ICoT 5000 Smart Valve Positioner Operating Manual Westlock Controls Limited 22 Chapman Way Royal Tunbridge Wells, Kent TN2 3EF England Phone:+44 (0) 1892-516277 Fax: +44 (0) 1892-516279 10/31/02 Westlock Controls Corporation 280 Midland Avenue Saddle Brook, NJ 07663 Phone: 201-794-7650 Fax: 201-794-0913 Tech-304/DWO 14195 Westlock Equipamentos de Controle Ltda.
Table of Contents Section 1 - Introduction Page 1.1 Description of ICoT.......................................................................................... 1.2 Principal of Operation....................................................................................... 1.3 Special Features................................................................................................ 3 4 5-7 Section 2 - Ordering 2.1 ICoT 5000 Positioner Ordering Guide...............................................
Section 1- Introduction 1.1 Description of ICoT Positioner The ICoT Smart Valve Positioner is an electro-pneumatic servo system that continuously controls the position of a valve based on a 4 to 20 mA input signal. The ICoT is an instrument that derives its power directly from a control systems current loop. The instrument senses valve position via a non-contact Hall effect sensor and controls valve position through a current to pressure transducer.
1.2 Principal 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.
1.3 Special Features NON-CONTACT POSITION FEEDBACK 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 non-contacting means based upon characterization of flux strength as a function of position.
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) from the device it is controlling. In the event the control valve is located in either a high vibration or extremely corrosive environment, the non-contact position feedback feature allows for isolated placement of the positioner.
Negligible Bleed Designed to consume the least possible amount of control air at steady state, the ICoT 5000 Series positioner can greatly reduce the air consumption of your process and reduce the demand on instrument air compressors. To increase reliability, the ICoT employs a patented lapped spool and floating sleeve design. This balanced construction relies on an air bearing which eliminates any metal to metal contact.
Section 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.
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 4235 & 4335) 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, wire the positioner sensor back to the positioner using the cable provided (See Figure 3-4).
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. Full Stroke ICoT Assembly Housing Centerline of Magnetic Pick-Up Unit (Position Sensor) Stroke/2 Lower Limit of Travel Upper Limit of Travel 1/16” Magnet Assembly Location of Centerline Step 3.
Magnet Assembly at Upper Limit of Travel Actuator Yoke Upper Limit of Travel Mark Midpoint of Travel Mark ICoT Lower Limit of Travel Mark Magnet Assembly at Lower Limit of Travel Figure 3-6 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.
3.4 Mounting Remote Positioner on a Linear Actuator (Models 4215 & 4315) 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.
Step 2. Mount positioner at a remote location, wire the positioner sensor back to the positioner using the cable provided (See Figure 3-8).
3.5 Pneumatic Connection MOUNTING INSTRUCTIONS 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 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 Slide Off Terminal Strip from Keypad assembly 1. Remove positioner cover. 2. Locate terminal strip and carefully disconnect (slide off). 3. Connect the 4 to 20 mA loop signal to terminal points marked (+) and (-). See figure 3-10 for a wiring schematic. 4. If the positioner was ordered with an analog output, connect output wiring to terminal points 5 & 6, (Polarities Shown Below). The 4 to 20mA analog output requires an external 24 volt DC power supply. 5.
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 3-12) 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.
Section 4 - Calibration The ICoT positioner has an on-board help menu that can be accessed by pressing the Cal button and either arrow button simultaneously, anytime during calibration. 4.1 Enter Calibration (Menu Level) Enter the calibration routine by pressing and holding the CAL button. Continue to hold the CAL button until ACAL appears on the LCD. ACAL (Auto Cal Menu) is the first of four menus. By pressing the down arrow button you can cycle through the four menus.
4.3 Automatic Calibration The Automatic Calibration (ACAL) performs several self-adjustments, as well as a zero calibration, a span calibration, and tunes the positioners PID gain settings. Enter and start the Automatic Calibration from the Menu level. From the menu level press the down arrow button until ACAL is shown on the display (ACAL Routine Shown Below). Up Arrow (Exit Calibration) Down Arrow (From Previous Menu) Down Arrow (To Next Menu) ACAL Set 12mA Press CAL Key Auto Calibrate 1.
4.5 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.
4.7 Description of Menu’s The calibration functions of the positioner is organized into the following four menus: Menus • Menu 1: ACAL (Automatic Calibration) • Menu 2: MCAL (Manual Calibration) • Menu 3: Cofg (Configuration) • Menu 4: Stro (Manual Override of Input Signal) Menu desciptions are as follows: Menu 1: ACAL (Automatic Calibration) Entering this menu allows you to initiate an approximately seven minute self-calibration function.
Menu 3: Cofg (Configuration) Entering this menu allows you access to the following five configuration functions via the keypad: 1. -Flow- Positioner Output Flow Characteristics 2. -Type- Positioner Recognition of Magnetic Feedback, Rotary or Linear 3. -Flop- Positioner Fail Position, Open or Closed 4. -OPSP- Positioner Opening Speed Adjustment 5. -CLSP- Positioner Opening Speed Adjustment These functions allow display, speed and valve characteristic changes from standard factory settings.
PID The PID function allows the user to enter or change the PID settings of the positioner. This function is most often used to fine tune the PID values obtained from the automatic calibration function (ACAL). This function will allow the user to optimize the dynamic response of the positioner with respect to speed of response, overshoot and percent error by varying the appropriate gain settings.The Proportional (PCAL) and Derivative (DCAL) gain settings can be varied incrementally on a scale from 1-20.
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. Setting CLSP Approx.% Dynamic Speed 5 4 100% 80% 3 60% 2 40% 1 20% 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.
Section 5 - Trouble Shooting 5.1 Preliminary Checks Before operating the positioner check the following: 1. Voltage The positioner requires a 24 volt DC (nominal), 4-20 mA current loop. 2. Electrical Connection Check the polarity of the 4-20 mA current loop. The ICoT terminal strip visually designates the positive and negative terminal points for connection with a “+” and “-”, respectively. 3.
5. Supply Pressure The supply pressure should be regulated appropriately with regard to the actuator. If there is question as to the proper supply pressure, the actuator manufacturer should be contacted. 6. Positioner Pressure Rating If the supply pressure is above 40 PSI a high pressure ICoT positioner must be used. If the supply pressure is below 40 PSI a low pressure ICoT positioner must be used. (See Ordering Guide - Section 2.1) 5.
Section 6 - Specifications Hazardous Rating: Input Signal: Voltage: Pressure: 4 to 20 mA, two wire 12.3 Volts DC 15 - 45 psi (Low) 40 - 120 psi: (High) Intrinsically Safe Class I, Division 1, Groups A,B,C,D Class II, Division 1, Groups E,F,G Class III, Division 1 Output Flow Rate: 8.0 scfm @ 25 psi (Low) 16.2 scfm @ 90 psi (High) Pressure: 0 to 45 psi (Low) 0 to 120 psi (High) Actuator: Single Acting or Double Acting Technical Resolution: .2% Full Travel Linearity: .
Section 7 - Error Codes Err 3 (Error 3) Low Input Pressure or Clogged Filter Err 5 (Error 5) Intergrator Overflow - Position of actuator does not match setpoint of positioner Err 6 (Error 6) Calibration Error - Positioner could not successfully perform calibration ALR (Alert 3) Valve position is not being maintained within the deadband range. The deadband range (EDb) is set from the configuration menu during calibration (Section 4).
Appendix A Procedure to Adjust the Error 3 Setting Note: The error 3 message 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 setting the positioner must be mounted and set-up. See section 3 of this manual. 2.
Appendix B Procedure to Remove Display Board and Electronic Canister 1. Remove the three screws that fasten the display board. (See Figure Below). 2. Gently pull up the display board disconnecting the board from the 30-pin connector on the upper right corner of the display board. 3. Gently remove the transducer pin connector. Be careful not to pull any of the wires out of the connector. 4. Gently remove the hall effect sensor pin connector. Be careful not to pull any of the wires out of the connector. 5.
Appendix C Procedure to Check Transducer Operation (This procedure should only be used for trouble shooting) 1. Mount the positioner and connect the pneumatics as described in section 3 of this man- ual. 2. Remove the Display Board as described in Appendix B of this manual. The electronic canister does not need to be removed. 3. Locate Pin 2 & Pin 4 on transducer pin connector. (See Figure Below) Ref.: Pin 1 is furthest from the pressure gages, Pin 10 is nearest to the to the pressure gages. 4.
Appendix D Grounding Schematic { TO HPORT MUX (HART INTERFACE) PLC OR DCS 4-20 mA OUTPUT 1 2 2 TWISTED SHIELDED PAIR + - ICOT SMART POSITIONER + - SHLD 3 SHIELD SHOULD BE CONNECTED TO THE SHIELD TERMINATION POINT OF THE OUTPUT MODULE OR TO THE POWER SUPPLY GROUND 1 CONNECTION FROM DCS OR PLC TO POSITIONER IS 20 GAUGE SHIELDED TWISTED PAIR (BELDEN 8762 OR EQUIVALENT). MAXIMUM DISTANCE IS 5000 FEET.
Appendix E Control Schematic for Wiring of Intrinsically safe ICoT (WD-10836) (Sheet 1 of 4) NONHAZARDOUS LOCATION HAZARDOUS LOCATION CLASS I, DIV 1, GROUPS A,B,C,D CLASS II, DIV 1, GROUPS E,F,G CLASS III, DIV 1 ROSEMOUNT® 275 HART® COMMUNICATOR-NOTES 3,6 & 9 ASSOCIATED APPARATUS (INTRINSIC SAFETY BARRIERS) NOTES 1 & 2 ICoT SERIES POSITIONER 4-20mA CONTROL EQUIPMENT NOTE 4 NOTE 5 JP5 ANALOG OUTPUT REMOTE HALL EFFECT SENSOR (OPTIONAL) No. 5 IN 4TH DIGIT OF PART NUMBER. 50 FT MAX.
Appendix E Control Schematic for Wiring of Intrinsically safe ICoT (WD-10836) (Sheet of 2 of 4) NONHAZARDOUS LOCATION HAZARDOUS LOCATION CLASS I, DIV 1, GROUPS A,B,C,D CLASS II, DIV 1, GROUPS E,F,G CLASS III, DIV 1 ROSEMOUNT 275 HART COMMUNICATOR-NOTE 4 ICoT SERIES POSITIONER ASSOCIATED APPARATUS (INTRINSIC SAFETY BARRIERS) MTL MODEL 707 OR 787S NOTE 1 MTL MODEL 7087 USED FOR DIGITAL ON/OFF IN RTS 3 1 4 2 3 1 4 2 4 1 5 2 4 1 5 2 4-20mA CONTROL EQUIPMENT NOTE 2 NOTE 3 ANALOG OUTPUT {
Appendix E Control Schematic for Wiring of Intrinsically safe ICoT (WD-10836) (Sheet of 3 of 4) NONHAZARDOUS LOCATION HAZARDOUS LOCATION CLASS I, DIV 1, GROUPS A,B,C,D CLASS II, DIV 1, GROUPS E,F,G CLASS III, DIV 1 ROSEMOUNT 275 HART COMMUNICATOR-NOTE 4 ICoT SERIES POSITIONER ASSOCIATED APPARATUS (INTRINSIC SAFETY BARRIERS) MTL MODEL 3045 NOTE 1 MTL MODEL 7087 FOR DIGITAL ON/OFF INPUTS 3 1 4 2 3 1 4 2 4 1 5 2 4 1 5 2 4-20mA CONTROL EQUIPMENT NOTE 2 NOTE 3 ANALOG OUTPUT { MAGNUM SWIT
Appendix E Control Schematic for Wiring of Intrinsically safe ICoT (WD-10836) (Sheet of 4 of 4) NONHAZARDOUS LOCATION HAZARDOUS LOCATION CLASS I, DIV 1, GROUPS A,B,C,D CLASS II, DIV 1, GROUPS E,F,G CLASS III, DIV 1 ASSOCIATED APPARATUS (INTRINSIC SAFETY BARRIERS) NOTES 1 & 2 ICoT SERIES POSITIONER 4-20mA CONTROL EQUIPMENT NOTE 4 NOTE 5 ANALOG OUTPUT Entity parameters for each field wiring terminal pair of ICoT: Vmax = 30V Ci = 120 pF Imax = 100mA Li = OmH CSA Notes: 1.
Appendix F Procedure to Reset the EEprom to Factory Settings The ICoT Positioner is a digital device. Positioner operation relies on data that is stored in the positioner’s EEprom chip. Calibration and configuration data that has been established during the positioner’s calibration is stored in the EEprom. Under abnormal conditions this stored information can become corrupted. If this occurs it is necessary to reset the chip and re-calibrate the positioner. 1.) Remove power to the positioner.
Appendix G Hart® Communicator Menu Flow Chart 10/31/02 Tech-304/DWO 14195 Page 39 of 39
