ICOT2 SMART VALVE POSITIONER OPERATING MANUAL IOM: Tech-439 Prepared By: F. Oster, M. Twardowski, R. da Mata Reviewed By: M. Twardowski Revision: E Date: 10/27/10 Drafting Work Order: 20855 ECN: 12488 Date: 3/4/14 Approved By: R.
Revision History Revision Rev. A 1/12/10 7/21/10 Initial release Rev. B 2/4/11 Rev. C 5/2/13 Rev. D 11/7/13 Rev. E 2/26/14 Westlock Controls Offices USA Westlock Controls Corp. 280 North Midland Ave. Ste. 258, Saddle Brook, NJ 07663 Phone: (201) 794-7650 •Fax: (201) 794-0913 Email: westlockinfo@westlockcontrols.com Internet http://www.westlockcontrols.
Table of Contents 1. Introduction .................................................................................5 1.1 1.2 1.3 1.4 1.5 Product Certification. ............................................................................................................... 5 Warnings.................................................................................................................................. 5 Description of ICoT Positioner. ................................................................
General Maintenance Standard Flow ................................................................................................. 47 Appendix F.............................................................................................................................49 Grounding Schematic......................................................................................................................... 49 Appendix G ..................................................................................
1. Introduction 1.1 Product Certification. IEC Ex FMG 06.0002x Ex ia IIC T4 II 1 G Ex ia IIC T4 II 1G FM09 ATEX 0028 II3 DT 75~C Ex ia IIC T4 CLASS I DIV 1 GROUP A, B, C, D CLASS II DIV 1 GROUP E, F, G NI CLASS I DIV 2 GROUP A, B, C, D nnnn This product is designed for use in intrinsically safe systems when connected through the correct barriers. 1.2 Warnings Never remove enclosure cover or make/break electrical connections with power connected to the unit.
The ICoT is available in two versions, HART® and non-HART. The non-HART version allows calibration of the instrument through an on board keypad. The HART® version allows calibration and access to on-line diagnostic information via Rosemount 275/375 hand-held terminal or through software. The positioner has a local liquid crystal display which indicates valve position and set-point in percentage of full span. It also indicates whether the positioner is in calibration mode.
1.4 Principle of Operation Unlike conventional positioners, the ICoT Smart Positioner feeds back valve position without the need for linkages, levers, or rotary and linear seals. Position sensing is performed totally by non-contacting means, permitting use of advanced control strategies where knowledge of valve position is used in predictive and other algorithms.
1.5 Special Features Non-Contact Position Feedback To provide consistently accurate performance information, all linkages, levers and connecting rods, from the positioner to the control valve have been eliminated from the design. Valve position sensing is performed totally by noncontacting means based upon characterization of magnetic flux strength as a function of position. WESTLOCK CONTROLS CORPORATION 280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913 www.westlockcontrols.
Remote Position Control Since valve position feedback to the ICoT positioner is accomplished by non-contacting means, the ICoT has the unique ability to be mounted remotely (up to a distance of 50 feet, optionally 150 feet) from the device it is controlling. The remote position sensor also has the ability to work over a wider temperature range, from 40C to 125C (-40F to 257F).
2 Ordering The ICoT positioner is designed to handle a wide range of control valve applications. Please use the following ordering guide to help choose the ICoT positioner that best suits the application. 2.
3 Initial Setup 3.1 Mounting Positioner on a Rotary Actuator Step 1. Mount bracket and inner beacon coupler to actuator. If actuator shaft has a tapped hole, fasten using proper flat head screw. If actuator does not have a tapped hole, fasten using set screws on side of coupler. (See Figure 3-1) Figure 3-1 WESTLOCK CONTROLS CORPORATION 280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913 www.westlockcontrols.com 1/12/10 TECH-439/D.W.O.
Step 2. Press fit the inner beacon to the inner beacon coupler. The inner beacon needs to be properly oriented. Use the symbols on the top of the inner beacon to mount as shown in Condition 1 or Condition 2. (see figure 3-2). Condition 1 and Condition 2 show the placement of the inner beacon with respect to the positioner housing while the actuator is in the fail position. Step 3. Mount the positioner to the bracket.
3.2 Mounting Remote Positioner on a Rotary Actuator (Models 5235 & 5335) Step 1. Mount bracket and inner beacon coupler to actuator as described in Section 3.1 Step 1. Step 2. Press fit the inner beacon to the inner beacon coupler. The inner beacon needs to be properly oriented. Use the symbols on the top of the inner beacon to mount as shown in Condition 1 or Condition 2. (See Figure 3-3).
Step 4. Mount positioner at a remote location. Step 5. Remove the electronic canister cover by unscrewing (2) mounting screws. (Appendix B: Procedure to Remove Electronics Cover and Electronic Canister) Step 6. If necessary cut remote cable to required length, making sure to cut end opposite female connector. Wire the positioner sensor back to the positioner using the cable provided and replace cover. (See Figure 3-4).
Icot Direct Mount Condition 1: Actuator fails in a clockwise direction. Spring Return Actuator Output Port 2 is plugged Output Port 1 is piped to turn the actuator Counter clockwise Double Acting Actuator Output Port 2 is piped to turn the actuator clockwise Output Port 1 is piped to turn the actuator counter clockwise Placed at 6:00 Placed at 3:00 Condition 2: Actuator fails in a counter clockwise direction.
Icot Direct Mount Condition 1: Actuator fails in a clockwise direction. Spring Return Actuator Output Port 2 is plugged Output Port 1 is piped to turn the actuator Counter clockwise Double Acting Actuator Output Port 2 is piped to turn the actuator clockwise Output Port 1 is piped to turn the actuator counter clockwise Condition 2: Actuator fails in a counter clockwise direction.
3.3 Mounting Positioner on a Linear Actuator Step 1. Mount the magnet assembly to the stem of the actuator. A coupler block normally is needed to extend the magnet assembly outside the yoke area and into the sensing range of the magnetic pick-up unit. Step 2. Fasten the mounting bracket to the actuator. Step 3. Mount the positioner to the mounting bracket. The positioner should be mounted so the magnetic pick-up unit of the positioner is centered between the limits of the magnetic assembly’s stroke.
Figure 3-8 To Center the Positioner 1. Stroke the actuator to its upper limit and place a mark on the actuator’s yoke that lines up with the red arrow on the magnet assembly. 2. Stroke the actuator to its lower limit and place a mark on the actuator’s yoke that lines up with the red arrow on the magnet assembly. 3. Place a third mark on the yoke centered between the upper and lower limit marks. 4.
3.4 Mounting Remote Positioner on a Linear Actuator (Models 5215 & 5315) Step 1. Mount the magnet assembly and bracket to the actuator as described in Section 3.3 Step 1. Step 2. Mount the position sensor housing so that the conduit entry faces away from the diaphragm or cylinder. (See Figure 3-9) Figure 3-9 Note: For Fisher actuators model 657 & 667 sizes 34 thru 70, Westlock Controls supplies a slotted mounting kit design, to ease the mounting process.
Step 3. Mount positioner at a remote location, Step 4. Remove the electronic canister cover by unscrewing (2) mounting screws. (Appendix B: Procedure to Remove Electronics Cover and Electronic Canister) Step 5. If necessary cut remote cable to required length, making sure to cut end opposite female connector. Wire the positioner sensor back to the positioner using the cable provided and replace cover. (See Figure 3-10).
3.5 Pneumatic Connection Single Acting Actuator (Spring Return): For single acting actuators Outlet Port 2 is to be plugged. Outlet Port 1 is to be piped to the actuator inlet port that acts against the spring. (increasing set-point signal causes pressure to increase in Outlet Port 1 of the positioner). Double Acting Actuator (Double Return): For double acting actuators Outlet Port 2 is piped to drive the actuator towards the fail position.
3.6 Electrical Connection A) The certification applies to equipment without cable glands. When mounting the enclosure in the hazardous areas, only suitably certified cable glands and blanking elements must be used to maintain ingress protection of IP66. B) All unused cable entries must be plugged with suitably certified plugs that can maintain an ingress protection level of IP66.
Figure3-12 3.7 Setting of switches on a rotary ICoT 1. Operate the actuator to the desired extreme. 2. Loosen magnetic trigger bolt #1. (See Figure 3-13) 3. Slide trigger bolt #1 beneath the first switch and tighten with wrench. 4. Operate the actuator to the opposite extreme. 5. Loosen magnetic trigger bolt #2. 6. Slide trigger bolt #2 beneath the second switch and tighten with wrench.
4 Calibration The ICoT positioner has an on-board menu structure that can be accessed by pressing the Cal button. Exit any function by pressing both up and down arrow buttons simultaneously, anytime during calibration. 4.1 Enter Calibration (Menu Level) Enter the calibration menu by pushing the CAL button. ACAL (Auto Cal Menu) is the first of four menus. By pressing the CAL button again you enter go to a lower level menu or start a routine. Pushing the down arrow button you can cycle through the menus.
4.2 Automatic Calibration The Automatic Calibration (ACAL) performs several self-adjustments, as well as a zero calibration, a span calibration, and tunes the positioner’s PID gain settings. From the normal operation screen, press the CAL button until ACAL is shown on the display (the ACAL routine is shown to the right). Press and hold the CAL button until it starts the automatic calibration, of which the first step in the sequence is the Sensor Calibration.
4.3 Proceed to Exiting Calibration or Perform Advanced Calibration After the completion of an Automatic Calibration (ACAL) the calibration of the positioner is complete. The Automatic Calibration that was performed in Section 3 is adequate for most applications. If no advanced calibration is required proceed to Section 5 to exit calibration.
4.4 Exiting Calibration To exit calibration mode and return to normal operation use the up arrow key as follows: If the positioner is at Menu level in the calibration, as determined by LCD displaying a Menu name only (MCAL, etc.), press the up arrow key once to exit CAL mode. If the positioner is at function level in the calibration, as determined by LCD displaying a function and Menu name only (MCAL Lo, etc.), press the up arrow key once to enter the Menu level and once more to exit CAL mode.
4.6 Manual Override of Input Signal (Via On-Board Keypad) The positioner has a feature which allows the operator to override the analog set-point signal and change valve position from the keypad. This is done from the Stro (Manual Override-Stroke Menu). Enter calibration as described in section 4.1 and use the down arrow button to cycle to the Stro menu. Enter this menu and control the position of the valve as shown below. 4.
Menu 2: MCAL (Manual Calibration) Entering this menu allows you access to the following four calibration functions via the keypad: 1. -Lo- Low (Zero) Calibration 2. -Hi- High (Span) Calibration 3. -PID- Proportional, Integral and Derivative Gain Adjustment 4. -Snsr- Sensor Calibration 5. -Trnd- Transducer Calibration 6. -mA- Milliampere Calibration 7.
HI This function serves to set the fully energized (full travel) position of the actuator/valve. initially during this calibration the valve is driven to the fully energized (full travel) position (hard stop). The user will notice full pressure to Outlet Port 1 and zero pressure to Outlet Port 2. At this point the user has the option to select the hard stop as the high (span) position. or to select an arbitrary position as the high (span) position.
routine. The sensor calibration also shows up under the MCAL menu. This calibration only needs to be performed under the MCAL routine when the positioner is set-up on a new application and only if the ACAL routine is not performed. Trnd The purpose of this function is to calibrate the positioner’s pressure transducer. It should be performed only after a manual sensor calibration. -mA- This routine calibrates the positioner’s electronics to recognizing input current. This is done using 4.0 mA and 20.
OPSP This function allows for the setting of the opening speed of the actuator/valve. The range is 1 thru 5. Setting 5 is the fastest opening speed and setting 1 is the slowest opening speed. CLSP This function allows for the setting of the closing speed of the actuator/valve. The range is 1 thru 5. Setting 5 is the fastest closing speed and setting 1 is the slowest closing speed. Setting Approx.% Dynamic Speed 5 4 100% 80% 3 60% 2 40% 1 20% Setting Approx.
5 Trouble Shooting 5.1 Preliminary Checks Before operating the positioner check the following: 5.1.1. Voltage The positioner requires a 4-20 mA current source, with a minimum voltage of 9VDC at its terminals, over-current protected up to 35VDC. Current range: 3.2mA to 22mA, accordingly to the following table (NAMUR NE43): Loop Current [mA] 0.0 ≤ I < 3.2 3.2 ≤ I < 3.5 3.5 ≤ I < 3.8 3.8 ≤ I ≤ 20.5 I > 20.5 Electronics OFF ON ON ON ON Spool valve OFF OFF OFF ON ON HART comm OFF OFF ON ON ON 5.1.2.
Linear Positioner: The magnetic assembly supplied with the positioner should correspond to the stroke length and failure direction of the actuator. To make sure you have the appropriate magnet assembly, check the part. The stroke length and failure direction should be printed on the part. On the older ICoT the magnet assembly is not printed with this information, although there should be a serial number. Contact the factory with the serial number to verify that it is correctly matched to the actuator.
5.2.3. The positioner is properly set-up, and air is applied to the positioner. When powering up the positioner, the actuator goes into a state of constant oscillation. Check for air leaks and if assembly is tightly coupled: tubing, actuator, bracket, cables etc. The gain settings are probably too high for the actuator/valve assembly. If not done yet, perform a full automatic calibration (see section 4.7). If full auto cal has not given good results, perform a manual auto PID (see section 4.
6 Technical Specifications Input Remote Hall sensor: -40C to 125C (-40F to 257F) Set-point: 4-20 mA, two wire, Namur NE43 Normal Operation: 3.8≤ I ≤ 20.5 mA Fail Condition: I≤3.6 or I≥21.0 mA Minimum current w/o reset: 3.2mA Voltage: 9 to 35 VDC Over-current protection: < 70mA, 40VDC Impedance: 450 Ohms @ 20mA Pressure: 15 - 45 psi (Low) 40 - 120 psi (High) Instrumentation air quality must be according to ISA-7.
7 Error codes and LCD messages 7.1 Error codes that are backward compatible to previous versions of the ICoT positioner Err 3 (Error 3) Low Input Pressure Err 5 (Error 5) Integrator Overflow – Actual position does not match set-point Err 6 (Error 6) Calibration Error - Positioner could not successfully perform calibration ALR (Alert 3) Valve position is not being maintained within the dead-band range. The dead-band range (EDb) is set from the configuration menu during calibration (Section 4).
7.2 LCD error messages The ICoT positioner has built-in diagnostics that allow the user to identify and resolve most of the common installation and operation problems.
Message Meaning Solution Input pressure unstable Pressure was unstable during calibration Check: Pressure supply stability Actuator and tubing leaks Manifold and transducer assembly are tightly coupled to the enclosure and there are no leaks Check if the cable between the inner canister and the pneumatic transducer assembly is tightly connected Actuator/Valve assembly integrity Perform a full auto CAL Call factory for additional support HALL span too small Hall sensor used to read posit
Message Meaning Solution Comp range error An unknown error has occurred during calibration Check: Remove power for at least 1 minute and retry Remove power for at least 1 minute, perform a factory default (see Appendix I) and retry a full auto CAL Call factory for additional support Valve stuck Problems in the movement detection during calibration Check: Hall sensor connector and cable, especially if remote (see Figure 3-4, connector J8) Magnet assembly.
Message Meaning Solution PWM overflow During calibration an error occurred with the PWM signal that control the spool-valve driver and the position is not following the control signal Check: Hall sensor connector and cable, especially if remote (see Figure 3-4, connector J8) Magnet assembly is in correct position. o For rotary magnets check if it is not rotated 90 degrees (see figures 3.2, 3.3 and 3.4).
Meaning Solution Too few bytes received Message An unknown error has occurred during calibration Check: Remove power for at least 1 minute and retry Remove power for at least 1 minute, perform a factory default (see Appendix I) and retry a full auto CAL Call factory for additional support Current is not 12mA The current operation needs the loop current set to 12mA Check: Check if the loop current is set at 12mA Remove power for at least 1 minute and retry Recalibrate the loop current inp
Appendix A Procedure to Adjust the Error 3 Setting (or Low input pressure) Note: The error 3 message threshold is pre-set from the factory. For a low pressure positioner it is set to 15 psi and for a high pressure positioner it is set at 55 psi. If these settings come out of calibration or if it is necessary to change these settings, the following instructions can be followed. 1. Before adjusting the Error 3 threshold setting the positioner must be mounted and set-up. See section 3 of this manual. 2.
Appendix B Procedure to Remove Electronics Cover and Electronic Canister 1. Remove the two screws that secure the inner canister cover, unlock the latch by pulling it up and remove the canister cover (see figures below). 2. Disconnect all connectors from electronics canister; make sure to note connector locations. Remove the screw that secures canister housing and ground cable. Remove the screw that secures ground cable (see figures below). 3. Remove the canister with electronics from ICoT enclosure.
Appendix C Setting the Transmitter Output Fail current. The ICoT positioner conforms to Namur NE43 with an operating input current of 3.8 mA to 20.5 mA. Input currents between 3.2mA and 3.6mA and above 21.0 mA are considered outside the control range and are a current input failure. When the input current is out of range the LCD will display a Failure message and the transmitter output (if so equipped) will go to pre-determined current to indicate the failed state.
Appendix D Procedure to Check Transducer Operation This procedure should only be used for trouble shooting This procedure requires a 4-20mA current generator. 1. Mount the positioner and connect the pneumatics as described in section 3 of this manual. 2. Remove the cable that connects the inner canister to the pneumatic transducer assembly. The electronic canister does not need to be removed. 3. Locate Pin 2 & Pin 4 on transducer pin connector (see figure below). a. Ref.
Appendix E General Maintenance Standard Flow The positioner’s onboard filter should be replaced regularly or whenever it gets clogged. See diagram below for location of the filter. Note: the following instructions are for Standard Flow. For High Flow please contact the factory. Important: The positioner’s onboard filter is not a substitute for normal instrument air preparation. Supply air to the positioner should conform to ISA Standard S7.3 - Quality for Instrument Air.
polyester lint free clean room swab is recommended. These items can be obtained from most industrial supply companies or catalogs. Important: do not use an abrasive cleaner on the spool or sleeve. Never buff the spool or sleeve or use crocus cloth, and never attempt to remove the sharp edges from the spool lands. These practices will permanently damage the spool assembly and will affect the fit and action of the spool sleeve assembly.
Appendix F Grounding Schematic WESTLOCK CONTROLS CORPORATION 280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913 www.westlockcontrols.com 1/12/10 TECH-439/D.W.O.
Appendix G Control Schematic for Wiring of Intrinsically safe ICoT for ATEX & IECEX (Sheet 1 of 2) Entity parameters for each field wiring terminal pair of ICoT: Vmax = 30V Imax = 100mA Pi=0.75 Watt Ci = 0 pF Li = 17.25 uH 1. ATEX Entity approved associated apparatus used in an approved configuration, such that: A. ICoT Vmax Voc and Vt of associated apparatus. B. ICoT Imax Isc and It of associated apparatus. C. Ci of ICoT cable capacitance Ca of associated apparatus. 2.
Control Schematic for Wiring of Intrinsically safe ICoT for ATEX & IECEX (Sheet 2 of 2) Entity parameters for each field wiring terminal pair of ICoT: Vmax = 30V Imax = 100mA Pi=0.75 Watt Ci = 0 pF Li = 17.25 uH ATEX Notes: 1. Barrier must be a ATEX certified, single channel grounded shunt-diode zener barrier or single channel isolating barrier or one dual channel or two single channel barriers may be used where both channels have been certified for use together with combined entity parameters.
Appendix H Control Schematic for Wiring of Intrinsically safe ICoT (WD-10836) for US & CANADA (Sheet 1 of 4) Entity parameters for each field wiring terminal pair of ICoT: Vmax = 30V Imax = 100mA Pi=0.75 Watt Ci = 0 pF Li = 17.25 uH 1. FMRC Entity approved associated apparatus used in an approved configuration, such that: A. ICoT Vmax Voc and Vt of associated apparatus. B. ICoT Imax Isc and It of associated apparatus. C.
Control Schematic for Wiring of Intrinsically safe ICoT (WD-10836) for US & CANADA (Sheet 2 of 4) 1. Associated apparatus manufacturer’s installation drawing must be followed when installing this equipment. 2. Control equipment connected to associated apparatus must not use or generate more than 250V. 3. To maintain intrinsic safety, each field wiring pair (4-20 mA and Analog Output) must be run in separate cables or separate shields connected to intrinsically safe (Associated Apparatus) ground. 4.
Control Schematic for Wiring of Intrinsically safe ICoT (WD-10836) for US & CANADA (Sheet 3 of 4) 1. Associated apparatus manufacturer’s installation drawing must be followed when installing this equipment. 2. Control equipment connected to associated apparatus must not use or generate more than 250V. 3. To maintain intrinsic safety, each field wiring pair (4-20 mA and Analog Output) must be run in separate cables or separate shields connected to intrinsically safe (Associated Apparatus) ground. 4.
Control Schematic for Wiring of Intrinsically safe ICoT (WD-10836) for US & CANADA (Sheet 4 of 4) Entity parameters for each field wiring terminal pair of ICoT: Vmax = 30V Imax = 100mA Pi=0.75 Watt Ci = 0 pF Li = 17.25 uH CSA Notes: 1. Barrier must be a CSA certified, single channel grounded shunt-diode zener barrier or single channel isolating barrier or one dual channel or two single channel barriers may be used where both channels have been certified for use together with combined entity parameters.
Appendix I Procedure to Reset the Non-Volatile Memory to Factory Settings The ICoT positioner is a digital device. Its operation relies on data that is stored in the positioner’s non-volatile memory. Calibration and configuration data that has been established during the positioner’s calibration is stored in this memory. Under abnormal conditions this stored information can become corrupted. If this occurs it is necessary to reset the memory and re-calibrate the positioner. 1.
Appendix J HART® Communicator Menu Flow Chart WESTLOCK CONTROLS CORPORATION 280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913 www.westlockcontrols.com 1/12/10 TECH-439/D.W.O.
Appendix K DD and DTM for configuration and control system integration The ICoT positioner can be fully integrated into most of the configuration tools, control systems and asset management systems in the market. Westlock Controls provides DD files and DTM for this integration. DD files can be downloaded from: http://www.hartcommproduct.com/inventory2/index.php?action=viewprod&num=928 FDT certified DTM, compatible with FDT 1.2, contact Westlock Controls: http://www.westlockcontrols.
