i n s t r u c t i o n m a n u a l F a s Tr a k T M

Manual 4028 - Rev. 0 - 08/2008 www.stistrumentazione.com

i n s t r u c t i o n m a n u a l F a s Tr a k T M
1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5.0 5.1 5.2 5.3 5.4 6.0 Description Specifications Model selection Manufacturers identification General safety instruction Device Safety instrction Installation Maintenance Special instructions for FT positioners of explosion protection type Ex ia Electromagnetic interference Pneumatic safety Electrical safety Correct use Installation Pneumatic connections Power board connections Mechanical feedback linkage mounting Using Remote Control Software RemoteControl sw connection Starting software The main page Quick Buttons Tuning & standard System setup Main variables and status CFG Panel HART Panel The Graph window The Menu System Calibration : Self Tune Using Digital Interface Installation Connection Menu Setup Wizard Dimension Certification 3 4 5 6 7 8 8 8 8 9 9 10 10 11 11 12 19 20 20 20 21 21 22 23 24 27 28 29 30 34 34 35 36 37 38 39

Manual 4028 - Rev. 0 - 08/2008 -2-

i n s t r u c t i o n m a n u a l F a s Tr a k T M
1.0 Descrption
The FasTrak positioner is a high-capacity, high-precision digital-pneumatic valve controller that replaces a conventional positioner. The FasTrak has several advanced control and diagnostic features:

Excellent dynamic performance High precision and high flow Configuration and calibration through HART, serial or handheld device Self calibration Compatible with double and single acting actuators, with/without spring, piston or diaphragm Auto tuning on control stroking time applications from 0.5 sec to 50 sec Control and PID parameter independently adjustable for open and close Stroking time user independently adjustable for open and to close Travel limit position independently user adjustable for open and to close up to 50% of stroke Tight shut off position to open and to close independently adjustable up to 50% of stroke Pressure shut off to open and to close independently adjustable Split range user adjustable capability Travel characterization linear, eq% 25:1, 30:1, 50 :1, 1:50, 1:30, 1:25, user adjustable 16 point Visualization of selected characterization curve with limit and shut off by Remote Control Analog output 4-20mA Two digital inputs user configurable to fully open or fully close the actuator Two digital outputs user configurable as virtual limit switch or to indicate position error or low pressure Power/signal fail position mechanically configured (not software adjustable)
Manual 4028 - Rev. 0 - 08/2008 -3-

i n s t r u c t i o n m a n u a l F a s Tr a k T M
1.1 Specifications
Connection POWER: 2 wire from signal (min 3.5 mA, 12-30 Vdc) ELECTRICAL CONNECTION: Signal 1/2 NPT (or metric M20x1.5 on request) Auxiliary input/output 1/2 NPT (or metric M20x1.5 on request) PNEUMATIC CONNECTION: 1/2 NPT female COMUNICATION PROTOCOL: Hart, TTL RS232 Input TM ANALOG: 420 mA Hart protocol configurable split range ON OFF: 2x configurable digital inputs (optocoupler 24 Vdc) Output ANALOG: 420 mA passive loop ON OFF: 2x configurable digital outputs (optocoupler 24 Vdc) Stroke Movement FEEDBACK ANGLE OF ROTATION: 30120 (<30 with lower resolution) ADJUSTABLE SPEED: range 0300 seconds, individually configurable for each direction CHARACTERISTIC CURVE: Linear Equal percentage User defined CONTROL PARAMETER: individually configurable for each direction TRAVEL CONTROL: Min. and Max limits, settable stroke limits, adjustable pressure on seat Air supply INSTRUMENT AIR: free of oil, water and dust to ISO 8573-1 SUPPLY PRESSURE: 2.510 bar AIR CONSUPTION: 1.5 Nm3/h at 6 bar Performance Data (for angle >30) according to IEC 61514-2 HYSTERESIS+DEADBAND: 0.15% REPEATIBILITY: 0.15% SENSITIVITY: 0.1% LINEARITY: 0.3% INFLUENCE OF AMBIENT TEMPERATURE: 0.3% for every 10C FLOW CAPABILITY: 180Nm3/h at 6bar (CV 2.3) ACTION: configurable single or double Environmental capabilities HAZARDOUS PROTECTION: ATEX II 2G Ex ia IIC T6/T5/T4 AMBIENT: protection IP66 (NEMA4) operation temperature -30C to +80C VIBRATIONS: compliant with ISA-S75.13 CE MARK: CE conformity and EMC Material Aluminium, copper free for external side with stainless steel feedback shaft Weight 3.25 kg Options REMOTE FEEDBACK SENSOR UNIVERSAL LINKAGE FOR: Linear long stroke actuator (70-1500 mm) VDE/VDI 3845 for rotary applications Lever for side yoke or top mounting application DIRECTLY MOUNTED PNEUMATIC ACCESSORIES: gauges look up valve special booster CAPTURED OR HIGHLY SILENCED EXHAUST HIGH SPEED COMUNICATION KIT HIGH CORROSION RESISTANCE VERSION

Manual 4028 - Rev. 0 - 08/2008 -4-

i n s t r u c t i o n m a n u a l F a s Tr a k T M
1.2 Model selection

FT

Signal 0 420 mA H 420 mA Hart D Digital high speed

Feedback 1 standard 2 Linear kit 3 VDE-VDI (Namur) kit 4 Remote 5 Special

Housing O ordinary I intrinsically safe C corrosion resistant S special

Certification E European (CE or CE-ATEX) S Special

Display 0 blind cover 1 with display

Connection Electrical S 1/2 NPT M M20

Air supply 1/2 NPT 1/2 NPT

Air ports 1/2 NPT 1/2 NPT

Exhaust 1 standard IP66 2 conveyed 3 high silenced

Circuit options 1 supply/output gauges 2 lock-up device with supply/output gauges 3 special
Manual 4028 - Rev. 0 - 08/2008 -5-

i n s t r u c t i o n m a n u a l F a s Tr a k T M
1.3 Manufactorers identification

Every positioner FT is provided with a name plate with its serial number. The year of manufacturing is indicated by the first two digits of the serial number (*). P080000 year of manufacturing 2008

(*) The serial number is shown in the HART panel as Dev. ID see page 31
Manual 4028 - Rev. 0 - 08/2008 -6-

i n s t r u c t i o n m a n u a l F a s Tr a k T M
2.0 General Safety Instructions
In order that you can make the best use of this document and to ensure safety during commissioning, operation and maintenance of the equipment, please note the following explanation of the symbols used: as well as the instructions in this document, you must also follow applicable accident prevention and safety regulations. Please read this document carefully before installation and commissioning. Symbol definitions DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. (High level of risk). WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (Medium level of risk). CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. (Low level of risk). NOTE indicates a potentially harmful situation which, if not avoided, may result in damage of the product itself or of adjacent objects. (Damage to property). This chapter provides important instructions for your safety. Proper and safe operation of the FT positioner requires: proper transportation and storage mounting, electrical and pneumatic installation and commissioning by qualified personnel correct operation according to the instructions in this manual correct use careful maintenance Every positioner FT is provided with a name plate with its serial number. The year of manufacturing is indicated by the first two digits of the serial number. P081968 year of manufacturing 2008 In order to keep the device in a safe condition and ensure safe operation, please carefully read and follow the instructions given in the sections marked with the respective symbols. The device must be shut down and secured reliably against unintentional restart if it must be assumed that safe operation is no longer ensured. Possible reasons for this assumption can be: visible damage of the device failure of the electrical function exposure to a storage temperature of more than 85 C for a longer time period exposure to considerable strain or wear during transport. Only the manufacturer is authorized to repair the device. If the device is damaged or faulty do not continue use.

Manual 4028 - Rev. 0 - 08/2008 -7-

i n s t r u c t i o n m a n u a l F a s Tr a k T M
2.1 Device safety instructions
Observe the accident prevention rules of the H&S organizations. The non-observation of the following safety instructions and of the instruction manuals can result in serious injury. Installation must be carried by our qualified person. from the FT positioner and to avoid unpredictable movement of the actuator always remove the electrical power to the FT positioner electronics before changing electrical connections. Must be done by qualified person Cleaning must be done with a humid cloth Clean, dry air. No oil, no grease Product Disposal The disposal of this product should be carried out in a way that conforms to the 2007 Weee Directive, and any other locally applicable directions and regulations.

2.2 Installation
The electrical connections must be made according to the diagram and label. To achieve optimum performance from the FT Positioner, it is recommended that shielded cables be used when installing the positioner. The use of a ground strap between the FT positioner housing and a suitable earthed point is necessary. When changing electrical connections inside the FT positioner housing, observe ESD handling precautions. The use of a conductive, earthed, wrist strap is recommended. The pneumatic connections must be done according to the diagram and label, do not allow the FT Positioner supply pressure to exceed 10 bar. The supply circuit must be protected ito prevent the voltage or current exceeding the stated limits. The equipment must be provided with cable entries and filler plugs certified according to the required certification. The actuator must be installed and used according to the design specification. The fluid must be chemically compatible with the gaskets and lubricant used in the installation. If the FT positioner is to be installed in a hazardous area, ensure that electrical barriers are used between the FT positioner and the electrical power sources. To prevent injury always ensure that the air supply is removed from the FT positioner before the Mode Selection Plate is changed. Only trained personnel should permitted to alter the software control parameters stored within the FT positioner. Incorrect settings may lead to personal injury and or property damage.

2.4 Special instructions for FT positioners of explosion protection type Ex ia

In a hazardous area the FT positioner is to be installed with electrical barriers between the FT positioner and the electrical power sources. The type plate is attached to the positioner. It indicates the degree of explosion protection and the certificate valid for your positioner. For details please refer to enclosed Certificates. Additional electrical information are shown the internal electronic board label.

2.3 Maintenance
Before making changes to the pneumatic configuration, make sure that the compressed air supply is isolated The FT positioners mechanical enclosure and components are suitable for installation in hazardous atmospheres with protection constructional safety,

Manual 4028 - Rev. 0 - 08/2008 -8-

i n s t r u c t i o n m a n u a l F a s Tr a k T M
specifically tailored to the interests of non-electrical, according to the marking. II 2G c IIC T6 The FT positioner s electronic circuit and components are certified such that when used with the specified wiring device, the signal will not create any sparks and the surface temperature will not rise according to the marking. II 1G Ga Ex ia IIC T6/T5/T4 WARNING Do not use flammable gas nor oxygen or oxygenenriched gas as a pressure medium. Use cable entries and cables approved for a service temperature corresponding to the maximum ambient temperature increased by 10 K or corresponding to the minimum ambient temperature, respectively. improper settings. Do not use the (J7) communication interface when the positioner is installed and used in the hazardous area.

2.5 Electromagnetic interference

The complete FT positioner is suitable for installation in potentially explosive atmospheres 94/9/CE ATEX directive. I II 2G Ex ia IIC T6/T5/T4 Equipment group II surface industry, category 2 for use in zone 1 with explosive atmospheres caused by gases, vapours or mists, Group II and class of ignitability C in conformity to types of protection standardized EN 60079-0. The component is considered to be suitable for installation with temperature classification: with FT positioner supplied via connector J3, 4-20 mA loop, only, with no connection to connectors J6, digital input & J1 digital output or connector J10, analogue feedback T5 in ambient temperature -20 to +80C T6 in ambient temperature -20to +60C with FT positioner supplied using all of the inputs T4 in ambient temperature -20 to +80C T5 in ambient temperature -20 to +60C WARNING Any user-made changes or manipulations of the device are prohibited! Only the manufacturer and an expert explosion protection are authorized to modify the device. Before re-using a FT positioner that has already been used in another installation always reset the device to the factory setting. Never start the autoadjustment function before having restored the factory setting! Otherwise, hazardous situations may occur due to Do not lay signal lines close to power lines. Power lines produce interference in their near vicinity, which may affect measured value transmission on the signal line. When changing electrical connections inside the FT positioner housing, observe ESD handling precautions. The use of a conductive, earthed, wrist strap is recommended. It is recommended that the lid is rest closed in normal operation. WARNING Always observe the specifications and special requirements for your positioner stipulated in the applicable certificate.

2.6 Pneumatic safety

Observe the accident prevention rules of the H&S organizations. Observe the safety instructions for the pneumatic actuator used. NOTE Take suitable precautions to ensure that even in the case of malfunction the positioners max. admissible operating pressure is not exceeded. Otherwise, the positioner and/or the actuator may be damaged. The positioner must be supplied with instrument air free from oil, water and dust according to ISO 8573-1, Class 3 - Purity: max. particle size 5 m, max. particle density 5 mg/m3. - Oil content: max. concentration 1 mg/m3.

Manual 4028 - Rev. 0 - 08/2008 -9-

i n s t r u c t i o n m a n u a l F a s Tr a k T M
- Pressure dew point: maximum value 10 K below operating temp. - Before using these products with fluids other than air or for non-industrial applications, consult STI. Before connecting the air pipes, blow them out to remove dust, splinters and other particles. circuitry must meet the explosion requirements stipulated in the certificates protection

2.7 Electrical safety

WARNING Observe the common safety regulations and the accident prevention rules of the H&S organizations. Observe the common standards and safety regulations for the installation and operation of electrical systems. When connecting the device, observe all electrical specifications in these operating instructions or in the drawing. For the electrical installation of explosion-protected devices, observe all standards, regulations and directives governing explosion protection and applicable for the construction and use of explosion-protected systems, the directives for explosion protection (EN 60079), and the special requirements and specifications for your devices. In particular make sure that: - Used in situations that comply with the certification conditions stated in this handbook. - Maintained only by qualified personnel with adequate training on hazardous area instrumentation. - This product is not intended for use in life support systems. - The use of a ground strap between the FT positioner housing and a suitable earthed point is necessary. - The supply circuit must be protected to prevent current exceeding the limit fixed. - The equipment must be provided with cable entries and filler plugs certified according to the required certification.

DANGER Only those persons familiar with the installation, commissioning, operation and maintenance of the FT positioner or similar instruments who have the required qualification and have read and understood the operating instructions are authorized to work on the positioner. These persons must be sufficiently trained and experienced and know the relevant standards and regulations to be able to judge their assigned tasks and recognize potential hazards. Only persons who are qualified or have been trained adequately and who have the required certificates are authorized to work on explosion-protected devices.

2.8 Correct use

The FT positioner is an electro-pneumatic positioner for pneumatic final control elements. It is designed for being attached to linear and rotary actuators following the instructions in this manual. The positioner may be used only for the applications listed in these operating instructions. Any other use is considered as incorrect. The signal current circuit and the input and output

Manual 4028 - Rev. 0 - 08/2008 - 10 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
3.0 Installation
Remove the FT positioner from its packing, the pneumatic and electric port are protected by plastic plugs. These plugs must be removed and all ports not connected must be plugged with tight plugs suitable for the pressure rating and area classification. Double acting with spring: the port A must be connected to the actuator port that has lower volume on air fail (volume minimized by spring action). The port B must be connect to the other actuator air chamber, that has to be pressurized at 0 signal position. Single acting: the port A must be connected to the actuator air chamber. The port B must be plugged. Important: to set as single acting the plate (see page 14) FT must be moved to read single. The factory configuration of the FT is double acting. To check that the correct connections have been made, the system supply can be pressurised without any power signal. With no power rest that the valve/actuator moves to the 0% signal position.

3.1 Pneumatic connections

Pressure line and port A and port B are 1/2 NPT female. The full flow performance of FT positioner require that the piping between FT and actuators has to be 1/2 without any restriction and short as possible, the pressure line pipe has to be sized to avoid significant pressure drop during the actuator stroke. During piping connection be careful to keep the internal side of piping and fittings free from thread sealing material and any other contaminant. The FT positioner is suitable to operate from 2.5 to 10 bar but the line pressure must be set lower than actuator design pressure. No load or bending moment are allowed by the piping on FT connections. The FT positioner is suitable for rotary or sliding actuators; double acting with or without spring or single acting. The port A is fully vent in case of power fail and/or signal 0%. Double acting: the port A must be connected to the actuator air chamber that has to vent at 0 signal position. The port B must be connect to the other actuator air chamber, that has to be pressurized at 0 signal position. Port A connected to the stem side port on sliding actuator that has to extend stem on power fail and 0 signal. Port A connected to the port opposite of stem side on sliding actuator that has to retract stem on power fail and 0 signal.

Air Supply

PORT B

PORT A

Manual 4028 - Rev. 0 - 08/2008 - 11 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
3.2 Power board connection
TO SELECT MODE Loosen both M3x16 Screws and slide plate to set for Actuator Type

SINGLE ENDED

DOUBLE ENDED

RX 0V

MODE TX

ENCODER Supply (Red) ENCODER Signal (White) ENCODER Return (Black) 4 - 20mA Set Point 4 - 20mA Return SERIAL COMMS M3 x 16 Screws

Analogue F/Back Return MODE SELECT PLATE Digital Inputs Return HART MODEM Connection

+ 24V Dgital Outputs Return

Display Option

Factory Use Only

Manual 4028 - Rev. 0 - 08/2008 - 12 -

POTENTIOMETER FOR FACTORY USE ONLY

Analogue F/B +ve

i n s t r u c t i o n m a n u a l F a s Tr a k T M
4-20mA input signal: Input port J3 should be connected to HART compliant 4-20mA signal source.

Input signal is used to: Provide power to the positioner Inform the positioner about the desired position. The HART communications signal is superimposed on the 420mA signal. The signal generator and the intrinsically safe barrier must be compliant with the HART protocol .

NOTE 1. UNSPECIFIED EXCEPT THAT IT MUST NOT BE SUPPLIED FROM NOR CONTAIN UNDER NORMAL OR ABNORMAL CONDITIONS A SOURCE OF POTENTIAL WITH RESPECT TO EARTH IN EXCESS OF 250 VOLTS RMS OR 250 VOLTS DC 2. A POSITIVE ATEX CERTIFIED SHUNT ZENER

DIODE SAFETY BARRIER OR GALVANIC ISOLATOR FOR GROUP IIC ia, WHOSE OUTPUT Uo LESS THAN OR EQUAL TO 30V Io LESS THAN OR EQUAL TO 120mA Po LESS THAN OR EQUAL TO 0.65W AND IS SUITABLE FOR USE WITH SMART TRANSMITTERS. 3. THE ASSOCIATED APPARATUS (Co), LESS TERMINAL (Ci), GIVES THE TOTAL EXTERNAL CABLE CAPACITANCE PERMITTED FOR EACH

Manual 4028 - Rev. 0 - 08/2008 - 13 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
SEPARATE I.S. CIRCUIT. THE ASSOCIATED APPARATUS (Lo), LESS TERMINAL (Li), GIVES THE TOTAL EXTERNAL CABLE INDUCTANCE PERMITTED FOR EACH SEPARATE I.S. CIRCUIT. Refer to Hart Application guide, HCF-LIT-34 for important information about Intrisically safe barrier and Hart signals. Designing an IS System Using Shunt-diode Barriers Example: 26.0 V 340 22 mA = 13.0 V Designing an IS direct-current loop simply requires ensuring that a field device has sufficient voltage to operate, taking into account zener barrier resistance, the load resistor, and any cable resistance. When designing an IS loop using shunt-diode barriers, additional requirements must be considered: The power supply must be reduced by an additional 0.7 V Any cable resistance can be added as a series resistance and will reduce the voltage even further. In addition, the power supply to the zener barrier must also be set lower than the zener barrier conduction voltage. For example, a 28 V, 300 zener barrier would typically be used with a 26 V power supply. to allow headroom for the HART communication signal and yet not approach the zener barrier conduction voltage. The series resistance for the same zener barrier may be as high as 340 . To calculate the available voltage needed to power the positioner, use the following equation: Power Supply Voltage Zener Barrier Resistance X Operating Current (mA) = Available Voltage

Manual 4028 - Rev. 0 - 08/2008 - 14 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
Analog feedback:

The 4-20mA output must be energized from the loop.

NOTE 1. THE ASSOCIATED APPARATUS (Co), LESS TERMINAL (Ci), GIVES THE TOTAL EXTERNAL CABLE CAPACITANCE PERMITTED FOR EACH SEPARATE I.S. CIRCUIT. EXTERNAL CABLE INDUCTANCE PERMITTED FOR EACH SEPARATE I.S. CIRCUIT. THE ASSOCIATED APPARATUS (Lo),

LESS TERMINAL (Li), GIVES THE TOTAL. 2. A POSITIVE ATEX CERTIFIED SHUNT ZENER DIODE SAFETY BARRIER OR GALVANIC ISOLATOR FOR GROUP IIC WHOSE OUTPUT PARAMETERS ARE LESS THAN OR EQUAL TO THAT SPECIFIED. 3. I.S. INSTALLATION EARTH (REQUIRED FOR ZENER BARRIERS ONLY).

Manual 4028 - Rev. 0 - 08/2008 - 15 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
Digital IN/OUT

Digital INPUT: Digital Input is isolated by an optocoupler. The input resistance value is 2200 ohms. Apply a 24Vdc signal between the digital input and the return signal to energize the input.

Digital OUTPUT: Digital output is isolated by an optocoupler. The output is made by a transistor with a series resistor of 1Kohm. When the output is energized the impedance is less that 4 Kohm, when deenergized the impedance is greater than 100Kohm. The optocoupler requires an external power source to be energized via J1 pins 1 & 4.

Manual 4028 - Rev. 0 - 08/2008 - 16 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
High speed serial connection : A special interface cable is needed : STI code 81569

Intrisically safe data :

Manual 4028 - Rev. 0 - 08/2008 - 17 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
Electrical connection:

Manual 4028 - Rev. 0 - 08/2008 - 18 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
3.3 Mechanical feedback linkage mounting
The FT has been designed to work on feedback rotation angle between 30 and 120. Any feedback linkage must be able to generate a rotation angle between 30 and 120 on full actuator/valve stroke. Any backlash, linearity error, elasticity of feedback linkage will affect the positioning performance The feedback shaft has about 120 max reading angle on 360. There are no mechanical stops on the shaft, there is no chance to damage the positioner by overrotation during installation. The feedback shaft is 8mm diameter and fully cylindrical. It can be initially connected with any orientation to the feedback linkage. The alignment of linkage angle inside the 120 reading range can be done by rotating the feedback shaft with respect to linkage. The reading angle is shown on the RC sw or displayed on the handheld digital interface. By RC software: on CFG panel looking position sensor window. Unlock the connection between FT shaft and linkage. If the valve/actuator is not on hard limit 0% signal position drive it pressurizing port B by position sensor adjustment verify that the valve/actuator move to 0% signal position. WARNING When the send button is pressed the system can move.

Rotate the FT shaft slowly in the same direction (clockwise or counter-clockwise) that linkage would rotate to move valve/actuator. On each complete FT shaft turn the scroll bar index will move on 120 shaft rotation, moving always in the same direction (left to right or right to left ). Rotate the FT shaft until the scroll bar index start to move outside of the red/orange zone. Lock the connection between FT shaft and linkage. Now using position sensor adjustment it is possible drive the valve/actuator to check that both hard limit are in the right position. Both have to be out of the red/orange zones. By digital interface: hand held see the command tree pag. 44 Unlock the connection between FT shaft and linkage. If the valve/actuator is not on hard limit 0% signal position drive it pressurizing port B by position sensor adjustment (command 5). Rotate the FT shaft slowly in the same direction (clockwise or counter-clockwise) that linkage would rotate to move valve/actuator. On each complete FT shaft turn the variable will change between 0 and 4095 on 120 shaft rotation, moving always in the same direction (0 to 4095 or 4095 to 0). If the variable moves from 0 to 4095 rotate the FT shaft until the variable is 500 250 then lock the connection between FT shaft and linkage. If the variable move from 4095 to 0 rotate the FT shaft until the variable is 3600 250 then lock the connection between FT shaft and linkage.

Manual 4028 - Rev. 0 - 08/2008 - 19 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
Now using position sensor adjustment it is possible drive the valve/actuator to check that both hard limit are in the right position. Both have to be between 250 and 3850. An other alternative method to set the mechanical linkage in right position is: 1. with the positioner connected to the PC and without mechanical linkage rotate the FT shaft slowly until scroll bar index reaches the central position. 2. evaluate the angle between the actual position and the position at 50% of stroke of the actuator, the angle is measured on seat of lever where the FT shaft will be mounted. 3. rotate the FT shaft from central position to an angle about equal at angle measured to previous point with direction that bring the FT shaft in the position that it has if the mechanical linkage is connected. 4. connect the mechanical linkage to the FT shaft. 5. Now using position sensor adjustment it is possible drive the valve/actuator to check that both hard limit are in the right position.

4.0 Using remote control software

Sw installation Insert the CD (or download the installation file) Run setup.exe Follow the instructions on the screen. Only the available communication ports are displayed in the combo box. Select the Communication mode (TTL or HART). Disable AutoDownload and Refresh Vars if you want to reduce the refresh rate (and the traffic on the communication line). Press the OK button.

4.1 RemoteControl sw connection

HART interface connection: Connect your HART interface at the same cables of the 4-20mA input signal (J3). If the 4-20mA signal generator is not HART compliant communication problems may be expected. HART interface connection: Connect your HART inter DANGER The TTL High speed interface is not Intrisically Safe. Use this type of interface only in a Safe Area or take all the necessary precautions before using.

4.2 Starting the sw

Run the sw starting from the desktop icon or from the Windows Start menu. The Select Communication page is displayed.
Select the right communication port.

Select the right communication port.

Select the Communication mode (TTL or HART).

Manual 4028 - Rev. 0 - 08/2008 - 20 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
4.3 The Main page
Positioner Main vars and status information

Quick Buttons

Communication status led

Tuning & standard System Setup area

Advanced Menus

Main vars and Status Information are normally refreshed automatically. The other parameters are refreshed manually with the Download command. The refresh rate depends on the communication mode (HART or TTL) If the Autodownload and Refresh vars option is disabled, use the Download command to refresh the parameters use the Refresh button (located near the Communication Status Led when Autodownload is disabled) to refresh the main variables.

4.4 Quick Buttons

Download button Download all the parameters from the FT positioner. At the end of the download the values displayed on the RC sw are the same as the FT positioner.

Graph button Open the Graph window.

Password button Open the Login window. In order to change the parameters or to access configuration windows, a login is required. The default standard password is: 12345.

Manual 4028 - Rev. 0 - 08/2008 - 21 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
4.5 Tuning & standard System setup area
Definitions: Limit: when a limit is configured the Requested position is limited to this value. Example: Set the Limit at 95%. Even if the signal input is 20mA and the theretical Request position is 100%, the applied Request position is 95%. CutOff: When a cutoff is configured, if the Requested and Actual position falls inside the Cutoff area the Request position is fixed at the min (or max) value. Example: Set the cutoff at 5%. When the Request position is less of 5% and the Actual position is less of 5% a fixed pressure is applied in order to put the actual position at 0%. Tight (open/close) pressure: this defines the pressure applied when a cutoff is active. (Advanced parameter). Open/Close: Information related to Signal Fail Action configuration. WARNING The signal Fail Action setting informs the Positioner about what happens when the electrical power supply fails. This behaviour is determined by the pneumatic connection and is not software configurable. WARNING On some type of valves it is mandatory to enable a cutoff to ensure that the valve works properly ( to ensure full trust on seat). Travel control: Open Limit [50..100 %]: Specify if a Limit or a CutOff is configured in the open direction. Close Limit [0..50 %]: Specify if a Limit or a CutOff is configured in the close direction. Tuning: A lot of parameters are configurable with different settings for the open and close directions. This is to maximize the performance of the system. If the Mono flag is checked the first value of each parameter is automatically copied into the second one. Kp [0,1 .. 25]: Proportional gain is the multiplier of the error (difference between input signal and actuator actual position) and it is expressed in percent. It is active only for an error which is bigger than dead band value. A different gain for each stem direction can be selected. Ti [OFF- 10 .. 100000 ms]: Integral factor. The integral term accelerates the movement of the process towards setpoint and eliminates the residual steady-state error that occurs with a proportional only controller. However, since the integral term is responding to accumulated errors from the past, it can cause the present value to overshoot the setpoint value. A small Ti value is equal to an aggressive integral effect. A different integral factor for each stem direction can be selected. Td [0..1000]: Derivative factor The derivative term slows the rate of change of the controller output. Setting Td equal to 0 disable; the derivative factor. Increasing the value increases the derivative action. Dead Band [0..10]: Dead band prevents (at expense of the accuracy) that the valve, in the controlled condition, keeps continuously hunting for the target position. The dead band setting can be used to reduce continues cycling (hunting) around the target position. Increasing the value reduces the accuracy, but can improve stability. Velocity Limit [0..655 sec]: Velocity limit is the value expressed in seconds of the stroking time for each direction Damping Factor [0..255]: Apply a damping effect at the signal rate of change. Increasing the damping factor causes a smooth effect on the signal rate of change. Switched ctrl err threshold[0..100 %]: When the error is greater than this threshold:

Manual 4028 - Rev. 0 - 08/2008 - 22 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
the positioner tries to impose a fixed P in order to maximize the speed. the Integral contribution is reset to zero. Sweep pressure [0..10 bar]: Fixed P applied when the error is greater than Switched ctrl err threshold. Switched control function Enabled[ON/OFF]: Turn ON/OFF the Switched control function. Normally the following settings work well: sweep pressure equal to the line pressure the Switched ctrl err threshold equal to [100/min(Kp)]*[sweep pressure/10] PA [bar]: Pressure measured at port A of the positioner. DP[bar]: Differential pressure measured: portB-portA. Calibration status / Status: Displays the status of the internal sensor calibration. Calibration status / Error code: Calibration status / Data Source: Service State / Mode: Allow the selection of the Service State. - In Service: the Requested Position is evaluated continually by the positioner starting from the 4-20mA signal value. - Out Of Service (Manual): the Requested Position comes from the manual setting in the window. When the Service Mode is set to Out Of Service (Manual) the first manual setpoint is equal to the last Actual position in order to minimize the movement of the system. - Out of Service: special mode selected automatically when the system is not calibrated. In this mode port B is fully pressurized and port A is depressurized WARNING Changing from Out of Service to In Service can cause the actuator to move. When the positioner is turned ON it starts automatically in In Service or Out of Service based on the position sensor calibration status.

4.6 Main vars and status

This window reports information about the status of the positioner. The LED in the top-right position informs the user about the information status: YELLOW LED blinking: the communication is running. RED LED: communication problem. ActPos [%]: Actual position measured by the positioner. ReqPos [%]: Input signal or the request position. The source of the requested position depends on the service state. While in service the requested position comes from the 4-20mA input signal and the split range setting. While out of service the requested position comes from the manual setpoint setting. ErrPos[%]: ReqPos-ActPos. Input [mA]: Current read by the 4-20mA loop current Input channel. The user can calibrate the value displayed using the commands in the CFG area. PI [bar]: Line pressure

Manual 4028 - Rev. 0 - 08/2008 - 23 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
4.7 CFG panel

Position sensor: Pos. raw ADC reading (bits) This is the read value of the position sensor measured value before calibration. The same value is shown in the scroll bar below. During the mechanical linkage adjustment the user can use this scroll bar to verify the alignment: the raw ADC value must fall inside the range. The best condition is when the 50% mechanical position is near the middle value of the scroll bar (2048 +/- 500). Position sensor adjustment: This button opens a window that helps the user to move the actuator. The slide bar enables the user to select a safe speed to move in one direction or in the other. Move the slide to the desired position and press Send. To increase the movement speed, move the slider far from the middle position.

WARNING When the send button is pressed the system can move.

Manual 4028 - Rev. 0 - 08/2008 - 24 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
Digital inputs/outputs Refer to the electrical connection for information about the use of Digital inputs/outputs in Intrisically Safe area and proper connection to an IS barrier. Digital Input 1: Configure the action that the positioner will do when Digital Input 1 is activated. Shut down: the I/P is de-energized and the spool goes in the default position -> Port B is fully pressurized. Pressurize Port A: the I/P is fully energized and Port A is fully pressurized. WARNING The Pressurize Port A option is not safety: if the 420mA signal is removed, or the air closed, the system can move. Digital Input 2: Same as Digital Input 1. Digital Outputs: Open the Digital Outputs configuration window. For each digital outputs it is possible to select the rules of activation. Not IN SERVICE: Digital output is activated when the system is not IN SERVICE. Position Below Limit 1: Digital output is activated when the actual position is below the limit specified in Position Limit 1. CAUTION Dont use this is a virtual limit switches for a safety application. Position Above Limit 2: Digital output is activated when the actual position is above the limit specified in Position Limit 2. CAUTION Dont use a virtual limit switches for a safety application. Pressure Fail: Digital output is activated when the pressure of the line ( PI ) is below the limit specified in Min PI Pressure. Position error: Digital output is activated when the system is IN SERVICE and the position error is >= 5% for at least 10 sec.

Manual 4028 - Rev. 0 - 08/2008 - 25 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
SYSTEM CALIBRATION Starts the calibration and self-tuning procedure. The Only HARD LIMITS option allows the calibration of the travel without performing self tuning. WARNING When the Start Calibration button is pressed the system will move. 4-20mA CALIBRATION Start the calibration of the selected option: Loop Current ADC 4mA Reads the actual value of the input current and calibrate the internal system to always read this value as 4mA. CAUTION Be sure that you are supplying the positioner with a stable, accurate 4mA reference. Loop Current ADC 20mA Reads the actual value of the input current and calibrates the internal system to always read this value as 20mA. SPLIT RANGE INPUT Enables the split range function. The values in Lower range value and Upper range value are referred to the 4-20mA input. A minimum distance of 20% is required between Lower and Upper value, so up to 5 split range area can be configured in different concatenated positioners. The result of the split range is then evaluated by the Transfer Function Curve. If the Low range value is equal to 0% and Upper range value is equal to 100% the positioner interprets 4mA as the 0% Request position and the 20mA as 100%. If the Low range value is equal to 0% and Upper range value is equal to 50% the positioner interprets 4mA as the 0% Request position and the 12mA as 100%. Lower range value (%): Specifies the Lower range value. Upper range value (%): Specifies the Upper range value. Setpoint range function (enabled): Enable or disable the split range function. The Transfer Function Curve shows the effect of Split Range Function in a graphical way. INPUT CHAR The Characterization specifies the relationship between the Input signal and the Requested Position. Transfer Function: Select one of this characterization: Linear Standard 1-50 : equipercentage 1:50 Standard 50-1 : inverse equal percentage 1:50 User : user defined Standard 1-25 : equipercentage 1:25 Standard 25-1 : inverse equal percentage 1:25 Standard 1-30 : equipercentage 1:30 Standard 30-1 : inverse equal percentage 1:30 Transfer Function Curve button: Open the Transfer Function Curve window

- The Close and Open label in the Requested position axis shows the effect of the Signal Fail Action selection. - The 4.0mA and 20.0mA in the Signal Position

Manual 4028 - Rev. 0 - 08/2008 - 26 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
show the effect of the Split Range setup. - The effect of Limit and CutOff are showed on the graph. - Only the User Curve can be modified, the other curves are fixed if you want to start from a standard curve and generate a user curve you can: Select the starting curve Save the Table (File Save Table). Select User Curve Load the saved Table Modify the table - To Send a User Curve to the Positioner press the Send button. - The Signal Position steps are fixed, you can only change the Requested position value. - You can change a value in the table or click_&_drag the dot in the graph. - If you hold down the shift key and click on two dots, the system will automatically do a linear interpolation between these two points. Analog Output Analog Feedback - Selects the Analog Output (4-20mA signal out) report the Actuator position or the Reverse Actuator Position. the field device. The term originated when physical tags were attached to instruments for this purpose. Date: - The date is represented by three 8-bit binary unsigned integers representing, respectively, the day, month and year (minus 1900). Its a date code, used by the Master for record keeping (e.g. last or next calibration date). Descriptor: - The Descriptor is a 16 character (12 byte) Packed ASCII string used by the Master for record keeping. - The default value is a blanked string, 16 bytes long. Message: - The Message is a 32 character (24 byte) Packed ASCII string used by the Master for record keeping. - The default value is a blanked string, 32 bytes long. Polling address: - In the HART Protocol, the polling address is an integer used to identify the field device. It is used to construct the Short Frame Address. The Polling Address is set to 0 in point to point installations. Dev. ID: - This number is different for every device manufactured with a given Manufacturer ID and Device Type, it corresponds to serial number (see page 7). HART Protocol - Show some communication parameters which may be useful for debugging communication problem. HART Communication Hart Mode: - Time management and Time management (performance) are two different way to manage the Hart modem. If you experience of communication problems try changing this option.

4.8 HART panel

HART PARAMETERS

Tag: - The Tag is a 8 character label assigned by the end user based on the location and use of the field device. Its a 8 character (6 byte) Packed ASCII string used to identify

Manual 4028 - Rev. 0 - 08/2008 - 27 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
4.9 The Graph window
This feature allows user to record set point and position signal waveforms for 10 seconds. Moreover, it comes with some tools to analyze the acquired waveforms. This feature is only available on the Remotectrl program with a TTL connection.

Using the up/down and right/left arrows on the keyboard it is possible to move in the graphs window. Its also possible to zoom in: hold the right mouse button, define the window to be zoomed in, release the right mouse button. By pressing the Graph Cfg button, the user can choose the following signals on the graph:

Manual 4028 - Rev. 0 - 08/2008 - 28 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
4.10 The Menu
Menu: File Load: Load a saved set of parameters into the RC interface. Save: Save the current set of parameters in a .qtp file. Report: Create a document in .rtf format with the actual parameters (similar to the Save command but the file format is compatible with text editing software). Exit: Close the application. Menu: Device Download Performs the same function as the quick button. Upload Param Sends the displayed parameters to the positioner. Upload Param + Calib data The same as the Upload Param command but additionally sends information about the calibration. Menu: Password Login Performs the same function as quick button

Change Changes the password.

Manual 4028 - Rev. 0 - 08/2008 - 29 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
System Calibration: self-tune 4.11 The Graph window

The self tune wizard can be started by pressing the start system calibration button. You can find more information about this procedure in the specific Installation Instruction Manual. Starting page

You must specify what happens when the 4-20mA signal is removed (with the air present). Based on the pneumatic connection the actuator moves in one direction or in the other (when the 4-20mA signal is removed, portB is fully pressurized).

WARNING This panel is to inform the positioner about the action and is not to specify the user desired behaviour. The positioner is not able to change the mechanical defalt piston by itself.

Manual 4028 - Rev. 0 - 08/2008 - 30 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
Position sensor alignment

This page helps you align the position sensor. Pressing the Position sensor adjustment button opens a window where you can find a tool that allows you to move the valve.

Manual 4028 - Rev. 0 - 08/2008 - 31 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
Actuator volume Specify the size of the actuator

Actuator Type Specify the type of actuator. Remember to check the position of the Mode select plate inside the positioner.

Manual 4028 - Rev. 0 - 08/2008 - 32 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
Booster type

Only stroke or full calibration Select Control parameters and stroke if you want to perform a full SelfTune procedure. Select Only stroke if you want only to update the hardware limits of your valve. Press Start the perform the SelfTune. The progress bar informs you about the SelfTune status.

Manual 4028 - Rev. 0 - 08/2008 - 33 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
5.0 Using digital interface 5.1 Installation
375 Easy Upgrade Programming Utility is required to upload and download files to the 375 Field Communicator. The Programming Utility communicates with the Field Communicator and permits file movement between a PC and a 375. - Start the Programming Utility - Verify that the 375 is up-to-date, checking and updating the HART Application for 375 if its necessary. Refer to the 375 Field Communicator Users Manual for reference.

Manual 4028 - Rev. 0 - 08/2008 - 34 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
- Select File/Import DDs from Local Source.

- In the Select Path to DD Files dialog, browse to the location of the DDP (directory \375 on the FT installation CD). - Each DDP (Device Driver Package) consists of two files. A DD binary has an .hdd file extension, and a corresponding binary header has an .hhd file extension. - Select OK after the desired DDP(s) have been found. The Programming Utility adds the selected DDP(s) into its database.
2 5.1 Connection

- Connect the FT device to the 375 (refer to the 375 Field Communicator Users Manual if you need instructions). - Turn on the 375 Field Communicator. The 375 Main Menu is displayed with HART as the default application. - Double HART application to run the HART application. On startup, the HART application will automatically poll for devices. If a live HART device is connected to the 375 Field Communicator, the HART Application main menu will be displayed automatically with key parameters from the connected device.

Manual 4028 - Rev. 0 - 08/2008 - 35 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
5.3 Menu

2.1 Set Operation mode

1 Main Vars 2 System Status 3 System Setup 4 Manual Mode 5 Position Sensor 6 Calibration 7 Communication

1 ActPos 2 ReqPos 3 Input 4 PI 5 PA 6 DP 7 TE 1 Set operation mode 2 Operation Mode 2 Status 3 Calib.progr./err. 4 Progr./err. Details 5 Data source

100.00% 0.99% 4.00mA 6.00bar 6.00bar 6.00bar 13.70 C

1 Main Vars

1 In Service 2 Out Service - Manual

2 System Status

In Service

3 System Setup

1 Travel Control 2 Tuning

1 Open cutoff/limit 2 Open mode 3 Close cutoff/limit 4 Close mode

95% CutOff 5% CutOff

4 Manual mode

1 ActPos 2 ReqPos 3 Manual Setpoint

3.1 Travel Control

0.00%

1 System Calibration 2 0%/fail signal pos. 3 Actuator Volume 4 Actuator type 5 Booster or QE 6 PI 7 Norm.supply press. 8 Status 9 Calib.progr./err. 10 Progr./err. Details

6 Calibration

Close don't know Double Yes 7.00 bar 6.50 bar

1 Manufacturer 2 Model 3 Dev id 4 Write protect 5 Tag 6 Descriptor 7 Message 8 Date 9 Hart revision 10 Fld dev rev 11 Software version 12 Poll addr 13 Num req preamms

7 Communication

Manual 4028 - Rev. 0 - 08/2008 - 36 -

3.2 Tuning

1 Sens. pos. reading 2 Sens. pos. lower lim. 3 Sens. pos. upper lim.

451 0 4095

1 Kp opening 2 Kp closing 3 Ti opening 4 Ti closing 5 Td opening 6 Td closing 7 Dead band 8 Open velocity limit 9 Open vel.lim.funct. 10 Close velocity limit 11 Close vel.lim.funct. 12 Damping open 13 Damping close 14 Switched ctrl err 15 Sweep pressure 16 Switched ctrl funct.

1.0 1.0 0 msec 0 msec 0 msec 0 msec 0.20% 10.00s/100% Disabled 10.00s/100% Disabled 0 0 25% 10.0bar Enabled

5 Position sensor

i n s t r u c t i o n m a n u a l F a s Tr a k T M
5.4 Setup Wizard

Welcome to the setup wizard. This step by step sequence will help you to setup your positioner.

Setup Wizard starts from : 6 Calibration -> 6.1 System Calibration

Select 0% signal/signal fail valve position - Close - Open

Select Actuator Volume 1- SMALL 2- SMALL 3- SMALL 4-MEDIUM ,,,,

Select Actuator Type 1- Single 2- Double 3- Double with spring

Calibration in progress ... step 140

Boosters or Quick Exhaust - NO - YES

Self Tune completed

Select calibration - System Calibration - Only hard lim. calibr.

Return INSERVICE - NO - YES

Refresh parameters ... 1 Are you sure you want to start self-tune ? Valve will move!

Manual 4028 - Rev. 0 - 08/2008 - 37 -

i n s t r u c t i o n m a n u a l F a s Tr a k T M
6.0 Dimensions

Manual 4028 - Rev. 0 - 08/2008 - 38 -

S T I S . r. l . - V i a P a s c o l i 1 0 a / b 2 4 0 2 0 G o r l e ( B G ) I t a l y Te l . + 3 9 0 3 5 2 9 2 8 . 2 - F a x + 3 9 0 3 5 2 9 2 8 . 2 4 7 w w w. s t i a c t u a t i o n . c o m - i n f o @ s t i s t r u m e n t a z i o n e . c o m