to the desired end points max open or close Loosen magnetic trigger bolt 1 Slide trigger bolt 1 beneath the first switch and tighten with wrench Operate the actuator to the opposite extreme Loosen ma...

Page 39: ...s been established during the positioner s setup and calibration is stored in this memory Under certain abnormal conditions this stored information can become corrupted If this occurs it is necessary...

Page 40: ...he DIP switch FCT back to the off Figure 8 1 SW4 Detail ICoT 5400 ICoT 6400 Using the DIP switch located in the right side of the display SW2 Move the DIP switch 3 to ON position It is the THIRD switc...

Page 41: ...to receive the latest EDD files download the ICoT EDD directly from the Fieldbus Foundation registered products website link below http www fieldbus org index php option com_mtree task search Itemid...

Page 42: ...lockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 42 of 189 Figure 8 4 ICoT FF registration page at FF12 12 Although the picture illustrate only the ICoT 6400 model it is also compatible for the IC...

Page 43: ...stand which I O channels and function blocks are available The following function blocks are pre instantiated in the device Analog Input AI 1 one block available The AI block can be used to read an IC...

Page 44: ...lock Channel Channel Name Description 0 Uninitialized Default value for AI 1 Position Valve position The Analog Input units of measure must be of full span valve position This is the only transducer r...

Page 45: ...de must be OOS before modifying IO_OPTS In this way the BKCAL_OUT will publish the position feedback according to the READBACK parameter When using the ICoT the Analog Output units of measure must be...

Page 46: ...ation for example In this case a fault state condition can also be configured It s important to know that the Transducer block configuration takes precedence over the AO block In other words the fault...

Page 47: ...ge to MAN when a fault is detected Then block may be manually15 set to its normal target mode after the fault conditions are cleared In case the mode is changed to Auto or Cas and the external conditi...

Page 48: ...ers in the Transducer block that can be used to configure the transducer actions in case of fault state detection PSNR_FSTATE_OPT whenever the Transducer block enters into a fault state AO sends a BAD...

Page 49: ...oss of communication to CAS_IN is detected o the TARGET block mode of AO block is in Cas Auto o the ACTUAL block mode of the AO block is in LO Local Override mode o the parameter CAS_IN of the AO bloc...

Page 50: ...8 6 Fault State Configuration and the Field Diagnostic mechanism is described in Section 9 1 2 FF Field Diagnostics Another way to get diagnostic information from The ICoT is to use the local display...

Page 51: ..._OPT to NormalShed_NormalReturn o PV_SCALE UNITS_INDEX to o XD_SCALE UNITS_INDEX to o MODE_BLK TARGET to CAS mode C Download the above configuration This is host or control system dependent18 Please c...

Page 52: ...ng the local display and calibration Menu tree using either the local push buttons or non intrusive magnetic tool19 To use the local calibration menu functions there is no need to setup the host syste...

Page 53: ...edicated for the internal use only and should not be used by the operator To exit PASSWORD setup function press simultaneously Up and Down buttons again Figure 8 10 Password screen The calibration fun...

Page 54: ...nternally can be accessed externally The positioner comes with a magnetic tool part number TL 30003 that is used to operate the non intrusive feature Use single pin side or dual pin side of the magnet...

Page 55: ...guration in the device 2 Simulate Enable or Disable the FF Simulate parameter 3 Factory Default Initialization See Section 8 2 2 4 Auxiliary Not used Figure 8 12 ICoT5400 DIP switch SW4 ICoT 6400 Conf...

Page 56: ...ansducer block parameters and commands of ACAL MCAL Cofg and Stro available in the local display menu are shown in the following sections ATTENTION Before executing any calibration and configuration i...

Page 57: ...een press the CAL button until ACAL is shown on the display Press and hold the CAL button until it starts the automatic calibration Automatic calibration goes through the five sequences and when compl...

Page 58: ...of the actuator valve Initially during this calibration the valve is driven to the fully energized full travel position hard stop The user will notice full pressure to Outlet Port 1 and zero pressure...

Page 59: ...ter PSNR_COMMAND by selecting the option Arm and then selecting the option Start Auto Cal The ICoT FF will execute the same internal procedures as the command ACAL available in the local display menu...

Page 60: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 60 of 189 Figure 8 18 Manual calibration MCAL routine...

Page 61: ...ner error according to the inverse of the Ti value Also a lower value of Ti will have less damping of the dynamic response This means the lower the Ti the more oscillations at a higher frequency may b...

Page 62: ...ction and Menu name only MCAL Lo etc press Up button once to enter the Menu level and once more to exit CAL mode 3 If the positioner is performing any calibration function e g ACAL Trnd press and hold...

Page 63: ...Positioner Fail Position Open or Closed 4 OPSP Positioner Opening Speed Adjustment 5 CLSP Positioner Closing Speed Adjustment 6 EDb Positioner Operating Dead band over the Set point Adjustment 7 Tout...

Page 64: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 64 of 189 Figure 8 19 Positioner s parameters configuration Menu Tree Part I...

Page 65: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 65 of 189 Figure 8 20 Positioner s parameters configuration Menu Tree Part II...

Page 66: ...f Quick Opening is selected and a setpoint of 20 is sent to the ICoT the local display will show SP 36 9 and when it reaches position at 36 9 open it will display PS 36 9 PS position The Lin Linear po...

Page 67: ...e position will be OUT of the deadband region if it is equal or greater than 25 5 or lower than 24 5 i e 25 0 5 The positioner s factory default is set to off When the feature is turned on the deadban...

Page 68: ...wn in Table 15 Table 15 Cofg parameters available in the local display menu and in the TB Cofg parameters in the local display menu Cofg parameters in the Transducer block Flow CHARACTERIZATION Type A...

Page 69: ...the full closed position These functions set the positioner to digital control mode network independent and therefore allow override of the network setpoint control signal The positioner has a featur...

Page 70: ...l mode network independent and therefore allows override of the network setpoint control signal CLs This function sets the valve to the fully de energized position via the pushbuttons Outlet Port 1 0...

Page 71: ...ssion and it always reset the device after the modification is confirmed disrupting the normal operation of the positioner However some host system cannot work with some addresses in particular ranges...

Page 72: ...n PCs or handhelds Section 11 5 Device Description presents more information about the FF Device Description technology presents a basic menu tree diagram implemented in the ICoT EDD files Section 11...

Page 73: ...ariables menu or Process Variables Root Menu available in the ICoT are standard according FF specification and they should be used by PC based host applications The next picture presents the Configure...

Page 74: ...9 Then next picture presents the Device Diagnostics menu available in the ICoT Figure 8 27 Device Diagnostics menu available in the ICoT The next picture presents the Process Variables menu available...

Page 75: ...rtant parameters functions and methods available in the EDD menus are presented in the following sections and in the Chapter 11 Appendix B Foundation Fieldbus Network NOTE Before executing any calibra...

Page 76: ...via ICoT EDD menus is available in the 3 1 Transducer Calibration menu by pressing the Auto Calibration button After pressing the Auto Calibration button the following message can be shown Figure 8 30...

Page 77: ...utomatic calibration method is started If the automatic calibration method is complete successfully the Auto Calibration Finished with success message is shown Figure 8 33 Auto Calibration Finished wi...

Page 78: ...zero position or to select an arbitrary position as low zero position This function appears in the local display as Low Zero Calibration and Acal Lo High Span Cal This function serves to set the full...

Page 79: ...ration as determined by LCD displaying a Menu name only MCAL etc press the up key once to exit CAL mode If the positioner is at function level in the calibration as determined by LCD displaying a func...

Page 80: ...hers 1 Characterization Flow in local display menu Positioner Output Flow Characteristics 2 Actuator Type Type in local display menu Positioner Recognition of Magnetic Feedback Rotary or Linear 3 Flop...

Page 81: ...istics This allows the positioner setpoint to represent a closer approximation to the actual flow The options are Linear Percent Quick Opening and Custom21 When Equal Percentage and Quick Opening are...

Page 82: ...r Type function This function configures the positioner regarding the type of the actuator The options are Rotary or Linear This configuration is necessary in order to configure the positioner to reco...

Page 83: ...f option is for fail closed applications and the on option is for fail open application When off is chosen the local display will read 0 at the zero Lo Calibration and 100 at the span Hi Calibration W...

Page 84: ...Figure 8 38 Characterization function Valve Open Slew Limit function This function is used to configure the opening or closing speed of the actuator valve There are 5 options available where 5 is the...

Page 85: ...lower than 24 5 i e 25 0 5 How to find the Configuration options in the Transducer Block The functions available in the EDD menus for configuration of the positioner s parameters also have their equiv...

Page 86: ...e Valve to the Full Open Position when the SP is equal or greater than the cutoff value 3 Final Value Lo Cutoff CLs in local display menu Close Sets the Valve to the Full Closed Position when the SP i...

Page 87: ...i Lo Cutoff function Hi Cutoff This function sets the valve to the fully energized position Outlet Port 1 Supply psi Outlet Port 2 0 psi when the set point is equal or greater than the Final Value Hig...

Page 88: ...Section 11 4 3 for more information on the Transducer block parameters shown in the Table 19 These Transducer block parameters can be changed only if the MODE_BLK parameter of the Transducer block is...

Page 89: ...similar23 to the ones shown in the next pictures It consists of 6 steps STEP1 Select the positioner from the live list STEP2 Select the Device Root Menu STEP3 Select the Calibration STEP4 Select 3 1 P...

Page 90: ...b parameters Target determines which mode the user wants the block to assume Usually it needs to be set to OOS before any configuration parameter can be changed Actual set by the block during its exec...

Page 91: ...r fail closed valves Pneumatics has to be installed accordingly though After the Transducer block is properly configured it can be used to control the IP converter output as well as read the position...

Page 92: ...sent in Table 12 it is necessary to select the command Arm available in the same parameter Note See Section 11 4 3 to have more information about the Transducer block parameters present in Table 12 Ex...

Page 93: ...The AI and PID are additional function blocks that enhance the flexibility of the ICoT to accomplish the user application requirements In the follow examples the initial condition is to use a brand n...

Page 94: ...LE UNITS_INDEX to o MODE_BLK TARGET to Auto mode PID BLOCK PID o PV_SCALE UNITS_INDEX to o OUT_SCALE UNITS_INDEX to o GAIN to 0 5 related to the Proportional element of the PID control o RESET to 1 re...

Page 95: ...ion Block Application window add the AI PID and AO blocks and connect them as shown in the next figure Figure 8 49 AI PID AO Application Example on NI Conf Tool 3 Download the project selecting only t...

Page 96: ...t picture Figure 8 51 NI Conf Tool in Monitoring mode 5 If the application is not running as expected see Chapter 9 Maintenance and Repair for diagnostics information and for troubleshooting Also as t...

Page 97: ...bus network to communicate with the DeltaV FF Host The next figure shows the ICoT as a decommissioned device as presented by the DeltaV Explorer tool Figure 8 52 ICoT FF on line in the DeltaV Explorer...

Page 98: ...n Figure 8 54 ICoT in Standby mode In this example the ICoT is physically connected to the second FF network P2 of the DeltaV controller To commission the ICoT in the DeltaV system drag it from the De...

Page 99: ...f 189 4 To configure the Transducer block parameter select the command Configure Setup Figure 8 56 Configure Setup command to configure the Transducer block 5 Configure the ACT_TYPE and MODE_BLK param...

Page 100: ...7 TECH 538 D W O 23160 Page 100 of 189 6 Create a new control module Figure 8 58 Creating a Control Module 7 Open the new control module with the Control Studio Figure 8 59 Opening the new Control Mod...

Page 101: ...plication Figure 8 60 Application Example with Signal Generator Function Block on DeltaV System 9 When one of the function blocks is selected the parameters field inferior left part of the Control Stu...

Page 102: ...OUT_SCALE UNITS_INDEX to o MODE_BLK TARGET to Auto mode ANALOG OUTPUT BLOCK FFAO o CHANNEL to 1 Channel 1 o SHED_OPT to for instance NormalShed_NormalReturn o PV_SCALE UNITS_INDEX to o XD_SCALE UNITS...

Page 103: ...Page 103 of 189 12 Select only the options related to the fieldbus port and to the ICoT and press OK button 13 Figure 8 63 Download Options 14 After the download is successfully start the on line mode...

Page 104: ...o be sure that the application is running well Figure 8 65 On Line Mode in DeltaV System 16 If the application is not running as expected see the Chapter 9 Maintenance and Repair for diagnostics infor...

Page 105: ...messages The messages in the FF CTR position indicate the source of the SP as following FF CTR Function Block AO as in the previous picture LO CTR Local Override the manual stroke functions are used...

Page 106: ...rs to get the diagnostics information are located in the Resource block Section 11 4 2 shows the complete list of the Resource block parameters and a short description of each one The Field Diagnostic...

Page 107: ...active the related alarm type FD_FAIL_ALM FD_OFFSPEC_ALM FD_MAINT_ALM or FD_CHECK_ALM won t be activated The user has to configure the alarm priority parameters with a value equal or bigger than 1 to...

Page 108: ...neumatic Connection Single Acting In most of the applications the Output port 1 should be piped to drive the actuator away from the valve fail position Then the Output port 2 should be plugged However...

Page 109: ...he stroke length and failure direction of the actuator To make sure that the appropriate magnet assembly was selected check the part characteristics The stroke length and failure direction should be p...

Page 110: ...ease consult the actuator manufacturer about the correct working pressure to be applied Also there are two types of pneumatic transducer used in the ICoT The Low pressure 15 45 psi and the high pressu...

Page 111: ...evision e g 0x03 o DD_REV the lowest oldest revision number of the EDD which was used to register the device e g 0x01 It s possible to have newer revisions that describe the device It s recommended to...

Page 112: ...ters of the device s tag is shown in the last row of the local LCD How to limit the SP travel range How to enable Open and Close Alarms If the control loop is Automatic mode the recommended way to lim...

Page 113: ...8 10 2 See Section 8 9 7 or Section 8 10 4 for configuration of the function Flow The positioner is properly set up and air is applied to the positioner When powering up the positioner the actuator go...

Page 114: ...ion have been performed If the cause for the Integrator Overflow error cannot be diagnosed please contact Westlock for support ICoT does not turn on and or the display does not show any information wh...

Page 115: ...iguring the AO channel the block error persists power cycle the device The valve does not go to FAIL position when ICoT is powered off When the device is not powered pneumatics and actuator assembly a...

Page 116: ...ill show the message NO RUN FF Comm Error In this case check wiring connectors terminators bus voltage between 9V and 32V barriers and signal quality Indication of valve closed or valve opened is wron...

Page 117: ...dicating actual valve position Check if the configuration was downloaded without errors Check block mode it should be in AUTO Check if parameter CHANNEL has been properly configured Check parameter XD...

Page 118: ...maintained within the deadband range The deviation deadband range EDb is set from the configuration menu during calibration see sections 8 9 7 1 8 10 4 1 and 8 12 2 The EDb must be set to other than...

Page 119: ...Uncertain InitialValue Constant CAS_IN is receiving a BAD status Check setpoint publisher Block mode is IMAN Block mode is CAS or AUTO but no CHANNEL has been assigned Good NonSpecific NotLimited Thi...

Page 120: ...d OutOfService NotLimited Block mode is in OOS check MODE_BLK parameter Check Resource block mode in OOS Good NotInvited NotLimited Block mode is CAS or AUTO but no CHANNEL has been assigned Check ass...

Page 121: ...g problems using BLOCK_ERR Block Error parameter The BLOCK_ERR parameter gives the user further insight into configuration errors and operational faults that prevent the expected operation of the devi...

Page 122: ...valid only if the Transducer block is configured with block mode is in AUTO o If there is any configuration error in the Transducer block the block mode will not go to AUTO therefore the DeviceMainte...

Page 123: ...configured with a valid channel associated with TRD See Analog Input channels table for more details XD_SCALE check if this parameter is configured with valid units OUT_SCALE check if this parameter i...

Page 124: ...r s onboard filter is not a substitute for normal instrument air preparation Supply air to the positioner should conform to ISO 8573 1 Air Quality Standards Important The filter s original color is ch...

Page 125: ...nt To clean the spool use a clean lint free cloth To clean the I D of the sleeve a polyester lint free clean room swab is recommended These items can be obtained from most industrial supply companies...

Page 126: ...to removing the spool make sure the positioner is out of service and all air pressure has been bled off the positioner and the actuator The spool piece and sleeve can be cleaned using any non chlorina...

Page 127: ...ectors from electronics canister make sure to note connector locations Remove the screw that secures canister housing and ground cable Remove the screw that secures ground cable 3 Remove the canister...

Page 128: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 128 of 189 10 Appendix A ICoT 6000 Series Local Display Menu Tree Figure 10 1 ICoT Local Display Menu Tree...

Page 129: ...d workstations FOUNDATION fieldbus is the only protocol with the built in capability to distribute the control application CIF across the network See Reference FOUNDATION Specification Technical Overv...

Page 130: ...ic layer of the FF specification called Function Block Application Process FBAP contains all the definitions and interaction rules for the Function Blocks See References FOUNDATION Specification Funct...

Page 131: ...23160 Page 131 of 189 Blocks relationship diagram The diagram below shows the way the function blocks AO and AI connect to the Transducer block through the I O channels and the most important paramete...

Page 132: ...aking use of the capabilities in field device diagnostics The diagnostics are broken down into four categories Failure Off Specification Maintenance and Check Function These categories are defined in...

Page 133: ...tic conditions are not evaluated if the target mode of the Resource block is Out of Service All alarms are cleared when the target mode is Out of Service If the target mode is not Out of Service the a...

Page 134: ...rameter reflects the value of the major version of Field Diagnostics specification that the device was designed too This allows hosts to distinguish between changes that may be necessary to be made in...

Page 135: ...s Parameters and Views Block Parameters Reference Common Definitions and Tables Default values are obtained after a Resource block RESTART parameter is written to 3 Restart with defaults FCT Default v...

Page 136: ...f service 0x00400000 No Output Channels No output channels have been assigned i e there can be no action 0x00200000 Open without Close An Open output channel has been assigned without a channel Close...

Page 137: ...ock R W 4 ALERT_KEY The identification number of the plant unit This information may be used in the host for sorting alarms etc 1 to 255 None R W 5 MODE_BLK The actual target permitted and normal mode...

Page 138: ...0x01 ICoT2 0x01 14 GRANT_DENY Options for controlling access of host computers and local control panels to operating tuning and alarm parameters of the block 15 HARD_TYPES The types of hardware availa...

Page 139: ...FREE_TIME Percent of the block processing time that is free to process additional blocks 26 SHED_RCAS Time duration at which to give up on computer writes to function block RCas locations 27 SHED_ROUT...

Page 140: ...system problems in the block The cause of the alert is entered in the subcode field The first alert to become active will set the Active status in the Status attribute As soon as the Unreported status...

Page 141: ...a bit string so that multiple conditions may be shown 45 FD_MAINT_ACTIVE This parameter reflects the error conditions that are being detected as active as selected for this category It is a bit strin...

Page 142: ...this category from being broadcast to the host through the alarm parameter 52 FD_OFFSPEC_MASK This parameter allows the user to suppress any single or multiple conditions that are active in this cate...

Page 143: ...itions which are not masked for this alarm category to a Host System 59 FD_FAIL_PRI This parameter allows the user to specify the priority of this alarm category 60 FD_OFFSPEC_PRI This parameter allow...

Page 144: ...in regards to older EDD revision s Read only 67 REVISION_ID The revision identifier of the device It shows firmware version for the ICoT module 68 REVISION_DATE The revision date of the device It sho...

Page 145: ...target permitted and normal modes of the block See MODE O S O S O S NA R W 6 Y BLOCK_ERR This parameter reflects the error status associated with the hardware or software components associated with a...

Page 146: ...0 0 0 0 None Read only 14 FINAL_VALUE The requested valve position and status written by an analog Function Block 0 0 0 None Man See note 1 15 FINAL_VALUE_RANGE The High and Low range limit values the...

Page 147: ...ck Application Process Part 1 FF 890 Rev FS 1 10 and FOUNDATION Specification Function Block Application Process Part 2 FF 891 Rev FS 1 10 0 0 0 26 RATED_TRAVEL29 Nominal travel of actuator valve in t...

Page 148: ...tions defined in Standard Tables TN 016 0 Hold Last Value30 1 Fail Closed 2 Fail Open 3 PSNR_FSTATE_VAL_D 4 7 Reserved 8 255 Mfg Specific 0 Hold Last Value 0 Hold Last Value 0 Hold Last Value E R W 33...

Page 149: ...2816 0X0B00 Start Low Zero Cal 3072 0X0C00 Start High Span Cal 3328 0X0D00 Start Transducer Cal 3584 0X0E00 Start Auto PID Tuning 3840 0X0F00 Abort 0 Normal Operation 0 Normal Operation 0 Normal Opera...

Page 150: ...ed in the Standard Tables TN 016 It is a recommendation that only the first four enumerations of the Last Va table be used 0 Undefined 1 Self closing 2 Self opening 3 Hold last value 4 Maximum value 5...

Page 151: ...ot available33 56 VST_DETAILED_RESULT Not available33 57 CLOSED_POS_DEADBAND Not available33 58 CLOSED_POS_SHIFT Not available33 59 CUSTOM_CURVE_DESCRIPTION Not available33 60 CUSTOM_CURVE_XY_NUM_PTS...

Page 152: ...3 89 FST_STRK_TRAV_TIMEOUT Not available33 90 FST_COMPLETION_TIMEOUT Not available33 91 PRESSURE_PORT_A Not available33 92 PRESSURE_PORT_B Not available33 93 PRESSURE_UNITS Not available33 94 PRESSURE...

Page 153: ...Flop Enable On Flop Enable Off Flop Enable Off Flop Enable Off 107 SERVO_GAIN Proportional gain Float 32 bits 108 SERVO_RESET Integral gain 0 256 109 SERVO_RATE Derivative gain 0 256 110 VALVE_OPEN_S...

Page 154: ...OPEN_PRES_A_SIGNATURE_POS Not available33 126 OPEN_PRES_B_SIGNATURE_POS Not available33 127 CLOSE_SIGNATURE_TIME Not available33 128 CLOSE_SIGNATURE_POS Not available33 139 CLOSE_PRES_S_SIGNATURE_POS...

Page 155: ...e calculated as a result of executing the function block OUT_SCALE 10 9 SIMULATE Allows the transducer analog input or output to the block to be manually supplied when simulate is enabled When simulat...

Page 156: ...Read only 22 ALARM_SUM The current alert status unacknowledged states unreported states and disabled states of the alarms associated with the function block 23 ACK_OPTION Selection of whether alarms a...

Page 157: ...189 Index Parameter mnemonic Description EDD Help Valid Range Default FCT Default Deep Default Units Write R W 40 SUPPORTED_MODES Read only parameter that indicates the modes supported by the block 0x...

Page 158: ...OUT_SCALE 10 10 SIMULATE Allows the transducer analog input or output to the block to be manually supplied when simulate is enabled When simulation is disabled the simulate value and status track the...

Page 159: ...dup and provide bumpless transfer to closed loop control PV Read only 26 RCAS_IN Target setpoint and status provided by a supervisory Host to an analog control or output block PV 27 SHED_OPT Defines a...

Page 160: ...lock PV_SCALE 10 PV 9 OUT The primary analog value calculated as a result of executing the function block OUT_SCALE 10 10 PV_SCALE The high and low scale values engineering units code and number of di...

Page 161: ...me specified by BAL_TIME Positive or zero 0 Sec 26 RATE Defines the derivative time constant in seconds Positive or zero 0 Sec 27 BKCAL_IN The value and status from a lower block s BKCAL_OUT that is u...

Page 162: ...automatically acknowledged 0 Auto Ack Disabled 1 Auto Ack Enabled 0 47 ALARM_HYS Amount the PV must return within the alarm limits before the alarm condition clears Alarm Hysteresis is expressed as a...

Page 163: ...Index Parameter mnemonic Description EDD Help Valid Range Default FCT Default Deep Default Units Write R W 67 SUPPORTED_MODES Read only parameter that indicates the modes supported by the block 0x08 A...

Page 164: ...ter like the CALIBRATION COMMANDS Although the FF Device Description DD and the enhanced version EDD source files are defined by the device manufacturer to best represent its device s objects the host...

Page 165: ...emented in the ICoT EDD files Figure 11 4 ICoT EDD Menu Tree ICoT 1 Device Root Menu 1 Basic Setup 2 Advanced Setup 3 Calibration 4 Function Block Utils 2 Diagnostics Root Menu 1 Field Diagnostics 2 B...

Page 166: ...tion com_mtree task search Itemid 324 ffbstatus Registered ffbmfg Westlock Controls ffbcategory 34 Follow the instructions of the Host manufacturer to know how to import these Sometimes it s possible...

Page 167: ...ockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 167 of 189 Figure 11 6 ICoT FF registration page at FF35 35 Although the picture illustrate only the ICoT 6400 model it is also compatible for the I...

Page 168: ...atest EDD files or download directly from the Fieldbus Foundation registered products website link below http www fieldcommgroup org 2 Unzip the downloaded file from the FF site or the one received fr...

Page 169: ...he OK button 5 Figure 11 9 Browsing ICoT EDD Files 6 If the Add Device Type command is successful the following message is shown Figure 11 10 Message of Add Device Type command is successful 7 Check i...

Page 170: ...alled in the FF host system is older than the one used to build the EDD files of the ICoT FF36 The EDD Installation Check method is available in the menu 3 1 Transducer Calibration After pressing the...

Page 171: ...5 1 and find the connector J6 for local or remote sensor connection for the ICoT 5400 See Figure 6 3 and find the connectors J3 and J4 for remote sensor connection for the ICoT 6400 The connector J2...

Page 172: ...valve driver Check Cable between the inner canister and the pneumatic transducer assembly is tightly connected Cable and connector between the transducer board and the spool valve coil Perform a full...

Page 173: ...ve the valve full span Check if the cable between the inner canister and the pneumatic transducer assembly is tightly connected Check the connector and cable between the transducer board and the spool...

Page 174: ...g the actuator mid position Set point stability current generator grounding issues cable shield is grounded properly cables entry ground is properly connected to a clean ground reference Pressure supp...

Page 175: ...mbly integrity Try to repeat a full auto CAL Call Westlock for additional support Sensor err not possible set gain down The calibration of the position sensor could not find a proper gain to work with...

Page 176: ...for local or remote sensor connection for the ICoT 5400 See Figure 6 3 and find the connectors J3 and J4 for remote sensor connection for the ICoT 6400 The connector J2 is used for local sensor conne...

Page 177: ...cted to a clean ground reference Sources of electromagnetic noise too close to the sensor or to the positioner cables like AC cables for motors inverters etc Try to replace the Position Sensor and or...

Page 178: ...An unknown error has occurred during calibration Check Remove power for at least 1 minute and retry Remove power for at least 1 minute perform a factory default initialization see Section 9 2 2 4 and...

Page 179: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 179 of 189 12 Appendix C Wiring in classified areas ICoT 5400 Control Drawing FISCO Figure 12 1 Wiring Instructions IS installations FISCO...

Page 180: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 180 of 189 Control Drawing Entity advanced information Figure 12 2 Control Drawing FISCO...

Page 181: ...V_TYPE 0x0001 DEV_REV 0x09 COMPATIBILITY_REV 0x05 means device can be used to replace device revisions 0x05 0x09 Even if minimum impact on the network is achieved in all cases it still recommended to...

Page 182: ...emote potentiometer Please make sure that the correct model was ordered and suitable to be used with a 4 20mA position sensor or the remote potentiometer source In case of doubt please contact Westloc...

Page 183: ...900 Rev 5 1 8 IEC 61514 2 Performance of Iintelligent Valve Positioners 9 IEC 60068 2 Vibration and Environmental Testing 10 IEC 61158 2 Fieldbus standard for use in industrial control systems Part 2...

Page 184: ...2 2017 TECH 538 D W O 23160 Page 184 of 189 16 Appendix G General Arrangement Drawings ICoT 6400 Dimensional drawings Figure 16 1 Dimensional drawings Standard Manifold Figure 16 2 Dimensional drawing...

Page 185: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 185 of 189 Figure 16 3 Dimensional drawings High Flow Manifold Figure 16 4 Dimensional drawings High Flow Manifold top view...

Page 186: ...om 5 12 2017 TECH 538 D W O 23160 Page 186 of 189 Figure 16 5 Dimensional drawings Beacon ICoT 5400 Dimensional drawings Figure 16 1 Dimensional drawings Standard Manifold Figure 16 6 Dimensional draw...

Page 187: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 187 of 189 top view Figure 16 7 Dimensional drawings Standard Manifold Bottom view Figure 16 8 Dimensional drawings High Flow Manifold...

Page 188: ...www westlockcontrols com 5 12 2017 TECH 538 D W O 23160 Page 188 of 189 Figure 16 9 Dimensional drawings High Flow Manifold top view...

Page 189: ...ies or guarantees express or implied regarding the products or services described herein or their use or applicability Westlock reserve the right to modify or improve the designs or specifications of...

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