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INSTALLATION AND MAINTENANCE MANUALS

0 13/10/2011 First issued A.Bisi I. Griffanti S. Caldara

Rev. Date Description Issued by Checked by Approved by

Doc:OIMM-F1-FA-001.Rev0 For any clarification please contact [email protected] Page 1 of 29

I�STRUCTIO�S,

STORAGE

I�STALLATIO� &

MAI�TE�A�CE MA�UAL

TRU��IO� BALL VALVES

“TSW” – FULLY WELDED TYPE

“F1 & FA” Models (O-RING SEALS)

Doc. �° : OIMM-F1-FA-001_Rev.0




SUMMARY 1. SCOPE ......................................................................................................................................... 3

2. PRELIMINARY INFORMATION ............................................................................................. 3

2.1 - SAFETY WARNINGS ............................................................................................................ 3

2.2 - VALVE FUNCTION AND SERVICE ................................................................................... 4

3. HANDLING & STORAGE ......................................................................................................... 5

3.1 – EQUIPMENT WEIGHT ......................................................................................................... 5

3.2 – PACKING AND SHIPPING .................................................................................................. 5

3.3 – STORAGE .............................................................................................................................. 5

3.4 - INSPECTION AND HANDLING OF THE EQUIPMENT ................................................... 5

4. VALVE INSTALLATION .......................................................................................................... 6

4.1 – VALVE LIFTING................................................................................................................... 6

4.2 – LINE INSULATION .............................................................................................................. 7

4.3 – COUPLING TO PIPELINE .................................................................................................... 7

4.4 – TYPICAL INSTALLATIONS. .............................................................................................. 8

4.4.1 – ABOVE GROUND INSTALLATION. ........................................................................... 8

4.4.2 – UNDERGROUND INSTALLATION. ............................................................................ 9

5. START-UP................................................................................................................................. 10

5.1 - PIPE CLEANING (LINE FLUSHING) ................................................................................ 10

5.2 - HYDROSTATIC TESTING OF THE LINE ........................................................................ 11

6. OPERATION ............................................................................................................................. 12

6.1 - VALVE OPERATION .......................................................................................................... 12

6.2 - LEVER (WRENCH ) OPERATED BALL VALVES INSTRUCTIONS ............................ 12

6.3 - GEARBOX OPERATED BALL VALVES INSTRUCTIONS ........................................... 12

6.4 - ACTUATOR INSTRUCTIONS ............................................................................................ 12

7. REQUIRED TESTING FREQUENCIES .................................................................................. 13

7.1 - FST / Full Stroke Test............................................................................................................ 13

7.2 - PST / Partial Stroke Test........................................................................................................ 14

8. PERIODIC INSPECTION & MAINTENANCE ...................................................................... 14

8.1 - SAFETY NOTES .................................................................................................................. 14

8.2 - ENVIRONMENTAL SAFETY............................................................................................. 14

8.3 - MAINTENANCE INTERVAL ............................................................................................. 15

8.4 – GREASE INJECTION .......................................................................................................... 15

8.4.1 – STEM LEAKAGE ......................................................................................................... 15

8.4.2 – SEAT LEAKAGE .......................................................................................................... 15

8.4.3 – GREASING PROCEDURE ........................................................................................... 16

8.4.4 – PRODUCTS FOR GREASING AND FLUXING......................................................... 16

8.5 – VALVE REPAIR .................................................................................................................. 16

9. ASSEMBLY & DISASSEMBLY ............................................................................................. 17

10. RECOMMENDED FOR ASSEMBLY .................................................................................. 18

11. SPECIAL TOOLS................................................................................................................... 19

12. RECOMMENDED SPARE PARTS ...................................................................................... 19

13. BODY CAVITY - SAFETY INFORMATION ...................................................................... 19

14. TYPICAL DRAWINGS ......................................................................................................... 20

ANNEX A - HANDLING AND STOCKING PROCEDURE ........................................................ 26

ANNEX B - TROUBLESHOOTING (FAULT FINDING CORRECTION) ............................... 27

ANNEX C – BOLT TIGHTENING TORQUE ............................................................................... 28

ANNEX D – REFERENCE DRAWINGS – PART LIST ............................................................. 29




1. SCOPE

The purpose of this manual is to provide users with the necessary instructions for properly

installing, commissioning and servicing the valves. In the various operations above mentioned it is

very important to strictly follow the instructions below to ensure a proper operation of the valve and

avoid any risky situation in order to ensure to have an expected lifetime of 20 years.

It has to be noted that the products to which the following instructions apply are designed and built

pursuant to the following regulations:

• API6D – ISO 14313.

• PRESSURE EQUIPMENT DIRECTIVE 97/23/EC – only if required by Customer’s P.O.

This manual provides instructions to define operation modes that avoid any possible risk and inform

about possible residual risks.

IT IS IMPORTANT TO NOTE WHAT FOLLOWS:

• The product’s compliance with API 6D ISO 14313 regulation is certified by the API mark

on the valve’s nameplate.

• The product’s compliance with PED 97/23/EC regulation (if applicable) is certified by the

CE mark on the valve’s nameplate.

• The API and CE marks certify the product was designed and built in compliance with the

rules and the requirements of PED and API regulations and under the supervision of a

Chartered Surveillance Body.

WAR�I�G - In case of maintenance that requires stem disassembling, it is mandatory to contact

RMT-VM not to invalidate valve warranty, API certification and CE certification (if applicable).

2. PRELIMI�ARY I�FORMATIO�

2.1 - SAFETY WAR�I�GS

• Pressure containing systems are intrinsically dangerous.

• Valve must be used, inspected and maintained by skilled personnel only.

• Strictly adhere to company & local authority procedure/laws.

• Always wear the correct safety equipment and clothing.

• Always use original spare parts only.

• Valve body cavity is isolated from the line when the valve is in fully open or fully closed

position.




WAR�I�G: Body cavity could be pressurised without pressure in line.

Before starting any maintenance action , before disassembling the valve from the pipeline (not

applicable for valves welded to the line) the following steps shall be performed:

1- Check pressure and temperature : valve shall be @ ambient temperature , line pressure shall

be ambient pressure , valve body cavity shall be relieved (ref. to sect. 5 on how to operate

vent and drain).

2- Any liquid , gas or other dangerous component trapped into the valve shall be drained and

properly handled according to the plant safety procedures & local authority procedure/laws.

3- Drain , flush and dry the valve. For safety reasons no fluid shall remain into the valve.

2.2 - VALVE FU�CTIO� A�D SERVICE

Valves supplied are designed for:

1- Bi-directional on-off service only;

2- This valve must be kept always either in fully open or fully closed position ;

3- Do not use as flow regulator (throttling service) to avoid detrimental phenomena like

cavitation .

Pressure / temperature limits of the valve and materials of the main components are stamped on

manufacturer plate (fixed to the valve body). Said limits shall not be exceeded.

The compatibility of used materials with the fluid processed is verified by valve manufacturer

whenever the service is fully documented in user specification and/or data sheets.

The user will be otherwise responsible for checking the fluid/material compatibility.

The valve is not provided with safety accessories against overpressure except when the valve seats

are DPE ( double piston effect ) design. In that case a pressure relief valve is installed on the valve

body only to prevent the increase of pressure in the vale body cavity. Setting of this valve depends

on the process condition.

The user shall therefore protect the line where the valve is installed with suitable safety devices to

avoid that the specified operational pressure / temperature limits are exceeded.

Pipeline pressure shock (water hammer) shall be avoided to prevent any valve serious damage.

Final user shall install any device useful to prevent pipeline pressure shock.

Pipeline thermal shock shall be avoided to prevent any valve serious damage.

Final user shall install any device useful to prevent pipeline thermal shock.

The user shall install the valve in such a way that any external load condition not considered in this

manual do not impair the valve operation.

WAR�I�G – Final user is responsible to protect the pipeline from excessive pressure or

temperature. Final user shall install any device to prevent pressure or temperature shock.




WAR�I�G - �either axial nor bending loads from the piping are considered within the valve

calculation.

WAR�I�G - �o wind or seismic loads are considered within the valve calculation


WAR�I�G - The plate on the valve shows several descriptive data and the necessary information

about residual risks and maximum pressure and working condition /limit accepted.

Removing or tampering this plate may be highly dangerous for those in charge of operation or

maintenance.

3. HA�DLI�G & STORAGE

3.1 – EQUIPME�T WEIGHT

The weight of the valve is specified on the dimensional drawing supplied together with the valve to

the customer. If required, a certified statement of the weight may be supplied as well.

3.2 – PACKI�G A�D SHIPPI�G

Please refer to the excerpt from CP 12 procedure of RMT-VM, ANNEX A herein enclosed.

3.3 – STORAGE

Please refer to the excerpt from CP 12 procedure of RMT-VM, ANNEX A herein enclosed.

Standard cases can be stored outdoor taking the precaution to fix a cellophane sheet on the top.

For optimum protection and in case of long storage period (more than one month), we recommend

undercover storage.

Do not remove any protection from the equipment during storage period.

3.4 - I�SPECTIO� A�D HA�DLI�G OF THE EQUIPME�T

On shipping documents (packing list) identify the equipment contained, gross and net weight.

Check the cases have not been damaged during the transport. If a tag number, commodity code or

piping class are specified by the customer, identify the valves using reference number stamped on

the manufacturer plate.

Visually inspect all the valves to assure that they have not been damaged during the transport.

In case of paint damaging, touch-up the damaged painted surface.

Do not remove any protection from the valve (end flanges, stem connection, etc.).

Protections shall be removed just before the installation in order to assure maximum protection to

valve internal parts and coupling surfaces.

If the valve is supplied with an operator ( gearbox ) already installed always use valve lifting lugs to

lift the complete equipment; do not use operator lifting points to handle the valve.

The valves are shipped in the fully open position (with exception of a fail spring close actuator

installed).




Always keep the valves in fully open or fully closed position (0°÷90°).

During handling pay particular attention to the valve ends in order to avoid any mechanical damage

of sealing surfaces or butt weld faces (as applicable).

For valve handling always use straps sized to the weight that has to be lifted: do not use chains or

hooks in contact with the machined surfaces.

4. VALVE I�STALLATIO�

To install the valve in the line, follow specific procedures provided by the constructor or by the

engineering company.

Before installing the valve in the pipeline:

• please remove the protection from the valve ends just before the installation to avoid that

foreign matters can fall inside the valve bore ;

• it is recommended to check all the operator functions (lever , gearbox , actuator as

applicable).

In case the operator is directly supplied by the valve manufacturer a functional test of the manual

operator or actuator (as applicable) is already performed as standard procedure.

Before the installation of the valve into the line make sure that the valve bore is perfectly aligned

with the pipe-line axis.

During the pipeline construction or valve installation:

• the valve shall not support the line ;

• avoid inducing any strain in the valve body.

4.1 – VALVE LIFTI�G

To lift the valve, belts or chains suitable for valve assembly weight must be used.

If the valve is provided with lifting lugs / lifting eyes (typically for DN 6” and larger, refer to

specific project valve drawings), the above devices must be used, on the contrary (for smaller

valves) the belts can be secured to valve body.

WAR�I�G: Do not use operator lifting points to lift valve + actuator/operator assembly.

Lifting instructions are put outside valve package, please find below an example.




NOT ALLOWED

VALVE HANDLING

INSTRUCTION

VALID FOR SIZE AS FAR 6" REDUCE BORE

VALID FOR SIZE AS FAR 6" FULL BORE & LARGER

NOT ALLOWED

4.2 – LI�E I�SULATIO�

Some valves may be used with fluids at high temperature and in this case the outside surface of the

valve may reach a dangerous temperature for users and in general for people and animals. In order

to avoid any damage, those in charge of operation and/or maintenance of the valve shall mount

protective devices that prevent any contact.

For safety purposes, in case of valves used for fluids having a temperature equal to or higher than

200°C, the outside surface shall be properly insulated to avoid remarkable differences in

temperature between the inside and outside of the valve.

If insulation is not made, there could be differential deformations between the inside and outside

that could generate some serious malfunctioning of the valve.

It is recommended to those in charge of operation or maintenance to effectively insulate the outside

surface of the valves that men or animals may touch if the temperature of the surface reaches

unacceptable values. In general the accepted temperature range varies from –20°C to +60°C.

4.3 – COUPLI�G TO PIPELI�E

Depending on the foreseen solution for coupling the valve to the pipe for the RF, RTJ, BW, SW

valves, do as follows:




• RF type: the coupling to the line is to be made with flanges that comply with ASME B16.5

regulation with regard to the GAUGE and based on which the flanges are to be

positioned (see ASME B16/5 regulation). Between each flange of the valve and each

flange of the line, flat gaskets shall be placed and they shall comply with ASME

B16/5 rules (and the coupling shall be made with bolts and nuts that comply with

ASME B16/5 rules).

• RTJ type: the coupling may be made as above mentioned for the RF type but with RING

JOINTS that comply with ASME B 16.5 rules.

• ENBLOC type: the coupling to the line is to be made via two end points with NPT threaded

holes (upon request GAS threaded) whose size and types can be inferred from the

valve’s plate.

• ENBLOC type with end point to be welded: the coupling to the line is to be made via welding

of the pipe to the BW or SW end points of the valve. The valve’s plate features the

DN and the type of material of the end points to be welded



WAR�I�G – �either axial nor bending loads from the piping are considered within the valve

calculation.



4.4 – TYPICAL I�STALLATIO�S.

TSW fully welded ball valves can be installed in two typical configurations:

• Above ground piping

• Underground piping.

4.4.1 – ABOVE GROU�D I�STALLATIO�.

For above ground installation, the typical valve design is made by:

• A standard glandplate (without stem extension);

• The operator is assembled directly on valve operator flange;

• Emergency grease injections (if available) are assembled directly on valve body.

• For valves with BW ends, depending on piping material (yield strength and thickness), the

Customer can require a transition pup-piece welded to valve closures. (OPTIONAL).

• If required by the Customer, for large sizes drain and vent connections can be provided with

Floating Ball Valves lever operated (OPTIONAL).




The figures below show a typical “above ground” installation.

4.4.2 – U�DERGROU�D I�STALLATIO�.

For underground installation, the typical valve design is made by: (see also dwg F1-2 at section 14):

• A stem extension, length as per Customer’s request;

• The operator is assembled on the top of stem extension;

• Emergency grease injections (if available) and vent/drain connections are provided with

“extension pipes” to put injection / venting points at the top lever of stem extension.

• For valves with BW ends, depending on piping material (yield strength and thickness), the

Customer can require a transition pup-piece welded to valve closures. (OPTIONAL).

• If required by the Customer, for large sizes drain and vent connections can be provided with

Floating Ball Valves lever operated (OPTIONAL).

The figures below show a typical “underground” installation (with an example from one site).

Standard

Glandplate

Operator on

the Gland

Optional FSE

vent & drain Optional

Pup-Pieces

Operator on

the Extension

Stem

Extension

Extended

Connections

for

Vent, Drain

& Grease

Injectors




�OTE: when stem extension is particularly long (>2m) it is possible to pack the valve separated

from stem extension, in order to reduce the dimensions on the package.

In this case, RMT provides to the Customer a special “Stem Extension Assembly Procedure”, to

ease site operations and warrant the alignment of the various flanges and brackets.

For this special option, fitting extension pipes (for drain, vent and injectors) are provided with

flanges, so they also can be delivered separately from the valve.

See Figure 5 “Stem Extension” at section 14 of this manual.

5. START-UP

WAR�I�G Before starting any of the start-up or commissioning operations each valve must be

proof tested (Full Stroke Test - FST) according to section 7.

5.1 - PIPE CLEA�I�G (LI�E FLUSHI�G)

Soft seated valves are designed to handle only clean fluid (without presence of abrasive or hard

particles).

Before using the valve keep it in fully open position in order to reduce the possibility of

accumulation of dirty inside the body cavity.

Please note that pipe cleaning is recommended in any case (even for metal seated ball valves).

Before operating the valve clean the line from all foreign matters that can be entered during the

construction.

To clean the line strictly adhere to specific procedure supplied by the constructor or the engineering

company.

Once the line is properly cleaned valve body cavity shall then be flushed :

• valve shall be placed in the partial open position and the applicable procedure for the line

flushing shall then be applied.

As alternative the body cavity shall be flushed using the drain and/or vent connection :

• valve shall be left or placed in the full open position , drain and/or vent connection shall be

used.

Whichever will be the procedure applied , body cavity shall be drained from the fluid and shall then

be dried using clean air : drain and/or vent connection shall be used.

Every time the drain / vent connection needs to be used please take care of the following

information:

• drain and/or vent connections are supplied with the valve;

• feature (standard is NPT threaded) , dimensions and quantity depend on valve size according

to the applicable standards and codes;

• vent connection and related fitting shall be used to reduce the pressure inside the valve body

cavity;

• drain connection and related fitting shall be used to empty the fluid trapped into the body

cavity after the venting.




Standard fittings installed on our valves are plugs or bleeders.

Following instructions shall be applied for a proper and safer use of the said fittings.

BLEEDERS

Valve body cavity is reduced loosen the screw inside the vent bleeder (screw is “held” and

secured by a safety ring to avoid the blow out risk ).

Once the pressure is reduced fitting shall be removed from its threaded connection to the

main valve body.

PLUGS

Drain plug shall be removed only after bleeding operation is completed.

Valves supplied with vent and drain connection (typically DN 6” and larger) shall feature:

• bleeder installed in the vent connection ;

• plug installed n the drain connection.

Valves supplied with drain connection only (typically DN 4” and smaller) shall feature:

• bleeder installed in the drain connection ;

5.2 - HYDROSTATIC TESTI�G OF THE LI�E

If a line hydro-testing is performed during start-up, some precautions shall be kept to avoid any

damage of the valve internals.

Before the pressure is applied :

• always check the fittings for the proper wrench-tightness.

• Put the valve in “half stroke” (30°÷60° deg.) position.

Valve shall remain in “half stroke” condition just for the time of the hydro-test to avoid permanent

damages on the seat insert or seat contact surface.

The fluids used for hydro-testing and start-up operations shall be compatible with the metallic and

non-metallic components of the valve.




calculation.






6. OPERATIO�

6.1 - VALVE OPERATIO�

Trunnion ball valves shall be operated with:

• Lever;

• Gearbox;

• Actuator (electric , pneumatic , hydraulic….)

Valve closes by rotating the stem clock-wise and opens by rotating the stem anti-clockwise.

Rotation is 90°.

6.2 - LEVER (WRE�CH ) OPERATED BALL VALVES I�STRUCTIO�S

Valves supplied with lever operator shall be operated as follows:

• rotate lever anti-clockwise to open;

• rotate lever clockwise to close.

The valve is in open position when the lever is aligned with the flow direction.

6.3 - GEARBOX OPERATED BALL VALVES I�STRUCTIO�S

Valves supplied with gearboxes shall be operated as follows:

• rotate gearbox hand-wheel anti-clockwise to open;

• rotate gearbox hand-wheel clockwise to close.

Position & direction of operation are indicated on the gearbox with the means of a position

indicator.

6.4 - ACTUATOR I�STRUCTIO�S

For valves provided with actuator refer to the relevant actuator manual.




calculation.



WAR�I�G - Whichever will be the operator installed on the valve during the valve operation

Maximum Allowable Torque values shall not be exceeded.




7. REQUIRED TESTI�G FREQUE�CIES

The expected lifetime of the valves can be maintained and checked throughout a Proof Test (Full

stroke test-FST) in accordance with the procedure and frequency explained hereafter.

In order to increase the reliability of the valves RMT VM suggests also to use a Partial Stroke Test

(PST) with the procedure and frequency explained hereafter.

WAR�I�G - For valves with standard 20 years lifetime requirement, FST is mandatory (see par.

7.1 below).

7.1 - FST / Full Stroke Test

The Full stroke test is the same test performed in RMT-VM before the valve left the company and

it’s necessary to verify that no leakage arises and the valve can be easily and safely moved under

pressure.

Since the trunnion side entry ball valves could be installed in two different positions (fully open or

fully closed) before starting check the required position and then follow the steps below from 1 to 7

respectively.

In case of any problems during both the tests refer to the troubleshooting table –ANNEX B.

7.1.A - Valve installed in “fully open” position.

1. Move the valve in the fully closed position. During this cycle measure its closing time and

compare it with the performance spec. of the device or the valve datasheet

2. Pressurize one side of the valve with its max. shutoff pressure

3. Open the vent hole (if possible) and check for any seat leakage, if not please check for

pressure drop by a manometer on the pipe line. Check also the leakage towards external

environment through the joints.

4. Close the vent hole and move the valve to its initial open position. During this cycle measure

its opening time and compare it with the performance spec. of the device or the valve

datasheet

5. With the valve still pressurized, check for stem leakage (i.e. by removing the stem grease

injector – if possible) and for leakage through the body/closure joints and body/gland flange

joint

6. During this cycle verify that the movement is smooth.

7. Repeat the point 1 to 5 at least 3 times

7.1.B - Valve installed in “fully closed” position.

1. Pressurize one side of the valve with its max shutoff pressure

2. Open the vent hole (if possible) and check for any seat leakage, if not please check for

pressure drop by a manometer on the pipe line. Check also the leakage towards external

environment through the joints.

3. Close the vent hole and move the valve in fully opened position. During this cycle measure its

opening time and compare it with the performance spec. of the device or the valve datasheet




4. With the valve still pressurized, check for stem leakage (i.e. by removing the stem grease

injector – if possible) and for leakage through the body/closure joints and body/gland flange

joint.

5. Move the valve in the fully closed position. During this cycle measure its closing time and

compare it with the performance spec. of the device or the valve datasheet

6. During the cycle verify that the movement is smooth.

7. Repeat the point 1 to 5 at least 3 times.

7.2 - PST / Partial Stroke Test

The PST enables the customer to verify the status of the valve: with the valve in its starting position

(open or closed) turn the ball by 15° and then put it back in its initial position.

Check for external leak through the stem housing and through the body/closure joints and

body/gland flange joint .

Verify that the movement is correct and repeat the cycle at least 3 times

8. PERIODIC I�SPECTIO� & MAI�TE�A�CE

In standard condition the valve manufacturer do not require special maintenance.

RMT suggests only a periodic inspection of the valve, every 6 months about (External Visual

Check), with particular attention to the stem and stem gaskets.

8.1 - SAFETY �OTES

The staff in charge of maintenance operations shall be trained to operate on components used to

contain fluids under pressure. It is important that this staff is aware that before acting on the valve,

the piping shall be depressurised and the valve separated from the line under pressure and it must be

in the OPEN position to eliminate the residual pressure inside (the valve is open on the

depressurised and separated pipe).

WAR�I�G - Working on components while the pressure is on may cause serious damages or

injuries or the death of the user.

In case process fluid is an obnoxious liquid, before disassembling the valve it is necessary to

position the ball at 45° (50% open) and to accurately wash the valve inside and repeat the operation

at 135°(-50% open).

8.2 - E�VIRO�ME�TAL SAFETY

The pipe onto which the valve is installed may transport hazardous or lethal fluids for men and

animals or fluids that pollute the soil. In this case, before any intervention on the valve, agree on

the intervention modes with the person responsible for the safety of the system where the valve is

mounted.




8.3 - MAI�TE�A�CE I�TERVAL

Maintenance interval shall be scheduled taking into account the following activities:

Monitoring activity Every 6 month 5 Years

1 Body leakage N.A. N.A.

2 Seat leakage x

3 Stem leakage x

Maintenance activity

1 Actuator maintenance x

2 Trim verification N.A. N.A.

3 Replacement of stem gaskets x

4 Replacement of body-cover & stem gaskets x

5 Replacement of other soft seals N.A. N.A.

To ease maintenance, refer to the instructions for finding anomalies in ANNEX B herein enclosed.

8.4 – GREASE I�JECTIO�

RMT-VM valves do not require any lubrication but are equipped with a grease injector for

emergency interventions to eliminate or reduce leakage from the stem.

Upon request for big sizes (DN 6” and larger) some grease injectors may be positioned also in the

area of the seat seals units for emergency interventions to provisionally limit any leakage.

8.4.1 – STEM LEAKAGE

In case of stem leakage, this can be provisionally eliminated by injecting

sealing grease using stem injector (pos.59) mounted on the gland. It is

recommended to use sealing grease suitable to working fluid temperature. If

stem leakage cannot be eliminated entirely or in any case for greater safety,

stem graphite (pos.73) can be replaced without removing the valve from the

line (see disassembling section 9, below).

8.4.2 – SEAT LEAKAGE

In case of seat leakage, this can be provisionally eliminated by injecting

sealing grease using seat injectors (pos.60) if present on the valve. It is

recommended to use sealing grease suitable to working fluid temperature.




8.4.3 – GREASING PROCEDURE

Before injecting the grease it is always important to flux with a suitable fluid.

The injection pressure of the fluxing fluid and grease shall never exceed by more than 7kg/sq. cm

the pressure of the line where the valve is installed.

Do as follows:

- Inject washing fluid by opening and closing the valve 2 or 3 times.

- If the leakage does not stop, close the valve and inject sealing grease; see section 8.4.4

below for the types and quantities of grease.

- If the leakage continues, operate 2 or 3 times the valve, always in the OFF position, and

repeat the operation.

8.4.4 – PRODUCTS FOR GREASING AND FLUXING

The recommended products for fluxing and greasing are the following:

Sealing grease: RS Clare&CoL.td BTR555 or Total Lube 911

The grease shall have the following characteristics:

CAS classification: the product is a blend of different types of grease and therefore it cannot be

classified under CAS

Base product: Vegetable oil (CAS no. 68178-84-8)

Solubility in water: None or neglectable

Quantities to inject: around 13 grams/inch size/SEATseat&insert unit

around 10 grams/inch size/stem

For the first greasing operation on valves that have not undergone this treatment before, the above

quantities shall be tripled.

The recommended fluxing fluid is Apex Industrial Chemicals Ltd ECO-SOLV. Other types of

products may be used, only if they are suitable with the working fluid..

WAR�I�G – Grease injection activities may create dangerous situations for the staff. It is

therefore recommended to remove the protective cap of the grease by initially unscrewing it by

half a tour to make sure it does not show any remarkable leakage. In this case, interrupt the

operation and repair.

8.5 – VALVE REPAIR

These instructions refer to the glandplate flange / stem group only, because no other

components can be removed on TSW fully welded ball valves.

First of all isolate the part of pipe where it is mounted and depressurise the pipe upstream and

downstream.

Before any maintenance, it is recommended to check the spare parts available that are usually

necessary and are specified under section 12.




As underlined in section 1, in order not to invalidate valve warranty, the valve stem / gland may be

disassembled only by the producer (RMT-VM).

If the user intends to proceed autonomously to its repair, he may disassemble the various

components and reassemble them as per section 9 below.

For safety reasons, it is necessary the user performs the pressure tests foreseen by API 6D

regulation before reinstalling the valve.

After a positive test, the same user is required to certify the results clearly mentioning the type of

valve, the maker and the serial number on the valve’s plate.

To reassemble the valve glandplate, the coupling capscrews shall be secured with a dynamometric

spanner pursuant to the torque wrench settings specified in ANNEX C.

WAR�I�G - Reinstalling a valve in line without carrying out API6D tests may cause serious

accidents and/or cause events that may pollute the soil and the environment in general.

9. ASSEMBLY & DISASSEMBLY

SAFETY WAR�I�G

• Pressure containing systems are intrinsically dangerous.

• Valve must be used, inspected and maintained by skilled personnel only.

• Strictly adhere to company & local authority procedure/laws.

• Always wear the correct safety equipment and clothing.

• Always use original spare parts only.

• Valve body cavity is isolated from the line when the valve is in fully open or fully closed

position.

Before starting any maintenance action , before disassembling glandplate and stem please perform

the following steps:

1. Check pressure and temperature : valve shall be @ ambient temperature , line pressure shall

be ambient pressure , valve body cavity shall be relieved ( ref. to sect. 5 on how to operate

vent and drain ).

2. Any liquid , gas or other dangerous component trapped into the valve shall be drained and

properly handled according to the plant safety procedures & local authority procedure/laws.

3. Drain , flush and dry the valve. For safety reasons no fluid shall remain into the valve.





LEVER OPERATED FULLY WELDED BALL VALVES DISASSEMBLY

(REF. TO ATTACHED DWG “F1”)

1. CLOSE THE VALVE.

2. REMOVE THE STEM NUT (51A).

3. REMOVE THE MANUAL LEVER OPERATOR (96) AND THE SECOND STEM NUT (51A).

OPERATE UP TO THIS POI�T FOR LEVER MAI�TE�A�CE O�LY.

4. UNSCREW THE CAPSCREWS (52).

5. REMOVE ADAPTER FLANGE (12) , REMOVE STEM GASKET (73) & GLAND FLANGE (09),

REMOVE GLANDPLATE SEAL (35) & GASKET (74). STEM BEARING (16) & STEM SEALS

(34).

6. REMOVE THE STEM (05) FROM THE BALL (04).

OPERATE UP TO THIS POI�T FOR GLA�D FLA�GE / STEM MAI�TE�A�CE O�LY.

CHECK THE COMPO�E�TS I�TEGRITY (SEALS, O-RI�GS, STEM) A�D WHE� �ECESSARY

REPLACE THOSE DAMAGED.

GEAR OR ACTUATED FULLY WELDED BALL VALVES DISASSEMBLY

(REF. TO ATTACHED DWG “FA”)

1. CLOSE THE VALVE. ONLY FOR ACTUATED VALVES AFTER THE VALVE CLOSING

DISCONNECT THE ACTUATOR AND ACCESSORIES FEEDING SOURCE / CABLES /

TUBES ( refer to the actuator/accessories applicable maintenance manual ).

2. REMOVE SCREW OR NUTS CONNECTING THE ACTUATOR TO THE ADAPER PLATE (12)

3. REMOVE THE GEAR / ACTUATOR.

OPERATE UP TO THIS POI�T FOR GEAR / ACTUATOR MAI�TE�A�CE O�LY.

4. UNSCREW THE CAPSCREWS (52).

5. REMOVE ADAPTER FLANGE (12) , REMOVE STEM GASKET (73) & GLAND FLANGE (09),

REMOVE GLANDPLATE SEAL (35) & GASKET (74). STEM BEARING (16) & STEM SEALS

(34).

6. REMOVE THE STEM (05) FROM THE BALL (04).

OPERATE UP TO THIS POI�T FOR GLA�D FLA�GE / STEM MAI�TE�A�CE O�LY.

CHECK THE COMPO�E�TS I�TEGRITY (SEALS, O-RI�GS, STEM) A�D WHE� �ECESSARY

REPLACE THOSE DAMAGED.

10. RECOMME�DED FOR ASSEMBLY

For the assembly, repeat the sequence of section 9 in the opposite way and take care to clean and

lubricate all the parts with mineral oil or grease compatible with the pipeline fluid / gas .

Reccomended Lubricant: Grease MOLYGUARD MOLY TEF or Grease AUDCO 733X.




11. SPECIAL TOOLS

To install and remove RMT-VM valves no special tools are required.

For the installation, or during glandplate / stem assembly after disassembling, a dynamometric

spanner is necessary to secure the screw and/or nuts to the driving torques foreseen in ANNEX C.

12. RECOMME�DED SPARE PARTS

12.1) Starting-up and commissioning of the system

Before starting, make sure there is a complete set of spare parts each 5 valves (or fraction) per type

where the system is installed.

12.2) Spare parts for the operation

To meet the repair requests over a working period of two years, it is advisable to dispose of a set of

spare parts every 3 valves.

Component part list, spare part list and recommended sets are specified in ANNEX D.

13. BODY CAVITY - SAFETY I�FORMATIO�

If the temperature of the fluid contained in body cavity registers

strong increases or status changes, this would generate

uncontrollable pressure increases in the locked cavity that could

exceed the designed pressure of the valve. To prevent the above

condition, TSE standard valves are equipped, the with “Self-

relieving seats” (SPE) that discharge automatically the fluid when

the pressure in the cavity exceeds by 2 to 7 bars the pipe’ pressure.

The same safe condition is applicable to valves in “dual”

configuration (one SPE seat and one DPE seat).

For special valves provided with “double piston effect” seats

(DPE), in order to prevent body cavity overpressure, a safety relief

valve is installed in body cavity, set to discharge body pressure

depending on process conditions.

WAR�I�G: The site manager is responsible for the effectiveness of the safety systems to

guarantee the suitable level of pressure in the cavity of the valve’s body. Any fracture or

explosion in the valve’s body may cause damage to personnel, pollute the environment and cause

production losses




14. TYPICAL DRAWI�GS

TSE trunnion Side Entry Ball Valves with O-ring seals can be provided with the following design /

configuration:

TSE Model Temp. Range

Definition Seating Seals / Service Notes

F1 STD. TEMP. Soft Seated O-Ring seals / Standard

FA STD. TEMP. Metal to Metal Seated O-Ring seals / Abrasive

The above models can be characterized by different optional features (not reported in the drawings

here attached):

• Optional Seat grease injectors (only for F1 model);

• Optional additional seals (O-rings) for valve threaded fittings;

• Optional stem extension;

• Optional DPE seats or Dual configuration (SPE upstream +DPE downstream);

• Optional double back-up, on each side of valve O-rings;

• Optional secondary mechanical stop for stem anti-blowout (in this case valve stem must be

removed from body internal and not from valve glandplate).

• Optional mechanical stops for stem rotation (in addition to actuator mechanical stops).

• Optional Floating Ball Valves installed on vent and drain connections (instead of standard

plugs / fittings).

In the following pages typical drawings for the configurations listed in the above table are reported.

However, please refer also to specific drawings prepared by RMT for the project, delivered with

valves documentation.

NOTE: for specific projects TSW valves made in 2-pieces can be provided (one only closure). The

same instructions for 3-pieces valve body, reported in this manual, can be assumed.

For some projects the following additional design configurations can be provided:

TSE Model Temp. Range

Definition Seating Seals / Service Notes

F1-1 STD. TEMP. Soft Seated O-Ring seals / Standard Lower trunnion instead of bearing retainer plates.

F1-2 STD. TEMP. Soft Seated O-Ring seals / Standard Underground application (see section 4.4 above)

All / / / Figure 5: stem extension to be assembled on site.




5.1 – Valve assembly c/w with stem extension. 5.2 - Extension pipe with flanged joint.

5.3 – Upper detail: remote fitting connections.

Fig. 5: Example of valve with stem extension to be assembled on site.




ANNEX A - HANDLING AND STOCKING PROCEDURE

(EXCERPT from RMT-VM Internal procedure n° CP12 )

PURPOSE

This procedure shall apply to the assembled valves and defines handling and stocking modes.

1. PACKAGING AND SHIPPING

1.1 Preparations for shipment

Flanges and threaded ends shall be protected by wooden or plastic disks or plastic sleeves to avoid

any damage.

Before mounting the protective devices, ensure (see API 6D 12.1-12-2-12-3) that the valve is fully

open, the inner part is dry and the surfaces exposed to the atmospheric agents and not painted are

protected by anti-corrosion products.

4. HANDLING

4.1 This activity shall be performed by using tools and means in compliance with the safety rules.

The staff in charge shall be properly trained.

4.2 It is preferable if the valves and their components are handled with bands rather than chains. If

chains are used, they shall not get in contact with wrought surfaces. Always use handles or

hooks.

4.3 Avoid to rewind the chains on handwheels or to have them pass through the breakthrough of

the valve when lifting.

4.4 Valves and their components shall never be positioned on concrete floors but on wooden,

plywood or cardboard surfaces (pay attention to the surfaces of the flanges).

4.5 Flanges shall always be protected by wooden or plastic disks.

4.6 Metal parts shall never touch any other metal part.

4.7 Ensure the valves and their components are never dragged or pushed on concrete floors.

4.8 After the hydraulic test, make sure the valves are emptied from the testing liquid, dried and the

wrought surfaces are oiled.

4.9 In handling parts, components or finished valves, the staff in charge shall make sure documents

and cards that define and trace the product are not lost or removed.

5. STOCKING

5.5 O-rings and rubber gaskets shall be stored in an ad hoc area protected from light and contained

in dark envelopes featuring the check dates - depending on the life cycle of the product - the

product’s code and the progressive identification number for each envelope.

The quality control staff shall keep a book ordered by expiry dates and envelope numbers in

order to maintain the quality of this type of material.

5.7 Areas for stocking finished components or complete valves are protected against atmospheric

agents and kept at room temperature, clean and properly lit.




ANNEX B - TROUBLESHOOTING (FAULT FINDING CORRECTION)

WAR�I�G: For any problem, before dismantling or touching anything, please contact RMT-VM

sending e-mail to [email protected] with all the necessary details.

FAULT FINDING CAUSES CORRECTION Seat leakage When in suspect of seat

leakage:

• Stroke the valve to the fully closed position.

• Discharge the residual pressure left inside body cavity through the drain valve and the vent plug.

• Allow the system to stabilize for half an hour minimum.

• If the valve is tight no water should drip out the drain valve.

Seat insert damaged by fluid particles (sand, dirt etc.).

Small leaks can be stopped by injecting sealant into grease nipples (refer to section 8.4.2).

Body/glandplate ext. leakage

When any of the body flanged connections drips verify that the bolt tightening torque of the joint concerned is in accordance with ANNEX C.

External seal damaged or aged.

External leaks can be stopped replacing glandplate or stem gaskets. (Refer to section 9).

Opening or closing time not in accordance with site requirements. Operating torque too high (manual valves).

Make a full stroke test, operate the valve and measure opening/closing time.

Sand, debris or dirt contained into piping fluid could be trapped around the stem or around ball bushings areas

Inject lubricant grease through the Stem and seat grease fittings. If this operation does not bring any benefit dismantle the stem/gland flange group and verify no galling, scores or damages have occurred. (Refer to section 8.4.1 and 9).

Ball movement not correct (not continuous but in steps)

Make a full stroke test, operate the valve and check for ball rotation.

The valve has been left in the same position without any partial stroke test and ball and seat are stick together or the actuator has a problem.

Flush valve body to clean ball bushings areas. Inject lubricant grease through the seat/stem grease fitting in order to reduce friction coefficient.

The valve can not be operated

Make a full stroke test, or a partial stroke test (if available) and check for ball rotation.

The valve has been left in the same position without any partial stroke test and ball and seat are stick together. The actuator has a problem. Stem packing too tightened (if present). Stem failure.

Flush valve body to clean ball bushings areas. Reduce line pressure and, at the same time, inject lubricant through the seat/stem grease fittings and try to operate the valve. If no change happens disassemble the stem, check for valve components (stem / ball bushings) and replace damaged ones.




ANNEX C – BOLT TIGHTENING TORQUE (GLANDPLATE CAPSCREWS)

Bolt size A193 B7 A320 L7

A193 B7M A320 L7M A453 Gr.660 A193 B8M Cl.2

8.8 UNI 3740

A4 Gr.70

[mm] [Nm] [Nm] [Nm] [Nm] [Nm] [Nm]

M8 11 10 11 9 10 2

M10 22 20 23 17 20 4

M12 37 33 38 29 34 7

M14 58 52 60 52 53 11

M16 88 42 52 42 82 17

M20 170 82 100 88 161 33

M24 292 141 172 152 278 58

M27 424 204 249 401

M30 578 279 340 548

M36 1001 483 590 955




ANNEX D – REFERENCE DRAWINGS – PART LIST

Here attached an example of standard documentation provided by RMT with the valves.

REFERENCE DRAWINGS P.O. No. : xxxxx RMT-VM JOB No. : yyyyy

Job-ITEM GENERAL ARRANGEMENTS

DRAWINGS

CROSS SECTIONAL DRAWINGS

PARTS LISTS

xxxx-1 xxxx-1

RMT Valvomeccanica S.r.l. Via dei Patrioti - 21058 Solbiate Olona (VA) – Italy - Ph.. +39 (0) 331 375 441 - Fax +39 (0) 331 376 847

[email protected] - www.rmtvalvomeccanica.com page 1 of 16

STEM EXTENSION ASSEMBLING INSTRUCTIONS STROKE SETTING - PAINTED MARKS FOR OPEN AND CLOSE POSITION

STROKE SETTING - REMARKS AND NOTES FOR SPECIAL FEATURES VALVE TYPE : TRUNNION MOUNTED BALL VALVE SIDE ENTRY FULLY WELDED NPS : 42” CLASS : 900 ENDS : BW + BW PUPS

Document nr. 101354 – INST – 001

0 25/05/2011 First issue Griffanti Caldara

Rev. Date Description Issued by Approved by



STEM EXTENSION ASSEMBLING INSTRUCTIONS Following instructions shall be applied for installation of stem extension and extended pipes on RMT Trunnion Mounted Fully Welded Ball Valves 42” #900 BW with Pups. To reduce and to facilitate the on-site operations extension and stem extension are shipped as a pre-mounted set. Some of the following photos are picked up during the installation in RMT factory that’s why valves and components may be shown unpainted. Preliminary operations Remove the protections installed on the components and carefully clean the surfaces. Lubricate the valve stem , the keys and the stem extension housing to facilitate the assembling. Lubrication shall be carried out just before starting the assembling. Lifting of the extension and stem extension Install the supplied lifting lug on the “head” of the stem extension. Connect a proper lifting device and lift the assembly. For safety and to increase the stability fix a rope or similar in two opposite holes located on the upper ribs of the extension.

WARNING : Ribs are installed to reinforce the extension , it increase the safety in particular during handling and installation of the valve. Ribs are provided with holes to facilitate lifting , handling and assembling. Holes on the ribs shall only be used for lifting the extension and stem extension as supplied ( pre-mounted set ). Valve shall be lifted using the four lifting points provided on the body.



Valve lifting points before painting ( pink lugs )

Valve lifting points after painting



Extension and stem extension installation on the valve Check the correct position of the plate that will fix the extended pipes for emergency seat sealant injectors ( seat greaser ) , vent , drain , emergency stem sealant injector ( stem greaser ).

Place the extension and stem extension on the top of the valve stem. Install the four pins supplied for the assembling ( holes for pins are blind holes on the valve mating flange ).



Check the position of the two stem keys and the two slots on the stem extension housing , also check the correct alignment of the holes for studs and pins located on the valve mating flange and the respective holes located on the extension flange.

Rotate the extension and stem extension until the keys , slots and holes will be coincident.



Move down slowly the extension and the stem extension carefully checking the mating of the extension stem housing , and the valve stem.

Carry on until the pins mate with the holes on the extension lower flange.



Once the pin are engaged with extension flange move down slowly until the extension flange match with the valve mating flange

Install and tighten the supplied studs and nuts to finally fix the extension on the valve.



Extended pipes installation Identify the extended pipes for emergency seat sealant injectors ( seat greaser ) , vent , drain , emergency stem sealant injector ( stem greaser ). To facilitate the identification on each pipe is fixed a tag plate. The plate is printed as follows:

1. pipe “service” on the front side 2. PO nr. , tag nr. , valve serial nr. on the back side

For your convenience please check the following tag plate photos.

Tag plate front side Tag plate back side Vent and drain extended pipes are supplied in two different legs :

1. the first is connected to the valve body with a RTJ flange 2. the second is connected to the first with a RF flange.

Vent and drain extended pipe first leg is “double flanged” RTJ x RF. Stem and seat sealant injectors extended pipe are supplied in a single leg pipe ( 2 seat extension pipes , 1 stem extension pipe each valve ). Previously described tag plates are attached to every pipe leg.



For your convenience please check the following pipe sketches.



Installation of Vent & Drain extended pipes 1- Screw the studs on the body blind threaded holes 2- Install the RTJ gasket on its groove on the body ( vent ) or on the pipe extension (drain ) 3- Place the “first” leg on its final position mating the flange on the body connection 4- Screw and tighten nuts on the studs 5- Place the spiral wound gasket on the RF side of the first leg just installed 6- Place the second leg on the spiral wound gasket approaching the spacer plate welded on the

upperside of the extension 7- Install the studs and nuts 8- Tighten at the right torque value

Installation of Seat & Stem Sealant extended pipes

1- Place the spiral wound gasket on the RF connection 2- Place the flange of the extension pipe on the spiral wound gasket and on the spacer plate

welded on the upperside of the extension 3- Install the studs and nuts 4- Tighten at the right torque value

Installation of the rack plate To finally fix the extended pipes place the rack plate on the spacer plate on the upperside of the extension and fix it with the supplied screws.



STROKE SETTING PAINTED MARKS FOR OPEN AND CLOSE POSITION Marks showing the fully open and fully close position of the valve are located on the valve stem and on the valve mating flange (extension to valve side) , and also on the stem extension and on the extension mating flange (actuator to extension side). To verify the correct alignment of the ball marks are painted in RMT workshop according to the on-site assembler requirement.

Painted marks on the valve stem and on the valve mating flange

Painted marks on the extension upper flange and on the stem extension



STROKE SETTING REMARKS AND NOTES FOR SPECIAL FEATURES On the top of the extension a flange with machined mechanical stop is installed. This flange limits the stroke to 92° ( 90° standard stroke ; +1° for open position ; +1° for closed position ; total of 92°). This flange shall be used as a safety feature and gives a reference for “not to exceed” the open and closed position. Setting of the actuator stroke shall be carried out according to the actuator manufacturer instructions , taking care of not to engage the flange stops with the stem extension keys. Mechanical stop shall not bear the “full force” of the actuator , that’s why: actuator shall be operated preferably in manual mode; as alternative , in case of manual mode is not available , actuator shall be operated at the lowest pressure allowing the valve to move ( just enough to move SLOWLY ). Setting the stroke of the actuator shall be done only without pressure in the pipeline. Valve and extension pipes shall not be pressurized. Stroke the actuator before the installation on the extension check the position of the key slots on the actuator housing compare the position of the said slots with the keys on stem extension if the position is very different perform a preliminary stroke setting ( this reduce the risk of crashing the keys on the flange mechanical stops ) Repeat for the opposite stroke. Once the actuator is placed on the extension manually stroke it checking the painted marks. Stroke and set the actuator until the marks will be coincident. If the actuator stops to move do not “force” the stroke for any reason , lift the actuator and check the valve safety mechanical stop and stem extension keys are not engaged. In case of engaging Move/stroke the actuator on the opposite side check the status of the components set the actuator reducing the stroke along the first stroke direction For safety always check the keys versus mechanical stops position also in case of a “non-engaging” condition. Operate the acuator opening the valve , lift the actuator and check keys and mechanical stops. Repeat for the closing stroke.

Publication S175E V2.2 Issue 11/03

Modbus RTU Actuator Control MFU Option Card

Installation Manual

modbus

Modbus MFU Option Card Installation Manual

2 of 68 Publication S175E V2.2 Issue 11/03

Note 1:

Throughout this manual the Modbus Module Mk2 may simply be referred to as the module. Note 2: The information in this manual relates to the following firmware release EPROM version M201 Note 3: The Modbus Module MK2 described in this manual is suitable for inclusion in Rotork IQ, IQT, and Q range actuators.

As we are continually developing our products their design is subject to change without notice. © The contents of this document are copyright and must not be reproduced without the written permission of Rotork Controls Ltd. The name Rotork is a registered trademark Windows is a registered trademark by Microsoft Corporation

Contents


Contents

Glossary of Terms:..................................................................................................................5 Abbreviations: .........................................................................................................................5

1 INTRODUCTION............................................................................................................ 7 1.1 General ..........................................................................................................................8

2 MODBUS OPTION CARD PROPERTIES................................................................. 9 2.1 Mechanical properties ...................................................................................................9 2.2 Electrical Properties .................................................................................................... 10 2.3 Operation and Storage................................................................................................. 10

3 FITTING THE MODBUS MODULE OPTION CARD.............................................11 3.1 Inside an IQ or IQT actuator......................................................................................... 11 3.2 Inside a Q actuator....................................................................................................... 12 3.3 Replacing or Fitting a Modbus Module Option Card .................................................... 13

4 RS485 DATA HIGHWAY, CONNECTIONS AND MFU SETUP..........................15 4.1 Data Highway............................................................................................................... 15 4.2 Highway Topography................................................................................................... 16 4.2 Cable Types................................................................................................................. 17 4.4 Termination Network ................................................................................................... 17 4.5 Inter-connecting the Highway and Setting up the MFU................................................ 18

4.5.1 Single Highway with Analogue Input ........................................................................... 19 4.5.2 Dual Highway ........................................................................................................... 20 4.5.3 Single Highway with Internal Repeater ....................................................................... 21

5 THE ACTUATOR INPUT AND OUTPUT SIGNALS .............................................23 5.1 Control Outputs........................................................................................................... 23

5.1.1 Controls Priority ........................................................................................................ 26 5.1.2 Modbus Control using Individual Coil commands......................................................... 26 5.1.3 Modbus Control using the Actcon Register ................................................................. 27 5.1.4 Modbus Control using the Actuator Position DV register .............................................. 27 5.1.5 The IQ ‘S’ contacts (Modbus DO’s). ........................................................................... 27 5.1.6 IQ Modbus Network Control Disable feature ............................................................... 28

5.2 Actuator Digital Input Status Feedback ....................................................................... 28 5.2.1 Digital Inputs from All Actuator Types ......................................................................... 29 5.2.2 Digital Inputs from IQ and IQT Actuator ...................................................................... 31 5.2.3 Digital Inputs from IQT Actuator ................................................................................. 32

5.3 Actuator Analogue Input Feedback ............................................................................. 33 5.4 IQ Data Logger Information ......................................................................................... 33

6 MODBUS COMMUNICATION...................................................................................35 6.1 Electrical Specification ................................................................................................ 35



6.2 Outer Protocol ............................................................................................................. 35 6.3 Repeaters .................................................................................................................... 35 6.4 Dual Channel Mode...................................................................................................... 36

7 MODBUS DATA BASE..............................................................................................37 7.1 Modbus RTU Message Frame...................................................................................... 37 7.2 Modbus Address.......................................................................................................... 37 7.3 Function Code Support................................................................................................ 38 7.4 Broadcast Commands................................................................................................. 39 7.5 Data Location Offsets .................................................................................................. 40 7.5 Data Locations............................................................................................................. 40

7.5.1 Data Accessed with Function Code 01 - Read Coils .................................................... 40 7.5.2 Data Accessed with Function Code 02 - Read Discrete Inputs ..................................... 41 7.5.3 Data Accessed with Function Code 03 - Read Holding Registers ................................. 41 7.5.4 Data Accessed with Function Code 04 - Read Input Registers ..................................... 43 7.5.5 Data Accessed with Function Code 05 and 15 – Force Single and Multiple Coils........... 44 7.5.6 Data Accessed with Function Code 06 and 16 – Preset Single and Multiple Registers ... 45 7.5.7 Data Accessed with Function Code 07 – Read Exception Status .................................. 45 7.5.8 Data Accessed with Function Code 08 – Loopback Diagnostic Test ............................. 45 7.5.9 Data Accessed with Function Code 17 – Report Slave ID ............................................ 46

7.6 Data Base Summary: ................................................................................................... 46

8 CONFIGURATION REGISTERS ..............................................................................49 8.1 Actuator Related Configurable Parameter Registers................................................... 51

8.1.1 Action on Loss of Comms (Register 7)........................................................................ 51 8.1.2 Limited Range Position Minimum and Maximum (Registers 8 and 9)............................ 51 8.1.3 Deadband and Hysteresis (Registers 10 and 14)......................................................... 52 8.1.4 Motion Inhibit Timer (Register11) ............................................................................... 53 8.1.5 Auxiliary Input Mask (Register 12) .............................................................................. 53 8.1.6 Comms Lost Position (Register 13) ............................................................................ 54 8.1.7 Slow Mode Range (Register 15) ................................................................................ 54 8.1.8 Valve Jammed Time (Register 16) ............................................................................. 54 8.1.9 Manual Movement Travel (Register 17) ...................................................................... 54 8.1.10 Watchdog Timeout (Register 18)................................................................................ 55 8.1.11 ESD DI4/Net Disable (Register 19) ........................................................................ 55 8.1.12 Analogue Input Max (Register 20) .............................................................................. 55 8.1.13 Comms Fault Timer (Register 21) .............................................................................. 55

8.2 Modbus Network Related Configurable Parameter Registers...................................... 55 8.2.1 Modbus Address (Register 22)................................................................................... 55 8.2.2 Baud Rate (Register 23)............................................................................................ 56 8.2.3 Parity and Stop Bits (Register 24) .............................................................................. 56 8.2.4 Data Base Format (Register 25)................................................................................. 56 8.2.5 Actuator Tag Name (Register 26 to 31) ...................................................................... 56

9 SETTING UP AND MAINTAINING THE MODBUS MODULE ............................57 9.1 Using a Network Configuration Tool............................................................................ 57 9.2 Setting up an IQ or IQT with the Setting Tool............................................................... 57

Contents


9.3 Maintenance and Repair .............................................................................................. 59 9.4 Records ....................................................................................................................... 59

APPENDIX A – MODBUS MODULE MK1 DATA BASE...............................................61 A.1 Introduction..................................................................................................................... 61 A.2 Input and Output Signals............................................................................................. 61

A.2.1 Control Outputs......................................................................................................... 61 A.2.2 Digital Input Status Feedback .................................................................................... 62 A.2.3 Analogue Input Status Feedback ............................................................................... 62

A.2 Modbus Communication.............................................................................................. 63 A.3 Modbus Data Base ....................................................................................................... 63

A.3.1 Function Code Support .............................................................................................. 63 A.3.2 Broadcast Messages ................................................................................................. 63 A.3.3 Data Locations .......................................................................................................... 64

A.4 Configuration............................................................................................................... 67 A.5 Records ....................................................................................................................... 67

Glossary of Terms:

Address The unique address for a node on the fieldbus, range 0-247 Fieldbus The digital, two-way, multi-drop communication links. Field Unit The Modbus option card fitted to the actuator Interoperability The capability for a device from one manufacturer to interact with that

of another manufacturer, on a fieldbus network, without loss of functionality

Master/Slave The method of communication used by the Modbus Module. The fieldbus requires a Modbus master to control the data exchange on the highway.

Modbus The communication protocol used for data exchange. Modbus RTU The version of the protocol available from the Rotork module. Node A single device on the fieldbus RS485 The electrical properties of the data highway as defined by the IEC

standard, copper conductors, 2 wire twisted pair. Segment A section of an RS485 fieldbus that is terminated in its characteristic

impedance. Each Segment can include up to 32 devices. Abbreviations:

Comms Communications MFU Modbus Field Unit RAM Random Access Memory ROM Read Only Memory RTU Remote Terminal Unit SW Software



(This page is intentionally blank)

Introduction


1 INTRODUCTION

The Rotork Modbus Module Actuator Control option card (MFU) uses 2 wire RS485 and the Modbus RTU protocol to allow for information exchange and control over the data highway between the actuator and a suitable host system with a Modbus capability. The current version of the MFU assembly may be fitted into the IQ, IQT or Q range of electric actuators, including modulating versions. The module is an integral part of the actuator in which it is housed and is fitted within the main double sealed electrical housing. This electrical housing need never be opened once the actuator leaves the assembly plant. All adjustments to the settings for the module may be made via the Modbus data highway using a Modbus master. The IQ and IQT actuators also allow the primary settings to be adjusted via the infra-red programming link. (If the data highway speed was not specified at time of order, or it is changed, it may be necessary to change the links on a Single Highway plus Repeater option.) The Modbus module circuits do not impinge on the actuator control electronics; the actuator itself remains fully self-protecting. The module performs the tasks of network interface, actuator data collection and the issuing of actuator commands. The Modbus module may command the actuator into which it is fitted to open, stop, close, perform an ESD operation or move to a set position. Commands to the module come from the network and will have been generated in a master controller. The module operates in Master/Slave communication mode only using Modbus RTU protocol.

Terminal Cover

Local Controls

Handwheel

Electrical Compartment

Motor

Terminal Cover


Local Controls

Handwheel


Terminal Cover

IQ range

IQT range

Q range

Handwheel

Local Controls

Fig 1: The Modbus Module Mk2 Option Card Actuator Compatibility



1.1 General

The Modbus module has three variants:

q Single RS485 highway plus one analogue input channel q Dual Independent isolated RS485 highways q Single RS485 highway with inbuilt isolating repeater

Communication Media RS485 2 wire highway (single or dual), half duplex Protocol Modbus RTU Mode Master/Slave, module is a slave

Fig 2: The Types of Modbus Module Mk2 Option Card

RS485Highway

AnalogueInput

Single Highway + Analogue Input

Dual Highway

Single Highway + Repeater

RS485Highway 1

RS485Highway 2

RS485Highway 1

RS485Highway 1

MFU Properties


2 MODBUS OPTION CARD PROPERTIES

2.1 Mechanical properties

The MFU comprises two printed circuit boards connected together and the assembly is fitted inside the actuator electrical housing.

q Mezzanine Card - The small printed circuit board carries the RS485 highway

connections and protection circuits. There are two versions of the mezzanine, one for single highway and a second for two highway (or one highway with repeater) use.

q Main Card The larger motherboard is profiled to suit the actuator into which it fits.

The IQ actuator assembly is shown. It carries the processor, memory components and power supplies for the module.

The primary connection to the actuator circuits is by a multipin connector on the Main Card that, due to its physical shape, may only be fitted in the correct polarisation. Internal wiring harnesses connect to the Main Card for other signals and options within the actuator. The Mezzanine Card carries the RS485 connector and termination and biasing resistors, this couples to the wiring harness routed to the terminal compartment of the actuator. Power for the Mezzanine Card is taken from the Main Card and the whole assembly is powered from the actuator. All the connectors are polarised to prevent incorrect insertion.

Fig 3: The MFU dual highway module showing the mezzanine and main board (IQ actuator)

Mezzanine

Main card

Jumper links



2.2 Electrical Properties

The MFU connects directly to the main board of the actuator. The MFU does not sit in the main control path for the actuator and does not affect the actuator control integrity. An EPROM stored program controls the processor on the module, the software can be updated by replacing this chip. The Modbus RS485 fieldbus data highway connections are fully isolated from the actuator electronics. 2.3 Operation and Storage

The MFU is designed to be stored in the actuator and operated within the same environment as the actuator. The constraints are:

q Operating temperature: -40oC to +70oC q Storage temperature: -50oC to +85o C q Relative Humidity: 5% to 95% (<50oC) non-condensing

Fitting the MFU


3 FITTING THE MODBUS MODULE OPTION CARD

3.1 Inside an IQ or IQT actuator

The MFU is suitable for fitting into IQ Mk2 actuators with 3000 or 5000 series wiring diagrams and IQT with 6000 or 7000 series wiring diagrams. The connections and fitting in an IQT is similar to that for an IQ and the following information effectively relates to both actuator types. The MFU is normally located in the first option board slot inside the IQ/IQT electrical housing using connection SK1. In addition the MFU can be fitted inside IQ Mk1 actuators in certain cases.

The Interface card must be correctly profiled and loaded with the appropriate connectors to match the IQ/IQT actuator. The illustration (Fig 4) shows the IQ/IQT version of the MFU. With the IQ/IQT actuator the remote inputs are always present (they are conditioned by the MFU) and there is an option to include Digital Outputs from relay contacts. If the MFU is required to operate the 4 digital outputs that can be controlled from the card then the Extra Relay Indication card associated with these outputs must be fitted into the actuator. The following table describes the wiring harnesses and their function in the IQ and IQT actuator. MFU Socket Wiring Harness

SK2 24V power supply input from actuator SK3 Modbus RS485 Fieldbus connection SK5 Remote Digital Input connections SK7 Digital Output connections 1 SK8 Data Logger Information SK10 Analogue Input connection 2

Note: 1 – Requires Extra Relay Indication board to be fitted 2 – Only available on Single Channel module, 3000-400 or 6000-400

Fig 4: The MFU profiled for the IQ or IQT actuator

SK5 SK7 SK10

EPROM

SK

1

SK2

SK8

SK

3



3.2 Inside a Q actuator

The MFU is fitted in the option board position in this actuator. Only one option board may be fitted at any one time. The necessary internal components must also be present; in this case a potentiometer and auxiliary limit switches at end of travel must be fitted to the actuator. The illustration (Fig 4) shows the Q version of the circuit board.

Digital Outputs from relay contacts are not supported from the Q actuator, nor is the ability to report the status of the remote control inputs as Digital Inputs. The following table shows the wiring harnesses that must be fitted and the function of each loom for the Q range actuator. MFU Socket Wiring Harness

SK2 24V power supply input from actuator SK3 Modbus RS485 Fieldbus connection SK9 Limit switches SK10 Analogue Input connection 1 SK11 Potentiometer

Note: 1 - Only available on Single Channel module In a Q actuator there is a direct connection from PL2 on the Modbus Module to SK5 of the actuator main board.

Fig 5: The MFU module profiled for the Q actuator

SK10

EPROM

SK

1

SK9 SK11SK2

SK

3

Fitting the MFU


3.3 Replacing or Fitting a Modbus Module Option Card

The MFU should be replaced or fitted only in a suitable environment. The actuator must be made electrically safe before opening any covers and in the case of an IQ or IQT it is advisable to disconnect the internal battery. The electrical housing cover should be removed and the existing MFU carefully unplugged from its main connector. Once removed from the main connector the wiring loom connectors should be removed. The replacement board is fitted in the reverse order to removal. The wiring harnesses are polarised so that only the correct one will fit its mating part on the circuit board. If the operation is to fit an MFU for the first time then the necessary wiring looms must be added to the internal wiring harness of the actuator. The actuator wiring diagram shows the connectors and harnesses used. The wiring harnesses are fitted inside the actuator before attempting to fit the MFU. Once the looms are in place connect them to the MFU, then fit the MFU to the actuator main board connector. Once the module is fitted the actuator should be re-assembled and, in the case of the IQ or IQT, the battery replaced. The MFU must not be split between its Mezzanine card and the Interface card. Only complete assemblies should be fitted or exchanged.

RS485 Data Highway, Connections and MFU Setup


4 RS485 DATA HIGHWAY, CONNECTIONS AND MFU SETUP

4.1 Data Highway

The MFU uses RS485, 2 wire, half duplex, Modbus RTU communications at various data rates. The rules governing the installation and connection of an RS485 highway should be observed at all times to produce a successful installation. The RS485 highway does not allow power to be transferred and the MFU is powered from the actuator itself. The MFU can only report data when the actuator is powered up.

The data highway must be terminated with a proper termination resistor at the end. The highway itself can use tapped spur or stub connections to the actuators but it is recommended to keep any stub lengths to a minimum for successful operation. Alternatively the connection can be made in and out of each actuator in a daisy chain arrangement. The length of the highway and number of devices connected will vary from project to project. The standard permits up to 32 devices to be connected on a section, though one of these will be the PLC. If more devices are needed (up to the maximum addressable of 247) then RS485 repeaters may be added after each group of 32. The standard default address used by the Modbus Module is 247. The length of the highway will determine the maximum speed for the data transmission. The greater lengths are obtained at the lower transmission speeds. Although RS485 requires only 2 wires for data transmission the standard also requires that all the nodes on the network have a maximum common mode differential of +7 volts. This requires the ground potential at all points to be within the 7volt limit. If the equipment is distributed over a wide area, or an area with poor ground conductivity, it may be necessary to connect a third wire between all the nodes. Most successful installations use 3 wires and Rotork provides a ‘common’ terminal on the actuator. Since the data passes over a single 2 wire cable there are periods between messages when no devices are actively driving the lines. In order to ensure that data continues to flow correctly after these periods it is advisable to ensure the lines are biased to suitable voltage levels during the time the line is idle. The MFU contains internal biasing circuits that ensure suitable levels are maintained on the line even with no device transmitting.

Fig 6: Typical RS485t Data Highway

TerminatorT

2 wire highway Screened cable

PLC



Fig 7: RS485 Data Highway Topology

4.2 Highway Topography

Two different connection topologies can be used for RS485. The first system is to use a trunk line with various spurs or drop lines from it. This system will require the location of the taps in junction boxes near to the actuators. With the second the actuators can be directly connected to the trunk line in a daisy chain. All the configurations require the cumulative total of the drop lines and stub lines to be kept within the permitted maximum for the network speed to be used. It is good practice to avoid spurs wherever possible.

The maximum Trunk length and that for each spur and the cumulative total are dependent on the system speed in use. The table below suggests the maximum figures for cable type A, also defined below. The segment length is the total of the trunk and all the spurs added together.

Data Rate (Baud) Maximum Segment Length

Total Spur Length

300 24.0 km 2.0 km 600 12.0 km 1.0 km 1k2 12.0 km 1.0 km 2k4 6.0 km 500 metres 4k8 3.0 km 500 metres 9k6 1.5 km 500 metres 19k2 1.2 km 500 metres 38k4 1.0 km 300 metres 57k6 750 metres 200 metres 115k2 500 metres 100 metres

(Note that each actuator includes up to 0.6 metres of Drop length)

Actuator Type IQ IQT Q Internal Drop length (metres) 0.6 0.6 0.3

Within each actuator there is a short drop line or stub connection wire from the terminals to the MFU itself. This length must be included in any calculation for total and individual drop lengths.

PLC

T

TapTap Tap Tap Tap

PLC

T

Spur

Trunk Cable

Trunk Cable



4.2 Cable Types

The network must be connected using a suitable cable. Two conductors plus a shield and drain wire are required as a minimum, though Rotork recommends the use of a 3 wire cable to ensure the common mode voltage between all the actuators and the PLC is kept within the RS485 specified limits. Amongst the cable manufacturers Belden have the PVC jacketed 3105A single pair 2 core cable, which meets the minimum requirement. Belden 3106A has and extra core and therefore has sufficient conductors to include a common wire between all the nodes on the network and meets the Rotork recommendation. Information on Belden cable may be found on the Belden web site (www.belden.com) or at http://bwcecom.belden.com/, where a search on RS-485 will reveal technical papers and cable information.

Belden Part No. Total Number of Conductors

AWG (stranding) dia. Inches

Nom. DCR Insulation material Nominal

O.D.

Nom Impedance

(ohms)

Nominal Capacitan

ce

3105A

Paired - EIA Industrial RS-485 PLTC/CM

2 22 AWG (7 x 30)

48.2 ohm/km

Overall PVC jacket Datalene insulated

twis ted pair 7.26 mm 120 11.0 pF/ft

3106A

Composite - EIA Industrial RS-485

PLTC/CM

3 22 AWG (7 x 30)

48.2 ohm/km

Overall PVC jacket Datalene insulated

twisted pair 7.67 mm 120 11.0 pF/ft

The terminals to which the wires connect in the each actuator type will be different and the actuator wiring diagram must be consulted to establish the connections. 4.4 Termination Network

In order to operate correctly all RS485 highways must be terminated at each end of the main trunk line using a 120 ohm resistor. These will usually be near the scanner PLC and near the furthest actuator. The resistors are connected across the data line A and data line B. If the termination resistors are not fitted there is a possibility that the network communications will be unsatisfactory. In some cases network data line biasing may also be necessary, however to minimise this requirement the actuator transceiver chips include secure turn round components. There is a termination resistor inside each actuator, one side of the resistor is brought to a terminal whilst the other is already connected to data line A. Linking the Terminator terminal to data line B completes the connection to place the resistor across the data lines.

Fig 8: Typical RS485 cable

Data Pair

Screen

Belden 3105A Belden 3106A

Common

Data Pair

Screen



4.5 Inter-connecting the Highway and Setting up the MFU

The three MFU variations allow for various different highway connections. The single channel version can be used for simple highways, and where there is an analogue transmitter connected it will also return the value from the transmitter signal. The dual channel version is used for redundant highway applications where the highway integrity is important and the single highway with repeater can be used for either ring topology connections or applications where distances are extended. In some cases the single channel with repeater is applied in a ring connection so that the communications can travel either way around the ring. In this mode the number of devices that can be interconnected will depend on the speed of operation of the highway as each unit introduces a small propagation delay.

Fig 9: Termination for RS485 highway

Note: When using the single highway with internal repeater the termination should always be fitted on both sides of the repeater since there are no other devices on the highway section.

RS485Highway

AnalogueInput

120 ohm

Data 1BData 1ATerminator

Single Highway + Analogue Input

Dual Highway

Single Highway + Repeater

RS485Highway 1

RS485Highway 2

RS485Highway 1

RS485Highway 1

120 ohm


120 ohm


120 ohm


120 ohm




4.5.1 Single Highway with Analogue Input

With the single channel option the actuator is connected to only one highway and an additional input is provided for measuring and reporting an analogue variable. The connection of the actuator to the highway uses terminals 1A and 1B, the terminal numbers depend on the actuator type and are indicated on the actuator wiring diagram. The last actuator on the highway has the termination resistor connected by linking the highway 1B terminal to the Terminator terminal. Take care to ensure that the correct polarity is observed on the data highway connection, all the 1A terminals must be connected together on one data line and all the 1B terminals on the other.

q Data line 1A is positive with respect to data line 1B when the MFU is transmitting a ‘1’. If an analogue input is being used it is connected to the analogue input terminals. The MFU caters for both current and voltage analogue signals. There is no power supply on the card for the analogue transmitter and an external power supply must be used to power it.

q For voltage inputs connect I/P A to the positive signal and analogue Common to the negative signal from the transmitter

q For current inputs connect I/P A to I/P B (to insert the conditioning resistor). The current input positive is to I/P A and I/P B whilst the current input negative is connected to the analogue Common.

There are no links or settings required on the MFU card when this version is being used.

Fig 10: Single Highway + Analogue Connections

RS485Highway

AnalogueInput

1B1A

Terminator

Terminator

1A1B

cCommon

Common

c

c

PLC/ Host

Tx

Actuator

Actuator

4-20 mA

+

I/P AI/P B

CommonTx Power Supply -



4.5.2 Dual Highway

Fig 11: Dual Highway Connections

Fig 12: Jumper Settings for Dual Highway Option

LK6

LK5

SK5 SK7 SK10

EPROM

SK

1

SK2

SK8

SK

3

SK3

LK10987

4321

Terminator 1

1A1B

c

Common 1

Actuator

c

Terminator 2

2A2B

Common 2

RS485HighwayChannel 1c

PLC/ Host

Terminator 1

1A1B

cCommon 1

Actuator

c

Terminator 2

2A2B

Common 2

cChannel

2

Channel 1

RS485HighwayChannel 2



The actuator can be connected to two highways when redundant communication links are required. The connection of the actuator to the highways uses terminals 1A and 1B for highway 1 and 2A and 2B for highway 2, the terminal numbers depend on the actuator type and are indicated on the actuator wiring diagram. The last actuator on the highway has the termination resistors connected by linking Terminator terminal to the B terminal on the appropriate highway connection. Take care to ensure that the correct polarity is observed on the connection on each data highway, all the 1A terminals must be connected together on one data line and all the 1B terminals on the other for highway 1, all the 2A terminals are connected together on one data line and all the 2B terminals on the other for highway 2.

q Data line A is positive with respect to data line B when the MFU is transmitting a ‘1’. The dual channel MFU uses a single Modbus address common to both channels, so it is not possible to run the same highway to both channels on the card.

q One Modbus address for the card common for both channels

There are a number of jumper links on the mezzanine board, which must be in the correct position. These links determine the function of the card and when in the dual channel mode they must be positioned as shown in the diagram. 4.5.3 Single Highway with Internal Repeater

With this option a single highway passes through the Modbus Module and an internal repeater regenerates the data signals. The input to output connection is also isolated and this then allows the next section of cable to reach the maximum specified distance and the number of connected devices on the section to be 32. Termination resistors may be required at all connection points. In addition to allowing for signal regeneration with the internal repeater it is also possible to connect the last device on the network back to the PLC in a ring configuration. As each highway section is isolated from its neighbours the ring topology affords a degree of redundancy. The PLC channels must not be used simultaneously unless there is a section of the network that is broken.

q Data line 1A is positive with respect to data line 1B when the MFU is transmitting a ‘1’. There are a number of jumper links on the mezzanine board that must be in the correct position for the card to function as a single channel module. The repeater section is able to wait for the correct period after transmitting data before changing to receive mode, this is important to ensure good communications on the highway. The time for the delay is set by jumpers on the mezzanine and varies according to the data transmission speed chosen.

q The internal repeater supports data speeds from 2400 to 115200 baud

Jumper Settings: Speed (Baud) LK1 LK2 LK3 LK4 LK5 LK6 LK7 LK8 LK9 LK10 2400/4800 Left Left Left Left Top Top Left Left Left Left 9600/19200 Left Left Left Left Top Top Right Left Right Left 38400 - 115200 Left Left Left Left Top Top Right Right Right Right



Fig 14: Jumper Settings for Single Highway with Internal Repeater Option

Fig 13 Single Highway with Internal Repeater Connections

Terminator 1

1A1B

cCommon 1

Actuator

c

Terminator 2

2A2B

Common 2

Terminator 1

1A1B

c

Common 1

Actuator

c

Terminator 2

2A2B

Common 2

RS485Highwayc

PLC/ Host

cChannel

2

Channel 1

Optional Return RS485Highway

SK5 SK7 SK10

EPROM

SK

1

SK2

SK8

SK

3

SK3

LK6

LK5LK10

987

24004800

960019200

3840057600

115200

Speed(Baud)

4321

Input and Output Signals


5 THE ACTUATOR INPUT AND OUTPUT SIGNALS

The Modbus Module allows the actuator to be controlled by, and to report data to, a suitable host device using Modbus RTU protocol. This section explains the data signals that are available for exchange and their meaning in relation to the actuator functionality. The data locations used for the Modbus registers and coils is given later in this manual. This section also gives information on the other control inputs available for moving the actuator.

q Inputs are defined as signals originating at the actuator and fed back to the PLC over the

RS485 network.

q Outputs are defined as signals originating at the PLC and operating the actuator controls.

5.1 Control Outputs

The Modbus module can be used to control the actuator and position the valve. The valve may be moved fully closed, fully open or to an intermediate position. Additionally the actuator can make the valve adopt an Emergency Shut Down position. The actuator may also be operated from its local controls or by hard wired direct contact inputs (in the case of the IQ and IQT the Auxiliary Input Mask must be correctly set). As well as controlling the actuator the MFU can also be used to operate 4 discrete output relays when fitted to an IQ/IQT actuator with the relay card fitted. The control commands have three potential sources:

q Modbus RS485 network generated commands q Actuator Local Controls q Direct contact input controls

The full list of commands is shown in the table. The actuator types show whether the command is applicable to that actuator type.

RS485 data highway

Outputs - Commands

Inputs - Feedback

PLCActuator

Fig 15: Input and Output Data Direction



Command IQ actuator IQT actuator Q actuator

Modbus over the network Open ü ü ü Close ü ü ü Stop ü ü ü Emergency Shut Down ü ü ü Relay output DO-1* ü1 ü1 û Relay output DO-2* ü1 ü1 û Relay output DO-3* ü1 ü1 û Relay output DO-4* ü1 ü1 û Analogue Position demand ü ü ü

Local Controls Open ü ü ü Close ü ü ü Stop ü ü ü

Direct Hard Wired Inputs Open ü ü ü2 Close ü ü ü2 Stop/Maintain ü ü û2 Emergency Shut Down ü ü ü2 Open Interlock (active prevents opening) ü ü û Close Interlock (active prevents closing) ü ü û

Note: 1 – Requires Extra Relay Indication board to be fitted 2 – Push to Run action only. Maintained action not available if analogue positioning is

used The Modbus RS485 network commands will operate the actuator provided -

• Local/Local Stop/Remote selector is in ‘Remote’, • Modbus commands are not inhibited by the ‘Inhibit/DI4’ input parameter setting and DI4

condition • No interlock is active on IQ or IQT actuators. • There is no standing hard wired control input active • No alarm condition prevents it from moving

q Open A digital command to cause the actuator to open to the fully open

position as indicated by the Open limit switch. Under correct operation the actuator stops either when the open limit switch is reached, when the torque exceeds the value set and the open limit switch has been reached, or a new command is sent over the network.

q Close A digital command to cause the actuator to close to the fully closed

position as indicated by the Close limit switch. Under correct operation the actuator stops either when the close limit switch is reached, when



the torque exceeds the value set and the close limit switch has been reached, or a new command is sent over the network.

q Stop With no other command present this digital command causes an

actuator motor that is running to stop.

q Emergency Shut Down A digital command that causes the actuator to drive to its Emergency position. There are settings within the actuator to determine if this is a closed, open or stay put action.

q Relay Output DO1 to DO4 These 4 commands are used to energise and de-

energise the internal relays on the additional relay board in an IQ or IQT actuator. (These outputs are referred to as S5-S8 in the standard actuator documentation when there is no MFU in the actuator.) The resulting outputs can be used for operating other equipment such as a pump or indication light. The IQ/IQT actuator is not able to control these relays directly from the main board when the MFU is fitted. They will maintain their last state if power is removed from the actuator. On restoration of power the relays will be reset to their de-energised condition and the coils will report ‘0’.

q Analogue Position This function is only available over the Modbus RS485 network.

To initiate Analogue Position Control a value must be written the Position DV register (range 0-100.0%, resolution 0.1%), the valve will open to the appropriate amount and stop in that position (within the deadband setting). If a subsequent digital command to open or close the valve is issued, from any source, this will take priority over the analogue position command. Once the setpoint is reached the positioning controller is switched off. A new write to the Position DV register will initiate positioning mode once more. The register location is listed later in this manual. Provided limited range positioning is not invoked the values 0% and 100% written to this register produce a special case output where the command is revised so as to fully close the valve to its tight shut off position (0%) and fully open the valve (100%).

q Hard Wired Stop The hard wired stop input acts as a change of state input. If the actuator is moving, opening the Stop input will stop the actuator. If the Stop input is already open and a Modbus command is sent to the actuator, the command will be initiated. To stop the actuator the hard wired input must be closed and opened again.

Note: Many IQ multi-turn actuators are set to open until the open limit switch is reached and, close until the closing on torque switch trips, but it is dependant on the type of valve. The IQT and Q normally operate 90-degree valves, use stop bolts on the actuator or gearbox, and stop when these are reached. The control room indication is always taken from the end of travel limit switch settings



5.1.1 Controls Priority

Since there are three potential sources for control inputs the Modbus module assigns a priority for those occasions when two or more commands are applied simultaneously. In addition, for the IQ and IQT actuator, the remote control hard wired inputs can be used as discrete input signals, to report the status of other devices. The associated Auxiliary Input Mask parameter must be set for the IQ or IQT to select the required function. In the case of the hard wired input for ESD this can be configured either as an ESD/DI-4 signal or as a ‘Modbus Command Inhibit’ to prevent network control signals from moving the actuator.

High Priority çççççççççççççççççççççççççççç Low Priority

Local Stop� Local Close� Hard Wired Close Modbus Close� Local Open� Hard Wired Open Modbus Open� Hard Wired ESD� Hard Wired Stop4 Modbus Stop� Modbus ESD�� Modbus Position� � Mechanically interlocked to prevent both at the same time � The IQ/IQT can be set so that Local Stop has a higher priority than ESD � Only one Modbus command is possible at a time 4 If a Modbus command is applied whilst Hard Wired Stop is present, stop is cancelled

Fig 16: Controls Priorities 5.1.2 Modbus Control using Individual Coil commands

The open, close, stop, ESD and DO-1 to DO-4 controls can be written using function code 05 or 15 to write to single or multiple coils. Writing the value FF00 turns a coil on and 0000 turns it off. The MFU provides a degree of intelligence in operating the coils for the open, close, stop and ESD functions. When one coil is turned on, all the others are turned off, so only one can be on at a time. The actuator will obey the last command it receives, so if two writes using function code 05 follow each other closely the last one will win. A multiple coil write by function code 15 to turn on more than one of the open, close, stop and ESD coils in the same command is not permitted. If an attempt to energise more than one of these coils in one command is made an exception response is generated and the multiple write ignored. With the open and close coils these will turn off once the actuator completes the command, a new command is sent, the actuator is placed in local or some other interruption occurs. For example the close coil will de-energise once the actuator reaches the close position and stops. The stop and ESD coils remains latched once turned on and are cleared by another command or writing 0 to the coil. The ESD action works slightly differently in that even if the coil is reset to 0, the action remains latched in the actuator. This is because a network ESD command overrides the actuator local controls. In order to remove the ESD action it is necessary to write a new command and if the actuator has local selected then the only command that will clear the latch is a write to the stop coil. In the case of the DO-1 to DO-4 relays they will follow the command, energising when turned on and de-energising when turned off. These relays also maintain their status if the actuator power is removed and reset to the de-energised state only when the power is restored.



5.1.3 Modbus Control using the Actcon Register

A single register is provided to allow the digital control of the actuator. Writing a value to the register with function code 06 or 16 causes the actuator to open, close, stop or ESD and at the same time cancels any other command set. This method of control removes the need to reset commands written with a code 05 coil write with a second write to the same location. The number written changes any coil states already set to the new value.

Actcon Register (Register 5) Value Stop Close Open ESD

0 ü û û û 1 û ü û û 2 û û ü û 3 û û û ü

4 – 255 No action No action No action No action 5.1.4 Modbus Control using the Actuator Position DV register

The analogue position control function will take priority over an earlier coil or Actcon register command to open, stop, close or ESD the actuator when a value is written to the Actuator Position DV register. The controller will then position the actuator to the desired value. The analogue position control function is cancelled either by the actuator achieving the desired position or a coil or Actcon register write to one of the open, stop, close, ESD coils. Note that when limited range positioning is used and the actuator is in the fully closed or fully open positions, DV values of 0% and 100% (plus the deadband setting) are not acted upon since under or over range position values (those outside 0-100%) are not catered for. 5.1.5 The IQ ‘S’ contacts (Modbus DO’s).

The IQ/IQT actuator has four ‘S’ contact outputs that may be configured to report the status of the actuator with signals such as Open Limit, Closed Limit etc. These are identified as S1 to S4. In addition an optional additional relay board can be fitted with four more relays. The status of these relays is then adjusted by Modbus commands on outputs DO-1 to DO-4. Note that these relays are latching and, if energised, will not change state when the actuator power is removed.

Fig 17: IQ and IQT relay outputs DO-1 to DO-4

S1 - S4Actuator

Main Board

IQ or IQT with Additional Relay Output board fitted

DO-1to DO-4

Output BoardMFU



5.1.6 IQ Modbus Network Control Disable feature

It is possible to set the IQ or IQT ESD/DI-4 input so that the IQ/IQT actuator ignores open, stop, close, ESD and position control signals sent over the Modbus network. If the ESD DI-4 / Net Disable parameter is set to Active then when the ESD input is connection is made (i.e. 24 volts applied to ESD), Modbus control is not allowed. This feature is independent of the Auxiliary mask setting. When the ESD DI-4 / Net Disable parameter is set to active, no ESD will be available.

5.2 Actuator Digital Input Status Feedback

The Modbus module can report over the network a comprehensive data set relating to the status of the valve and actuator as indicated in the table below. The conventional contact indications are also available from the actuator limit switches and indication contacts.

Status Feedback IQ actuator IQTactuator Q actuator

Actuator Moving ü ü ü Close Limit ü ü ü Open Limit ü ü ü Running Closed ü ü ü Running Open ü ü ü Remote selected ü ü ü Local Stop selected ü ü ü Local selected ü ü ü Thermostat Tripped ü ü ü Monitor Relay ü ü ü Valve Obstructed ü ü ü Valve Jammed ü ü ü Valve Moving by Hand ü ü ü Moving Inhibited ü ü ü Position Control Enabled ü ü ü Watchdog Recovery ü ü ü Battery Low ü ü û Open Interlock input ü ü û Close Interlock input ü ü û DI –1 ü ü û DI –2 ü ü û DI –3 ü ü û DI –4 ü ü û Slow Mode � ü �

Note: 1 – This bit is reported when within the slow mode band, but does not affect the actuator.



5.2.1 Digital Inputs from All Actuator Types

q Actuator Moving Whenever the actuator position is changing due to the motor running or in the case of the IQ or IQT if the output drive is moving, this bit will be set true (1).

q Close Limit This data bit indicates that the actuator has reached the closed

position. The limit switch should be set slightly within the actual valve stroke to allow for torque seating or overshoot on closing without damaging the valve. The data bit will remain true (1) even if the position is passed through or exceeded.

q Open Limit This data bit indicates that the actuator has reached the open position. The limit switch should be set slightly within the actual valve stroke to allow for torque seating or overshoot on opening without damaging the valve. The data bit will remain true (1) even if the position is passed through or exceeded.

q Running Closed Whenever the actuator motor contactor used to drive the actuator in

the closing direction is energised this bit will be true (1).

q Running Open Whenever the actuator motor contactor used to drive the actuator in the opening direction is energised this bit will be true (1).

q Remote Selected This bit is true (1) when the actuator three position remote/local

stop/local selector is in the Remote position. The selector must be in this position for Modbus control to be permitted.

q Local Stop The actuator three position selector passes from Local to Remote or

Remote to Local through the Local Stop position. The switch can also be placed in Local Stop. When the switch is in the Local Stop position this bit will be true (1). Remote control of the actuator is not possible when the selector is in this position.

q Local Selected This bit is true (1) when the actuator three position remote/local

stop/local selector is in the Local position. Remote control of the actuator is not possible when the selector is in this position.

q Thermostat If the temperature of the motor windings rises above the thermostat

trip value, the thermostat contact will open and this signal will be present (1). There are no adjustments for the temperature at which the thermostat trip operates. The motor will be stopped if the thermostat trips. Only once the motor has cooled down and the thermostat has reset itself can a new Remote, Host or Local command to move the actuator be carried out. A setting on the actuator main board allows the ESD command to override the thermostat. The bit will remain set at logic 1 until the motor cools down and the thermostat resets itself.

q Monitor Relay This signal is true (1) when actuator remote control is not available.

The actuator Monitor Relay status is a composite signal for a number



of alarms. This signal will be set true if the actuator selector is in Local or Local Stop (not in Remote) or if the thermostat trips. The mains supply is also monitored and if one of the three phases is lost the monitor relay bit is set. If the actuator is operated from a single phase supply and this is lost then communications with the actuator will also be lost. Where a 3 phase supply is used, if the phase associated with the control circuits is lost then communications with the actuator will be lost.

q Valve Obstructed This bit will be true (1) if the actuator stops in mid travel, following a command, when not expected to do so. If the actuator torque exceeds the trip value set during commissioning then the motor will stop and motion will cease. The reason for the actuator stopping will be the high torque due to an obstruction and not a ‘Stop’ signal or reaching the desired setpoint position. The bit will remain true (1) until the actuator position changes by 2% or more.

q Valve Jammed This bit will be true (1) if the actuator is stationary at the end of travel

and fails to move away from the seat of the valve when a network command requests it to do so. The actuator will trip on excessive torque due to the valve being jammed in the seat. The MFU fails to see movement and reports this status after the time set in the associated parameter during the MFU set up. The bit will remain true (1) until the actuator position changes by 2% or more.

q Valve Moving by Hand The manual movement of the valve is reported as true (1)

if the actuator is moved by the handwheel away from the last position. The percentage of travel required to trip the indication is set in the associated parameter during MFU set up. The bit will remain true (1) until the actuator is moved electrically by either the local controls or a network command.

q Moving Inhibited This bit will be true (1) when the Motion Inhibit Timer is active or, in

the case of the IQ/IQT, the Interrupter Timer is active, or both are active.

Note: Attempting to restart the actuator to move towards the obstruction (even if the obstruction no longer exists) is not possible, the actuator will not restart. The actuator must be electrically reversed away from the obstruction before attempting to continue in the original direction.

Note: Attempting to restart the actuator to move out of the seated position is not possible. The actuator must be reversed before it will run in the same direction again. The jammed seat must first be released manually before electrical control is attempted. The problem may be overcome by adjusting the actuator torque setting which is designed to provide extra power on leaving the seated position.



The Motion Inhibit Timer is used in position control to prevent the actuator from exceeding its prescribed number of starts per hour, or to reduce the effects of hunting during closed loop control. The Interrupter Timer in the IQ/IQT can be used over part or the entire actuator stroke to slow down the effective speed of valve travel. When under network control, the control signal does not need to be re-applied when this bit is true, as the action will continue once the time has elapsed.

q Position Control Enabled This bit will be true (1) when a Position command is

being actioned. This data can be used to indicate that positioning mode has control of the actuator.

q Watchdog Recovery The MFU watchdog automatically resets the processor if

it is tripped. This bit will be true (1) following a watchdog trip for the time period set in the associated watchdog timeout parameter.

5.2.2 Digital Inputs from IQ and IQT Actuator

q Battery Low Applicable to IQ and IQT actuators only. The status of the internal battery is monitored and should it fall below a critical level this signal will become true (1). The battery is used to power the circuits used to keep track of the valve position when the actuator mains power is switched off. This battery is used only when the actuator has no power feed and the valve is actually moved.

q Open Interlock Applicable to IQ and IQT actuators only. The input contact to the

Open Interlock is monitored by the MFU. Whenever the input contact is closed this bit will be true (1). If the actuator is not using the interlock function then this input can be used as a digital status feedback for a plant signal not associated with the actuator. If the interlock circuit is being used then this bit will indicate the existence of an interlocking input that can prevent the actuator from opening.

q Close Interlock Applicable to IQ and IQT actuators only. The input contact to the

Close Interlock is monitored by the MFU. Whenever the input contact is closed this bit will be true (1). If the actuator is not using the interlock function then this input can be used as a digital status feedback for a plant signal not associated with the actuator. If the interlock circuit is being used then this bit will indicate the existence of an interlocking input that can prevent the actuator from closing.

q Digital Input DI-1 Applicable to IQ and IQT actuators only. This bit reports the status of

the contact connected to the actuator hard wired Open terminals. The input can be used to control the actuator or simply to report the status of a plant feedback signal. The function is set in the Auxiliary Input Mask parameter which determines whether the bit is reported as true (1) for a closed contact or an open contact and whether the input controls the actuator or not. Note that the input is always reported even when it is also controlling the actuator.




the contact connected to the actuator hard wired Close terminals. The input can be used to control the actuator or simply to report the status of a plant feedback signal. The function is set in the Auxiliary Input Mask parameter which determines whether the bit is reported as true (1) for a closed contact or an open contact and whether the input controls the actuator or not. Note that the input is always reported even when it is also controlling the actuator.


the contact connected to the actuator hard wired Stop/Maintain terminals. The input can be used to control the actuator or simply to report the status of a plant feedback signal. The function is set in the Auxiliary Input Mask parameter which determines whether the bit is reported as true (1) for a closed contact or an open contact and whether the input controls the actuator or not. Note that the input is always reported even when it is also controlling the actuator.


the contact connected to the actuator hard wired ESD terminals. The input can be used to control the actuator or simply to report the status of a plant feedback signal. The function is set in the Auxiliary Input Mask parameter which determines whether the bit is reported as true (1) for a closed contact or an open contact and whether the input controls the actuator or not. Note that the input is always reported even when it is also controlling the actuator. A configuration feature also allows DI-4 to be set to act as a ‘Disable Fieldbus Control’ input. In this mode when the input is made (irrespective of the Auxiliary Mask setting) the actuator cannot be controlled over the network. This can be useful during plant commissioning to prevent unwanted valve movement.

5.2.3 Digital Inputs from IQT Actuator

q Slow Mode Applicable to IQT actuators only. In positioning mode, when the IQT actuator approaches its setpoint the motor automatically switches to ‘slow mode’ and the actuator runs at a lower speed. This allows any developed inertia to be dissipated and a better positional accuracy to be achieved without overshoot. The deviation from the setpoint at which slow mode is adopted is set in the associated parameter. When slow mode is in use this bit will be true (1). The IQ and Q actuators also report this bit, but these actuators do not have a slow mode capability.



5.3 Actuator Analogue Input Feedback

The Modbus module makes available over the network a number of analogue variables. These contain information about the valve and actuator. If the single highway with analogue input variant of the Modbus module is used one associated plant measurement is also available.

Analogue Feedback IQ actuator IQT actuator Q actuator

Actuator Instantaneous Torque ü ü û Valve Position ü ü ü Analogue Input 1 ü ü ü

Note: 1 – Requires the Single Highway + Analogue Input Modbus Module

q Torque The currently developed torque value is reported as an Integer Value in the range 0 to 120 (0-78 hex) representing the percentage of actuator rated torque generated.

q Valve Position The current valve position is reported as an Integer Value in the range

0 to 1000 (0 – 3E8 hex) representing the percentage position to 0.1% resolution. The IQ and IQT actuator automatically scales the valve position value reported from the setting of the limit switches. The Q actuator requires the valve to be stroked fully between the open and close limit switches for the value to be automatically scaled. This scaling is retained in EEPROM when the actuator power is removed. If Limited Range Positioning is invoked by setting the appropriate parameters, then the reported valve position 0 to 100% follows the limited range of valve travel.

q Analogue Input The current value of the analogue input is reported as an Integer

Value in the range 0 to 1000 (0 – 3E8 hex) representing the percentage value to 0.1% resolution. The input may be 0 to 5V or 0 to 20mA d.c. from an externally powered field transmitter (the actuator does not provide the power for the transmitter). The input must be calibrated during the set up of the MFU using the Analogue Input Max parameter. Apply a 100% signal and write a value to the parameter, the current value will then be reported as 100%. The scaling is retained in EEPROM when the actuator power is removed.

5.4 IQ Data Logger Information

The Modbus module also makes available some of the IQ and IQT data logged information from registers in the data base. The data available is updated between 90 and 120 seconds after the actuator stops moving provided the actuator selector is in Remote.



q Close Torque Set The actuator setting for the maximum generated torque value permitted when the actuator is moving towards the closed position is recorded in this register.

q Open Torque Set The actuator setting for the maximum generated torque value

permitted when the actuator is moving towards the open position is recorded in this register.

q Torque at x% when opening There is a set of registers that each record the last value

for the torque generated when the actuator is moving from closed to open and reaches a particular position (x%). The registers contain 11 values of torque generated in 10% position increments between 0% and 100% of valve travel.

q Torque at x% when closing There is a set of registers that each record the last value for the torque generated when the actuator is moving from open to closed and reaches a particular position (x%). The registers contain 11 values of torque generated in 10% position increments between 100% and 0% of valve travel.

q Motor Starts – Closing Direction Two registers (one double register) contain the

total number of times the motor contactor to close the valve has been operated. The first register contains the low order 16 bits. The counter cannot be reset to zero.

q Motor Starts – Opening Direction Two registers (one double register) contain the

total number of times the motor contactor to open the valve has been operated. The first register contains the low order 16 bits. The counter cannot be reset to zero.

Modbus Communication


6 MODBUS COMMUNICATION

6.1 Electrical Specification

Line Electrical Specification: RS485, two wire, half duplex 6.2 Outer Protocol

Modbus Transmission Mode RTU (8 bit Binary data) Supported Baud Rates 300, 600, 1k2, 2k4, 4k8, 9k6, 19k2, 38k4, 57k6, 115k2

(2k4, 4k8, 9k6, 19k2, 38k4, 57k6, 115k2 when using the internal repeater option)

Number of bits per character Start bits 1 Data bits (LSB first) 8 Parity (configurable) Odd, Even, None Stop bits (configurable) 1 or 2 Error checking CRC Message turn round time/delay time Minimum period between request and response:

Data Speed (Baud) 300 600 1k2 2k4 4k8 9k6 19k2 38k4 57k6 115k2

Turn Round Time (mS) 188 100 60 40 28 24 20 20 20 20

Repeater Delay1 ( ìS) NA2 NA2 NA2 3.5 3.5 3.5 3.5 3.5 3.5 3.5

Note: 1 – In the Single Highway with Internal Repeater Modbus Module option there is a propagation delay in the repeater.

2 – NA = not applicable, the repeater function cannot be used below 2400 baud. Maximum period between request and response: 190 mS

6.3 Repeaters

A single segment supports up to 32 nodes, one of which is usually the PLC. The addition of repeaters allows the segment to be extended in length or increase the number of nodes connected or both. The maximum lengths at different speeds are discussed in section 4.2. The number of repeaters in a single highway should be kept to a minimum and the usual recommendation is no more that 9. If more repeaters are added this can seriously extend the delay between a message being sent and the response arriving at the PLC. The Single highway with Inbuilt Isolating Repeater version of the Modbus Module introduces propagation delays as mentioned above. Care must be taken in any system design to allow for these delays.



6.4 Dual Channel Mode

The dual channel version of the Modbus module has two ports and allows two data highways to be used for communication from the host system to the module. These highways operate independently with a limit of 32 devices per segment and the ports on the module communicate with their associated highway. There is some interaction between the ports since a single processor serves them and the following points must be noted.

q The module only has one setting for the unit’s address, communication speed and format. Both the comms ports share one set of common values for these parameters.

q When communication is active, every device on the highway reads all the data request or

command messages. Each unit then responds only those messages aimed at its address.

q Port 1 has priority over Port 2. Since every message is read the host system must allow

an idle time on Port 1 to allow Port 2 time to read its messages completely.

q A minimum time gap equivalent to 11 bytes of data should be left between data requests on both highways. This will ensure that the processor has sufficient time to respond to messages directed at Port 2. Without this idle period messages directed at Port 2 may not be acknowledged and a response may not be generated.

Modbus Data Base


7 MODBUS DATA BASE

The data in the Modbus Module may be collected using a number of different Modbus function codes. Similarly the commands to the MFU can be either register or discrete based. This inbuilt flexibility is designed to allow for any host device to be able to access the actuator over a Modbus network in the simplest way. This section provides information on the function codes supported and the data that may be collected or commands issued using those codes. In all cases registers and discrete locations are numbered from 0 and do not include any offsets. 7.1 Modbus RTU Message Frame

Message synchronisation is maintained by simulation, the receiving MFU monitors the elapsed time between receipt of characters. If 3 and one-half character times elapse without a new character or frame completion, then the next byte received will be the start of a new message and begin with the address.

Modbus Address

Function Code

Register or Discrete Address

Number of Registers or

Bits

Data Field

CRC Check

8 bits 8 bits 16 bits 16 bits N bits 16 bits

7.2 Modbus Address

The Modbus Module allows slave addresses in the range 0 to 247 to be used for devices; the addresses above 247 are reserved for special functions. Address 0 is recognised by all the slaves and is used for global Broadcast messages only. This leaves 247 addresses for use by the connected Modbus Modules on the data highway. Note that the dual highway unit uses a single address for both highway connections.

q Single RS485 highway plus one analogue input channel Address range supported = 0 to 247 (0 for broadcast) q Dual Independent Isolated RS485 highways Address range supported = 0 to 247 (0 for broadcast) Both channels must share the same address q Single RS485 highway with inbuilt isolating repeater Address range supported = 0 to 247 (0 for broadcast)

Fig 18: Modbus transaction format



7.3 Function Code Support

Details of the Request and Reply formats for messages can be found in the Modbus Reference Guide. PI-Mbus-300. The following table lists the function codes supported by the Modbus Module.

Function Code Modbus Name Addressing

01 Read Output Coil Status Discrete 02 Read Input Status Discrete 03 Read Holding Registers Register 04 Read Input Registers Register 05 Force Single Coil Discrete 06 Preset Single Register Register 07 Read Exception Status 08 Loopback Diagnostic Test 15 Force Multiple Coils Discrete 16 Preset Multiple Registers Register 17 Report Slave ID

Exception Response

Code Meaning

01 Illegal function code or incorrect message length 02 Illegal data address (Register or discrete address invalid) 03 Illegal data value 06 Busy

To read data the function code to use will depend on whether the data is to be read as single bits or as 16 bit registers. For example, code 01 reads data as discrete bits, whereas code 03 reads the data as registers. In many cases Discrete and Register access reads the SAME data.

q Code 01 - Read Coils This is used to read discrete (bit) data from the data base to obtain information about the status of the output coils (commands).

q Code 02 - Read Input Status Requests

This is used to read discrete (bit) data from the data base to obtain information about the actuator current status such as open or closed positions achieved.

q Code 03 - Read Holding Register Requests

All the data in the MFU can be read using function code 03. Discrete data is mapped into registers that are available for this command.

q Code 04 - Read Input Register Requests

Actuator position and torque registers, plus the status bits are accessible with function code 04.

Modbus Data Base


q Code 05 and 15 - Force Single Coil or Multiple Coils The output coils are the discrete outputs from the actuator or its digital control commands. Code 05 writes one coil per message whilst code 15 can write values to several at once.

q Code 06 and 16 - Preset Single Register or Multiple Registers

Registers are used for position control and also for digital control and can be accessed singly, or in multiples with these codes. Function code 06 writes a single 16 bit register whilst function code 16 can write several in one transaction.

q Code 07 – Read Exception Status

This is a specific short message function code which returns predetermined discrete data from the MFU. The message is used to allow fast transfer of a small data packet.

q Code 08 - Loopback Diagnostic Test

The purpose of the Loopback Test is to test the communication system between the Modbus module and the host. The MFU supports this test when used with diagnostic code 00, Return Query Data, and 02, Return Diagnostic Register. No other diagnostic test codes are supported.

q Function Code 17 – Report Slave ID

This function code generates a response that contains specific information about the MFU and actuator (providing the data has been entered on setup).

q Exception Response Codes

Error code 01 will be presented back to the host if the function code in the data message is not one of those supported by the Modbus Module or the message length is not as expected. Error code 02 will be presented back to the host if the Data Address is not valid for the Modbus Module. Error code 03 will be presented back to the host if the value to be written in a coil or register write is not valid for the register or coil location chosen in the MFU. Error code 6 will be generated back to the host if the MFU is unable to respond with a correct message because it is busy.

7.4 Broadcast Commands

Broadcast commands are only supported for specific registers, coils and commands.

q Stop and ESD Code 05 writes to coils 0 (Stop) and 3 (ESD) are supported for address 0 broadcast.



Code 06 writes to register 5 (Actuator Digital Control) with values 0 (Stop) and 3 (ESD) are supported for address 0 broadcast.

7.5 Data Location Offsets

The locations given in the data base are those, which should appear in the messages as they are transmitted on the Modbus link. Some host systems offset the addresses so far as the user is concerned. In such cases the address programmed into the host would be different to those listed. All data locations listed start from 0. Please check the host system documentation carefully to determine if any offsets are required. Typical Offsets are:

Function Code

Offset to be added to formulae result

1 1 2 10001 3 40001 4 30001 5 1 6 40001

7.5 Data Locations

The data locations in the following tables are all numbered from 0. For a definition of the actuator functions listed refer to section 5. Not all the listed signals are available from every actuator type. For the DO-1 to DO-4 options on IQ and IQT the relay output board must be fitted.

7.5.1 Data Accessed with Function Code 01 - Read Coils

Location (Bit)

R/W Data Range

0 R/W Stop command output coil status 0-1 1 R/W Close command output coil status 0-1 2 R/W Open command output coil status 0-1 3 R/W ESD command output coil status 0-1 4 R/W DO-1 output coil status 0-1 5 R/W DO-2 output coil status 0-1 6 R/W DO-3 output coil status 0-1 7 R/W DO-4 output coil status 0-1

Note: Coil ‘on’ when the state is true, reports as a ‘1’.

Note: All data locations listed start from 0, it may be necessary to add an offset to match the number required for the PLC.

Modbus Data Base


7.5.2 Data Accessed with Function Code 02 - Read Discrete Inputs

Location (Bit)

R/W Data Range

0 RO Actuator moving 0-1 1 RO Closed limit 0-1 2 RO Open limit 0-1 3 RO Running closed 0-1 4 RO Running open 0-1 5 RO Remote selected 0-1 6 RO Local Stop selected 0-1 7 RO Local selected 0-1 8 RO Thermostat tripped 0-1 9 RO Monitor relay 0-1

10 RO Valve obstructed 0-1 11 RO Valve jammed 0-1 12 RO Valve moving by hand 0-1 13 RO Moving inhibited 0-1 14 RO Position control enabled 0-1 15 RO Watchdog recovery 0-1

16 RO Battery low 0-1 17 RO Open interlock active 0-1 18 RO Close interlock active 0-1 19 RO DI-1 0-1 20 RO DI-2 0-1 21 RO DI-3 0-1 22 RO DI-4 0-1 23 RO Slow mode 0-1

Note: When the input is true the status reports as a ‘1’. 7.5.3 Data Accessed with Function Code 03 - Read Holding Registers

The accessible registers that can be read with this function code also include the Input registers.

Location (Reg/Bit) R/W Data Range

0 0 RO Actuator moving 0-1 0 1 RO Closed limit 0-1 0 2 RO Open limit 0-1 0 3 RO Running closed 0-1 0 4 RO Running open 0-1 0 5 RO Remote selected 0-1 0 6 RO Local Stop selected 0-1 0 7 RO Local selected 0-1 0 8 RO Thermostat tripped 0-1 0 9 RO Monitor relay 0-1




0 10 RO Valve obstructed 0-1 0 11 RO Valve jammed 0-1 0 12 RO Valve moving by hand 0-1 0 13 RO Moving inhibited 0-1 0 14 RO Position control enabled 0-1 0 15 RO Watchdog recovery 0-1 1 0 RO Battery low 0-1 1 1 RO Open interlock active 0-1 1 2 RO Close interlock active 0-1 1 3 RO DI-1 0-1 1 4 RO DI-2 0-1 1 5 RO DI-3 0-1 1 6 RO DI-4 0-1 1 7 RO Slow mode 0-1 1 8 RO Reserved 0 1 9 RO Reserved 0 1 10 RO Reserved 0 1 11 RO Reserved 0 1 12 RO Reserved 0 1 13 RO Reserved 0 1 14 RO Reserved 0 1 15 RO Reserved 0 2 - RO Actuator Instantaneous Torque 0-78 hex

(0 –120%) 3 - RO Valve Position 0-3E8 hex

(0.0 – 100.0%) 4 - RO Analogue Input 0-3E8 hex

(0.0 – 100.0%) 5 - R/W Actuator Digital Control 0-3

0 = stop, 1 = close 2 = open 3 = ESD

6 - R/W Actuator Position DV (desired value) 0-3E8 hex

(0.0 – 100.0%)

26-31

- R/W Actuator Tag name 12 bytes ASCII char

The following Data Logger information is also accessed by function code 03. Torque values are in the range 0 – 120%. The registers are updated with new data a short period after the actuator stops

Modbus Data Base


movi ng provided the actuator selector is in remote. The values may not contain the updated information for up to 2 minutes.


32 - RO Close Torque set 0-78 hex 33 - RO Open Torque set 0-78 hex 34 - RO Torque at 0% - open direction 0-78 hex 35 - RO Torque at 10% - open direction 0-78 hex 36 - RO Torque at 20% - open direction 0-78 hex 37 - RO Torque at 30% - open direction 0-78 hex 38 - RO Torque at 40% - open direction 0-78 hex 39 - RO Torque at 50% - open direction 0-78 hex 40 - RO Torque at 60% - open direction 0-78 hex 41 - RO Torque at 70% - open direction 0-78 hex 42 - RO Torque at 80% - open direction 0-78 hex 43 - RO Torque at 90% - open direction 0-78 hex 44 - RO Torque at 100% - open direction 0-78 hex 45 - RO Torque at 0% - close direction 0-78 hex 46 - RO Torque at 10% - close direction 0-78 hex 47 - RO Torque at 20% - close direction 0-78 hex 48 - RO Torque at 30% - close direction 0-78 hex 49 - RO Torque at 40% - close direction 0-78 hex 50 - RO Torque at 50% - close direction 0-78 hex 51 - RO Torque at 60% - close direction 0-78 hex 52 - RO Torque at 70% - close direction 0-78 hex 53 - RO Torque at 80% - close direction 0-78 hex 54 - RO Torque at 90% - close direction 0-78 hex 55 - RO Torque at 100% - close direction 0-78 hex 56 - RO Close Contactor counts low order 0-FFFF hex 57 - RO Close Contactor counts high order 0-FFFF hex 58 - RO Open Contactor counts low order 0-FFFF hex 59 - RO Open Contactor counts high order 0-FFFF hex

7.5.4 Data Accessed with Function Code 04 - Read Input Registers


0 0 RO Actuator moving 0-1 0 1 RO Closed limit 0-1 0 2 RO Open limit 0-1 0 3 RO Running closed 0-1 0 4 RO Running open 0-1 0 5 RO Remote selected 0-1 0 6 RO Local Stop selected 0-1 0 7 RO Local selected 0-1 0 8 RO Thermostat tripped 0-1 0 9 RO Monitor relay 0-1 0 10 RO Valve obstructed 0-1




0 11 RO Valve jammed 0-1 0 12 RO Valve moving by hand 0-1 0 13 RO Moving inhibited 0-1 0 14 RO Position control enabled 0-1 0 15 RO Watchdog recovery 0-1 1 0 RO Battery low 0-1 1 1 RO Open interlock active 0-1 1 2 RO Close interlock active 0-1 1 3 RO DI-1 0-1 1 4 RO DI-2 0-1 1 5 RO DI-3 0-1 1 6 RO DI-4 0-1 1 7 RO Slow mode 0-1 1 8 RO Reserved 0 1 9 RO Reserved 0 1 10 RO Reserved 0 1 11 RO Reserved 0 1 12 RO Reserved 0 1 13 RO Reserved 0 1 14 RO Reserved 0 1 15 RO Reserved 0 2 - RO Actuator Instantaneous Torque 0-78 hex

(0 – 120%) 3 - RO Valve Position 0-3E8 hex

(0.0 – 100.0%) 4 - RO Analogue Input 0-3E8 hex

(0.0 – 100.0%) 7.5.5 Data Accessed with Function Code 05 and 15 – Force Single and Multiple Coils

Location (Bit) R/W Data Range

0 R/W Stop command output coil status 0-FF00 hex 1 R/W Close command output coil status 0-FF00 hex 2 R/W Open command output coil status 0-FF00 hex 3 R/W ESD command output coil status 0-FF00 hex 4 R/W DO-1 output coil status 0-FF00 hex 5 R/W DO-2 output coil status 0-FF00 hex 6 R/W DO-3 output coil status 0-FF00 hex 7 R/W DO-4 output coil status 0-FF00 hex

Using code 05 write FF00 (hex) to turn on the command, DO-1 to DO-4 are turned off by writing ‘0’. The other coil commands are cleared by various means as explained in section 5.1.2.

Modbus Data Base


Using code 15 write 1 to turn on the command and 0 to turn off the command. The commands to open, close, stop or ESD the actuator are not cancelled by writing a ‘0’. The actuator latches the instruction and will complete the action unless a subsequent counter command is received before the action is completed. 7.5.6 Data Accessed with Function Code 06 and 16 – Preset Single and Multiple Registers


5 - R/W Actuator Digital Control 0-3 0 = stop, 1 = close 2 = open 3 = ESD

6 - R/W Actuator Position DV (desired value) 0-3E8 hex

(0.0 – 100.0%) The Actuator Digital Control register allows one of the four commands to be selected by writing the appropriate value. Provided limited range positioning is not invoked, the Actuator Position DV register assigns a special importance to the values 0% and 100% written to this register. The command is revised so as to fully close the valve to its tight shut off position (0%) and fully open the valve (100%). 7.5.7 Data Accessed with Function Code 07 – Read Exception Status

Code 07 reads a predefined data set with minimal overheads and is used for fast data transfer. A single byte is returned.


0 RO ESD coil status 0-1 1 RO Open coil status 0-1 2 RO Close coil status 0-1 3 RO Stop coil status 0-1 4 RO Closed position limit 0-1 5 RO Open position limit 0-1 6 RO Monitor relay 0-1 7 RO Reserved 0-1

7.5.8 Data Accessed with Function Code 08 – Loopback Diagnostic Test

The Loopback Test is used to test communications only. In a correctly working unit the return message is the same as the query sent. Two codes are supported.



Code Data

00 Return query data 02 Return diagnostic register

The Diagnostic Register contains the following data.


- 0 RO Memory Status Fault 0-1 - 1 RO Auxiliary control input active 0-1 - 2 RO Position controller enabled 0-1 - 3 RO Highway ESD active 0-1

7.5.9 Data Accessed with Function Code 17 – Report Slave ID

The Slave ID data response includes 20 registers, (40 bytes) of ASCII data to give the device name, software version and service tag number.

Byte Data 0 – 23 ‘ Rotork Modbus Module.’ (first two characters are nulls)

24 – 28 Software version: ‘Mxxx ‘ (where xxx is the revision number) 29 – 40 Tag Number (12 bytes)

7.6 Data Base Summary:

Accessed by MODBUS function code Data Location (Reg / Bit)

Type (register = 16bits)

01 02 03 04 05 06 15 16 Other

Stop 0 Digital Output 01 03 05 07 15 Close 1 Digital Output 01 03 05 07 15 Open 2 Digital Output 01 03 05 07 15 ESD 3 Digital Output 01 03 05 07 15 Output DO-11(relays 5) 4 Digital Output 01 03 05 15 Output DO-2 (relays 6) 5 Digital Output 01 03 05 15 Output DO-3 (relays 7) 6 Digital Output 01 03 05 15 Output DO-4 (relays 8) 7 Digital Output 01 03 05 15 Actuator moving 0 / 0 Digital Input 02 03 04 Close position limit 0 / 1 Digital Input 02 03 04 07 Open position limit 0 / 2 Digital Input 02 03 04 07 Valve running close 0 / 3 Digital Input 02 03 04 Valve running open 0 / 4 Digital Input 02 03 04 Selector in remote 0 / 5 Digital Input 02 03 04 Selector in local stop 0 / 6 Digital Input 02 03 04 Selector in local 0 / 7 Digital Input 02 03 04 Thermostat tripped 0 / 8 Digital Input 02 03 04 Monitor relay 0 / 9 Digital Input 02 03 04 07 Valve obstructed 0 / 10 Digital Input 02 03 04 Valve jammed 0 / 11 Digital Input 02 03 04 Manual movement 0 / 12 Digital Input 02 03 04 MIT/Interrupter timer 0 / 13 Digital Input 02 03 04 Position control enabled 0 / 14 Digital Input 02 03 04 Watchdog 0 / 15 Digital Input 02 03 04 Battery low 1 / 16 Digital Input 02 03 04

Modbus Data Base


Accessed by MODBUS function code Data Location (Reg / Bit)

Type (register = 16bits)

01 02 03 04 05 06 15 16 Other

Open I’lock input active 1 / 17 Digital Input 02 03 04 Close I’lock input active 1 / 18 Digital Input 02 03 04 Hard wired input DI-1 1 / 19 Digital Input 02 03 04 Hard wired input DI-2 1 / 20 Digital Input 02 03 04 Hard wired input DI-3 1 / 21 Digital Input 02 03 04 Hard wired input DI-4 1 / 22 Digital Input 02 03 04 Slow mode 1 / 23 Digital input 02 03 04 Instantaneous torque 2 / - Input reg 03 04 Valve position 3 / - Input reg 03 04 Analogue input 4 / - Input reg 03 04 Actuator digital control 5 / - Output reg 03 06 16 Position demand output 6 / - Output reg 03 06 16 Action on loss of signal 7 / - Parameter reg 03 06 16 Min position 8 / - Parameter reg 03 06 16 Max position 9 / - Parameter reg 03 06 16 Deadband 10 / - Parameter reg 03 06 16 MIT 11 / - Parameter reg 03 06 16 Aux mask 12 / - Parameter reg 03 06 16 Comms lost position 13 / - Parameter reg 03 06 16 Hysteresis 14 / - Parameter reg 03 06 16 Slow mode range 15 / - Parameter reg 03 06 16 Jammed time 16 / - Parameter reg 03 06 16 Manual movement travel 17 / - Parameter reg 03 06 16 Watchdog timeout 18 / - Parameter reg 03 06 16 ESD DI4/Net disable 19 / - Parameter reg 03 06 16 Analogue input max 20 / - Parameter reg 03 06 16 Comms fault timer 21 / - Parameter reg 03 06 16 Address 22 / - Parameter reg 03 06 16 Baud rate 23 / - Parameter reg 03 06 16 Parity, Stop bits 24 / - Parameter reg 03 06 16 Database format 25 / - Parameter reg 03 06 16 Actuator Tag number 26 – 31 / - Parameter reg 03 06 16 Data logger data 32 – 59 / - Parameter reg 03 Memory status OK/Fault - / 0 Diagnostics 08 (02) Aux control input active - / 1 Diagnostics 08 (02) Positioner enabled - / 2 Diagnostics 08 (02) Highway ESD active - / 3 Diagnostics 08 (02)

Configuration Registers


8 CONFIGURATION REGISTERS

In order to make the best use of the MFU, the module has a number of configurable parameter registers that may be adjusted to optimise the performance of the actuator. All the parameter registers have factory default setting designed to meet the most common requirements for the actuator. If these are not suitable for a particular application then by using a Modbus communication tool the values can be changed. The Modbus Module contains 20 configurable parameter registers; with the IQ and IQT actuator some of these can be altered by using the infra-red communications link and the setting tool. By using a Modbus communication tool connected to the RS485 highway all the registers may be reviewed and altered to suit the particular application for the actuator. Care must be exercised with access to these parameter registers as they can alter the complete performance of the actuator, including selecting a different operating data base. This section of the manual describes each variable parameter register and should be used for reference when using the configuration tools. All the registers can be read using function code 03 (Read Holding Registers). The contained values may be altered using function code 06 (Preset Single Register) or function code 16 (Preset Multiple Registers).

q Actuator Related Network Configurable Parameter Registers

Description Value/Range Default Value

Location (Register)

R/W Access

Action on Loss of Comms 0 = Nothing (No Action) 1 = Open 3 = Close 5 = Stop 7 = Position Any other value = Off

0 = Nothing (0000 hex)

7 03 06 16

Limited Range Position Minimum

0 – 100% 0000 – 0064 hex

0% 0000

8 03 06 16

Limited Range Position Maximum

0 – 100% 0000 – 0064 hex

100% 0064 hex

9 03 06 16

Deadband 1 0.0 – 25.5% 2 0000 – 00FF hex

5.0% 0032 hex

10 03 06 16

Motion Inhibit Time 0 – 255 sec 0000 –00FF hex

3 sec 0003 hex

11 03 06 16

Aux Input Mask 0 – 255 0000 – 00FF hex

15 000F hex

12 03 06 16

Comms Lost Position 0 – 100% 0000 – 0064 hex

0% 0000 hex

13 03 06 16

Hysteresis 1 0.0 – 25.5% 0000 – 00FF hex

2.0% 0014 hex

14 03 06 16

Slow Mode Range 0 – 100% 0000 – 0064 hex

5% 0005 hex

15 03 06 16




Location (Register) R/W Access

Valve Jammed Time 0 – 255 sec 0000 – 00FF hex

5 sec 0005 hex

16 03 06 16

Manual Movement Travel 0 – 100% 0000 – 0064 hex

10% 000A hex

17 03 06 16

Watchdog Timeout 0 – 255 sec 0000 – 00FF hex

10 sec 000A hex

18 03 06 16

ESD DI-4/Net Disable DI-4 is ESD = 0 DI-4 is Net Disable = 1

ESD 0000 hex

19 03 06 16

Analogue Input Max 0 – 1023 0000 – 3FF hex

0 0000 hex

20 03 06 16

Comms Fault Timer 0 – 255 sec 0000 – 00FF hex

10 sec 000A hex

21 03 06 16

Note: 1 - Setting the deadband lower than the hysteresis, or the hysteresis greater than the deadband causes the hysteresis to be set to 0.1%

2 - IQ Setting tool only allows 0.0 to 9.9% deadband to be set

q Modbus Network Related Network Configurable Parameter Registers


Location (Register) R/W Access

Modbus Address 1 – 247 0001 – 00F7 hex

247 00F7 hex

22 03 06 16

Baud Rate (baud) 0 = not used 1 = 300 6 = 9k6 2 = 600 7 = 19k2 3 = 1k2 8 = 38k4 4 = 2k4 9 = 57k6 5 = 4k8 A = 115k2 (values in hex)

9k6 (0006 hex)

23 03 06 16

Parity/Stop bits 0 = No parity, 1 stop bit 1 = No parity, 2 stop bits 2 = Even, 1 stop bit 3 = Even, 2 stop bits 4 = Odd, 1 stop bit 5 = Odd, 2 stop bits

None/1 (0000 hex)

24 03 06 16

Data Base Format Modbus Mk1/Mk2 0 = Mk1 1 = Mk2

Mk2 (0001)

25 03 06 16

Actuator Tag Name Any ASCII char (12 characters max)

(blank) all = 0000

26 to 31 03 06 16



8.1 Actuator Related Configurable Parameter Registers

These parameter registers set up the response of the actuator will take to various control and network actions. 8.1.1 Action on Loss of Comms (Register 7)

This register is used in conjunction with register 13 (Comms Lost Position) and 21 (Comms Fault Timer). The Action on Loss of Comms register defines the actuator action that will result after the time set for the Comms Fault Timer (register 21) if there is no network communication activity detected by the MFU. The action may be

q Nothing (0) No action, actuator will complete any command in process (the default setting)

q Open (1) The actuator will open the valve q Close (3) The actuator will close the valve q Stop (5) The actuator stops q Position (7) The actuator will adjust the valve position to the setting given in the

Comms Lost Position (register 13).

8.1.2 Limited Range Position Minimum and Maximum (Registers 8 and 9)

These parameter registers are used to define the positions in the range of valve travel that will be reported as 0 to 100% if it the whole travel from the closed position to the open position is not used. In addition the position demand setpoint output value will also be modified to follow this limited range. It is possible to make the position data reported and the position controller relate to a reduced span of actual valve travel. In this mode the position data relates to the reduced portion of the valve stroke. This is sometimes used where the valve is required to have a 0% position (or 100% position) that is not the same as the fully closed position (or fully open position). These parameters define the actual limited range of valve travel that will be used for the position reporting and control by the positioner.

Note that the digital open and close commands will still make the valve travel over its full stroke. The special case analogue commands of 0% and 100% that would otherwise cause the actuator to travel to the limit switch or torque off positions are inhibited if values other than 0 and 100 are set in these parameters. The values inserted relate to the maximum total valve travel between closed and open and represent the point in the full stroke which will now be used for the limited stroke 0 and 100 values.

0% ----------------- Reported Position --------------------- 100% Valve Stroke

CLOSED OPEN

é Position Minimum Setting

é Position Maximum Setting

Fig 19: Limited Range Position Control and Reporting



8.1.3 Deadband and Hysteresis (Registers 10 and 14)

When using position control by sending a value to the Actuator Position DV setpoint there are a number of parameter registers used to tune the position controller and reduce the possibility of damage to the actuator. These two registers are set to prevent hunting around the setpoint due to high inertia of the valve. They will require adjustment for each specific application. In addition the Motion Inhibit Timer is used to ensure the actuator does not carry out an excessive number of starts in a given period.

q Deadband The control used for the positioner is proportional only. The MFU will run the actuator to the desired position and then it stops. As the actuator and valve combination have some inertia there is a possibility that the desired position may be overrun and the positioner will then reverse the direction of travel to make the valve adopt the desired position. This overshoot and return may continue for a number of cycles and is known as hunting, the valve and actuator combination will hunt around the setpoint if the inertia is high. To prevent this from happening there is a Deadband setting whereby once the actuator enters the deadband the motor will be stopped. For example a 5% deadband will cause the motor to be stopped once the actual position is within 5% of the desired position. The inertia will then bring the actual position nearer the desired position.

The deadband is the allowable error around the setpoint.

q Hysteresis In addition to the deadband a second setting, hysteresis, further

refines the performance of the position controller. The positioner will run the actuator towards the setpoint DV until the actual position is within the deadband minus the hysteresis setting. This has the effect of instructing the actuator to stop when it is nearer the DV. The actuator will not restart unless it overshoots and runs outside the deadband or a new command places the new desired position outside the deadband.

The Hysteresis is the amount of movement inside the deadband

permitted before the motor stops.

0% Setpoint DV = 50% 100% Valve Stroke Position MV = 50%

47% 48% 49% 50% 51% 52% 53%

. nnnnoooooooooooooonnnn

Hysteresis Hysteresis Hysteresis = 1% Deadband Deadband Deadband = 3%

CLOSED OPEN

é Position Minimum Setting

é Position Maximum Setting

Fig 20: Deadband and Hysteresis settings



8.1.4 Motion Inhibit Timer (Register11)

The Motion Inhibit Timer setting is the period that must elapse between consecutive starts of the actuator motor when in positioning mode. The idle period will prevent the actuator motor from exceeding its rated number of starts per hour. In addition, when tuning the valve positioner the setting can be used to allow the plant dynamics to stabilise between valve movements. 8.1.5 Auxiliary Input Mask (Register 12)

This parameter register relates to the IQ and IQT actuators only and allows the auxiliary inputs (open, stop, close, ESD) to be set to control the actuator or simply report their status. In addition it allows the sense of the input (open or closed contact) that is reported as true (1) to be set. Actuator control always requires a true (1) input signal. The status of the inputs is always reported over the network and they can be used to report associated plant inputs instead of controlling the actuator. The register should be considered in its binary format using the low order byte. The number has the binary form x7x6x5x4, y3y2y1y0, requiring 8 bits. Each bit in the high order nibble, x7x6x5x4, either enables or disables the associated input for control of the actuator. The bits in the low order nibble, y3y2y1y0, determines if the input reports a closed contact as a '1' or an open contact as a '1'. Only when the input is a '1' as set by the mask and the contact state will the actuator respond to the input if it is also set to control the actuator. To allow an input to act as a control signal its associated bit in the high order nibble must be set to a '1' in the mask. To allow a closed contact to be reported as a '1' then its associated bit in the low order nibble must be set to '1' in the mask.

Bit Position Value Function 0 Disable ESD input as command 7 X7 1 Enable ESD input as command 0 Disable Stop/Maintain input as command 6 X6 1 Enable Stop/Maintain input as command 0 Disable Close input as command 5 X5 1 Enable Close input as command 0 Disable Open input as command 4 X4 1 Enable Open input as command 0 Report closed contact on ESD input as ‘0’ 3 Y3 1 Report closed contact on ESD input as ‘1’ 0 Report closed contact on Stop/Maintain input as ‘0’ 2 Y2 1 Report closed contact on Stop/Maintain input as ‘1’ 0 Report closed contact on Close input as’0’ 1 Y1 1 Report closed contact on Close input as ‘1’ 0 Report closed contact on Open input as ‘0’ 0 Y0 1 Report closed contact on Open input as ‘1’

The following examples show how the Auxiliary Input Mask settings can be applied.



Most Significant Bit Least Significant Bit Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 X7 X6 X5 X4 Y3 Y2 Y1 Y0 Enable

DI-4 ESD

Enable DI-3 Stop

Enable DI-2 Close

Enable DI-1 Open

Invert DI-4

Invert DI-3

Invert DI-2

Invert DI-1

Example 1 0 0 0 0 1 1 1 1 Example 2 1 1 1 1 1 1 1 1 Example 3 0 0 0 0 0 0 0 0

q Example 1 The default value of '15' (0000,1111 binary or 0F hex) makes all 4

inputs report closed contacts as true (1) and none of the inputs will operate the actuator.

q Example 2 The value 255 (1111,1111 binary or FF hex) makes all 4 inputs report closed contacts as true (1) and all the inputs control the actuator in their predefined way.

q Example 3 The value 0 (0000,0000 binary or 00 hex) makes all 4 inputs report open contacts as true (1) and none of the inputs will operate the actuator.

8.1.6 Comms Lost Position (Register 13)

The setting in this parameter register determines the position in the range 0 to 100% that the actuator will move to if the Modbus network communications stops being received, provided the Fault Mode (Register 1) is set to 'Position'. No action will be taken unless the communications stops for a period equal or greater than the setting in the Comms Fault Timer (Register 21). 8.1.7 Slow Mode Range (Register 15)

This parameter register is only applicable to IQT actuators. The Slow Mode Range sets the deviation between the setpoint and current position in positioning mode inside which the actuator motor will slow to minimum speed. If the setpoint (DV) is 50% and the setting for this parameter is 10%, then when the actuator moves within the range 40% to 60% the motor will adopt low speed. The actuator does not use slow mode for digital (Open/Close) commands. 8.1.8 Valve Jammed Time (Register 16)

Parameter register 16 sets the time delay that must elapse without any actuator movement before deciding the Valve Jammed status bit must be set. Valve Jammed is only announced if the actuator is asked to move and fails to respond when it should. The time must be long enough to ensure that the valve is not moving at all. 8.1.9 Manual Movement Travel (Register 17)

Manual Movement Travel sets the amount of valve travel not under motor action that is permitted before being considered 'Manual Movement'. The setting must be sufficiently large to cover over run of position control due to valve inertia. Too small a setting will result in Manual Movement alarms each time the valve is positioned, particularly if the deadband is small.



8.1.10 Watchdog Timeout (Register 18)

If the watchdog trips to reset the processor the Watchdog Recovery data bit is set. The data bit will automatically reset to '0' after the time period set in this parameter register. 8.1.11 ESD DI4/Net Disable (Register 19)

In the IQ/IQT actuator this input determines the mode of operation for the ESD/DI-4 remote input. The input can be used either to disable control of the actuator from the network, or to act as an ESD/digital input. When this setting is made 'Active' the input will disable network control of the IQ/IQT when the contact input is closed irrespective of the Aux Mask setting. 8.1.12 Analogue Input Max (Register 20)

The MFU includes an analogue input channel for a process input. This input will require calibration to ensure it is accurately reported. This parameter can only be set when the MFU is on line and the analogue input should be connected to a calibration source. When the register is set this causes the analogue input to be sampled and the value read to be used for the input to be reported as 100.0%. If the parameter register is simply read then the value displayed is the raw analogue input value. Apply a 100% input and write any number between 1 and 1023, but different from the currently register value, write the new value and read back from the MFU. The number in the register will change to the raw A/D value equivalent to the currently applied analogue signal and the reported value for the Analogue Input in register 4 will read 1000 decimal, 03C8 hex(100.0%). 8.1.13 Comms Fault Timer (Register 21)

Parameter register 21, the Comms Fault Timer setting, determines the number of seconds that network communication must be absent before the setting for the Fault Mode will be carried out. 8.2 Modbus Network Related Configurable Parameter Registers

These parameter registers set up the MFU for network communications. 8.2.1 Modbus Address (Register 22)

The Modbus Address is the address on the network that the Modbus module will respond to. The address can be in the range 1 to 247, though 247 is generally not used as this is the default address and may be used by any newly introduced device on the network. With a dual channel unit both channels user the same address. Changes to the register altering the address will become effective only after the actuator power is cycled.



8.2.2 Baud Rate (Register 23)

Register 23 sets the communication baud rate. Note that the new setting for this register will not become active until the actuator power is cycled. On a dual channel unit both channels operate at the same baud rate. 8.2.3 Parity and Stop Bits (Register 24)

The parity and number of stop bits used in the communications is selected by altering the content of this register. Note that the new settings for this register will not become active until the actuator power is cycled. On a dual channel unit both channels operate using the same parity and stop bit setting. 8.2.4 Data Base Format (Register 25)

The Modbus module can utilise different data base formats, the one to use is selected by the content of this register. Note that the new settings for this register will not become active until the actuator power is cycled. On a dual channel unit both channels operate using the same data base. The Mk2 data base is as detailed in section 7. Where the MFU is being used as a spare part to replace the earlier design it is possible to select Mk1 data base where data and performance are as the older unit. Appendix A gives the data base locations used by the Mk1 protocol. 8.2.5 Actuator Tag Name (Register 26 to 31)

The MFU may be programmed to contain a 12 character tag name string in these registers. Each byte contains one character.

Setting Up the MFU


9 SETTING UP AND MAINTAINING THE MODBUS MODULE

In most applications the majority of the default settings in the Modbus Module will be suitable for the operation of the valve and need not be altered. However, in every case it will be necessary to alter the address since the default should never be used within a live system (the default value is 247). 9.1 Using a Network Configuration Tool

Any device capable of writing register values can be used to configure the Modbus Module. Changes to the actuator related parameter registers become active immediately they are altered. Changes to the network related parameters usually require a power cycle of the actuator. The individual register values required may be different for each actuator and will depend on the application and process being controlled as well as the actuator size, speed and other design features. 9.2 Setting up an IQ or IQT with the Setting Tool

The IQ and IQT actuator includes an infra red communication port for setting the actuator performance, limit switches and so on. This communication link can be used to set some, but not all, of the MFU parameter registers. The registers should still be checked with a Modbus host device to ensure optimum actuator and network compatibility. The diagram illustrates the access route through the actuator menu screens to reach the settings that affect the MFU. Note that the [Od] function must be set to [OP], if it is not then the card will not be able to control the actuator. The parameters that may be set by using the Setting Tool and the infra red link are listed below. The available range for the deadband setting when using the setting tool is less than the range found using the configuration tools.

Register No. Description Range Default

Value 7 Action on Loss of Comms Nothing (No Action),

Stop, Close, Open, Position

Nothing

8 Limited Range Position Minimum 0 – 100% 0% 9 Limited Range Position Maximum 0 – 100% 100%

10 Deadband 0.0 – 9.9% 5.0% 11 Motion Inhibit Time 0 – 255 sec 3 sec 12 Aux Input Mask 0 – 255 (00 – FF hex) 15 (0F) 13 Comms Lost Position 0.0 – 100.0% 0.0% 22 Address 0 – 247 247 23 Baud Rate (baud) 300, 600, 1k2, 2k4,

4k8, 9k6, 19k2, 38k4 9k6

24 Parity (1 stop bit) Odd, Even, None None



Note: Baud rate settings: Parity settings: 01 = 110 (Mk1 protocol only) No = No parity 03 = 300 En = Even parity 06 = 600 Od = Odd parity 12 = 1200 Stop bits always = 1 24 = 2400 48 = 4800 96 = 9600 19 = 19200 38 = 38400

Position Display ò

Position Display + Torque ò

Password ò CR ð R1

ò R2 ò R3 ò R4 ò A1 ð A2 ð A3 ð A4 ð A5 ð A6 ð A7 ð A8 ð A9 ESD

action ESD

contact type

ESD t/stat

bypass

ESD override interlocks

ESD override local stop

Maintained local

control

2-wire control

External interlocks

Conditional control

ò OE ð OI ð OF ð Od ð OP ð OJ ð Or ð OS Extra

indication contacts

CPT Folomatic remote control

(must be ON)

Remote control source

(must be set to OP)

Bus system option

(must be ON)

Interrupter timer

Setting tool local control

Power loss

inhibit

ò PA ð PB ð PF ð PP Address

Range 01-FF

Baud rate See note

Aux I/P mask

Parity setting

See note

ò FI ð Fr ð FL ð FH ð Fd ð Ft ð FA ð FF Set point

signal type

Set point signal range

Low set point 0% position

limit

High set point 100%

pos limit

Position control

deadband

MIT Action on loss

of signal

Action on loss

of signal position

ò R5 Etc.

Fig 21: Setting tool menu structure and MFU settable parameters

Setting Up the MFU


9.3 Maintenance and Repair

There is no periodic service requirement for the MFU. Repairs should not be attempted on the module. The mezzanine and main board are a pair and should never be separated. Replacing the complete MFU assembly with a new replacement device should rectify any failure. Static sensitive devices are used in the MFU, it is therefore mandatory to observe anti-static precautions when handling or working on the unit. 9.4 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 Modbus module on a network. The data should be recorded for each module.

q Actuator Configurable Registers

Param

No. Description Setting Notes

7 Action on Loss of Comms 8 Limited Range Position Minimum 9 Limited Range Position Maximum 10 Deadband 11 Motion Inhibit Time 12 Aux Input Mask 13 Comms Lost Position 14 Hysteresis 15 Slow Mode Range 16 Valve Jammed Time 17 Manual Movement Travel 18 Watchdog Timeout 19 ESD DI-4/Net Disable 20 Analogue Input Max 21 Comms Fault Timer

q Network Configurable Registers

Param

No. Description Setting Notes

22 Address 23 Baud Rate (baud)

Note: Make a note of all changes to register settings to ensure that, in the case of a failure, the replacement device can be swiftly set to the correct values.



Param No. Description Setting Notes

24 Parity and Stop bits 25 Data Base Format

26-31 Actuator Tag Name

Appendix A - Mk1 Data Base


APPENDIX A – MODBUS MODULE MK1 DATA BASE

A.1 Introduction

The Modbus Module Mk2 has the ability to replicate the data base used in the Mk1 design. This permits the use of the Mk2 card as a spare part to replace Mk1 cards in most applications. For exact compatibility please check the original system configuration. When the module is used to replicate the Mk1 the main difference fro the Mk2 is in the data base for collecting data and issuing commands. The electrical and physical properties remain as the same. This section describes the Mk1 data base. A.2 Input and Output Signals

A.2.1 Control Outputs

Command IQ actuator IQT actuator

Modbus over the network Open ü ü Close ü ü Stop ü ü Emergency Shut Down ü ü Position Enable ü ü Relay output DO-11 ü1 ü1 Relay output DO-21 ü1 ü1 Relay output DO-31 ü1 ü1 Relay output DO-41 ü1 ü1 Analogue Position demand (DV) ü ü

Local Controls Open ü ü Close ü ü Stop ü ü

Direct Wired Inputs Open ü ü Close ü ü Stop/Maintain ü ü Emergency Shut Down ü ü Open Interlock (active prevents opening) ü ü Close Interlock (active prevents closing) ü ü

Note: 1 – Requires relay output board to be fitted



A.2.2 Digital Input Status Feedback

Status Feedback IQ IQT Definition

Actuator Moving ü ü Centre column moving for any reason Close Limit ü ü End of travel position, closed position achieved Open Limit ü ü End of travel position, open position achieved Thermostat Tripped ü ü Motor temperature thermostat operated Monitor Relay ü ü Local or Local stop selected or Phase loss or

thermostat tripped Local selected ü ü Selector in local control position Remote selected ü ü Selector in remote control position Battery Low ü ü Battery power low Running Closed Actuator close contactor energised Running Open ü ü Actuator open contactor energised Interrupter Timer ü ü Interrupter Timer operating MIT Active ü ü Motion Inhibit Timer active Open Interlock input ü ü Open Interlock present Close Interlock input ü ü Close Interlock present Position Control Enabled ü ü Actuator in positioning mode Error ü ü Device Fault, use Loopback Test to determine the

error. S1 ü ü Setting for S1 on the actuator S2 ü ü Setting for S2 on the actuator S3 ü ü Setting for S3 on the actuator S4 ü ü Setting for S4 on the actuator DI –3 ü ü Remote input for Stop condition DI –2 ü ü Remote input for Close condition DI –1 ü ü Remote input for Open condition DI –4 ü ü Remote input for ESD condition

A.2.3 Analogue Input Status Feedback

Analogue Feedback IQ IQT Definition Actuator Instantaneous Torque ü ü Current torque value,

Scale: 0-120% = 0-65536 Valve Position ü ü Current position,

Scale: 0-100% = 0-65536



A.2 Modbus Communication

The electrical properties of the MFU in Mk1 mode are the same as in Mk2 mode: Line Electrical Specification: RS485, two wire, half duplex (4 wire not supported)

Modbus Transmission Mode RTU (8 bit Binary data) Supported Baud Rates 300, 600, 1k2, 2k4, 4k8, 9k6, 19k2, 38k4, 57k6, 115k2

(2k4, 4k8, 9k6, 19k2, 38k4, 57k6, 115k2 when using the internal repeater option)

Number of bits per character 1 start bit, 8 data bits, Parity bit, 1 or 2 stop bits Parity (configurable) Odd, Even, None Variants Single highway plus analogue input Dual highway (one common address and baud rate) Single highway with repeater

A.3 Modbus Data Base

Message format: RTU Modbus Address: 1 to 247 (Dual channel version both channels must have

the same address.) A.3.1 Function Code Support

Function Code Modbus Name Addressing

01 Read Output Coil Status Discrete 02 Read Input Status Discrete 03 Read Holding Registers Register 04 Read Input Registers Register 05 Force Single Coil Discrete 06 Preset Single Register Register 07 Read Exception Status 08 Loopback Diagnostic Test 15 Force Multiple Coils Discrete 16 Preset Multiple Registers Register 17 Report Slave ID

A.3.2 Broadcast Messages

Broadcast messages using code 05 and 06 are allowed to the following functions Open command ESD command



A.3.3 Data Locations

Read Output Status – Function code 01 Write Output Coil – Function code 05 and 15

Location (Bit)

R/W Data Range

0 R/W Stop command output coil status 0-1 1 R/W Close command output coil status 0-1 2 R/W Open command output coil status 0-1 3 R/W ESD command output coil status 0-1 4 R/W DO-1 output coil status 0-1 5 R/W DO-2 output coil status 0-1 6 R/W DO-3 output coil status 0-1 7 R/W DO-4 output coil status 0-1

Read Input Status – Function code 02


0 RO Actuator moving 0-1 1 RO Closed limit 0-1 2 RO Open limit 0-1 3 RO Thermostat Tripped 0-1 4 RO Monitor Relay 0-1 5 RO Local selected 0-1 6 RO Remote selected 0-1 7 RO Battery Low 0-1 8 RO Running Closed 0-1 9 RO Running Open 0-1

10 RO Interrupter Timer 0-1 11 RO MIT Active 0-1 12 RO Open Interlock input 0-1 13 RO Close Interlock input 0-1 14 RO Position control enabled 0-1 15 RO Error 0-1

16 RO S1 0-1 17 RO S2 0-1 18 RO S3 0-1 19 RO S4 0-1 20 RO DI –3 0-1 21 RO DI –2 0-1 22 RO DI –1 0-1 23 RO DI –4 0-1

Note: All data locations listed start from 0, it may be necessary to add an offset to match the number required for the PLC.



Read Output Registers – Function code 03 Write Output Registers – Function code 06 and 16

Location (Register) R/W Data Range

0 R/W Actuator Digital Control 0-3 0 = stop, 1 = close 2 = open 3 = ESD

1 R/W Analogue Position Demand (DV) 0-FFFFhex

(0.0 – 100.0%) 2 R/W Deadband 0-4147 hex

(0 – 25.5%) 3 R/W Motion Inhibit Time 0-00FF hex

(0 – 255 sec) 4 R/W Minimum position 0-FFFF

(0 – 100%) 5 R/W Maximum position 0-FFFF

(0 – 100%) 6 R/W Data Base Format

(power must be cycled for change to take effect)

0-1 (0 = Mk1 data 1 = Mk2 data)

Read Input Registers – Function code 04

Location (Register) R/W Data Range

0 RO Actuator Instantaneous Torque 0-FFFF hex (0 – 120%)

1 RO Valve Position 0-FFFF hex

(0.0 – 100.0%) Read Exception Status – Function code 07 (one byte response)


7 (msb) RO S1 0-1 6 RO S2 0-1 5 RO S3 0-1 4 RO S4 0-1 3 RO DI-3 (Stop) 0-1 2 RO DI-2 (Close) 0-1 1 RO DI-1 (Open) 0-1

0 (lsb) RO DI-4 (Esd) 0-1



Loopback Test – Function code 08 Supported Diagnostic Codes

Diagnostic Code Function

00 Return query data 01 Restart communications 02 Return diagnostic register 04 Force slave listen only 10 Clear diagnostic counts 11 Return bus message count 17 Return slave busy count

Diagnostic Register contents

Location (Bit)

Description

0 EEPROM timeout error 1 Checksum error 2 Checksum error 3 Checksum error 4 Watchdog recovery 5 Reserved 6 Reserved 7 Reserved 8 Reserved 9 Reserved

10 Reserved 11 Reserved 12 RS485 highway ESD active 13 Auxiliary control input active 14 Positioner MIT active 15 Positioner enable flag

Bits 0 to 7 generate the “error” bit in the digital status register. Bit 0 indicates an EEPROM timeout has occurred. Bit 1 to 3 indicates that a checksum error has occurred Bit 4 indicates whether the module has been reset by the watchdog. Bit 12 indicates that an ESD has been received via the RS485 highway. Bit 13 shows that an auxiliary input, (enabled for control), is active. Bit 14 when set the MIT is active. Bit 15 when set the actuator is operating in positioning mode Report Slave ID – Function code 17

Byte Data 0 – 25 ‘00Rotork IQ Modbus Module.’

26 – 47 ‘Software version: Mxxx’ (where xxx is the revision number)



Exception Reporting – Supported codes

Exception Response

Code Meaning

01 Illegal function code or incorrect message length 02 Illegal data address (Register or discrete address invalid) 03 Illegal data value 06 Busy

A.4 Configuration

The module should be placed into Mk2 mode to set up all the configurable registers. Once these are set the mode can be returned to Mk1 for use on the Mk1 network. The complete list of configurable registers is given in section 8. Some registers may be altered using the IQ Setting Tool – Figure 19 shows the functions that are accessible in this way. A.5 Records

A complete set of records as indicated in section 9 should be retained for each installed actuator.



UK Head Office Rotork Controls Ltd Bath England BA1 3JQ Tel: +44 (0) 1225 733 200 Fax: +44 (0) 1225 333 467 e-mail: [email protected]

USA Head Office Rotork Controls Inc 675 Mile Crossing Blvd Rochester New York 14624 USA Tel: +1 716 328 1550 Fax: +1 716 328 5848 e-mail: [email protected]

htpp://www.rotork.com

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