User’s Manual YVP Management Software ValveNavi IM 21B04C50-01E IM 21B04C50-01E Yokogawa Electric Corporation 5th Edition
Toc-1 YVP Management software ValveNavi IM 21B04C50-01E 5th Edition CONTENTS 1. 2. INTRODUCTION ...................................................................................... 1-1 1.1 About This Manual .......................................................................................... 1-1 1.2 Software License Agreement ......................................................................... 1-2 1.3 About This Software ...............................................
Toc-2 5. FOUNDATION FIELDBUS OVERVIEW .................................................... 5-1 5.1 6. 7. Reference Model Process Used in This User’s Manual ................................. 5-1 5.1.1 P & I D .............................................................................................. 5-2 5.1.2 Function block links ........................................................................... 5-3 5.2 Device Operational States and Block Modes .......................
Toc-3 7.3 8. 9. 7.2.4 Other Status ..................................................................................... 7-7 7.2.5 Temperature, Pressure, and I/P Graphs ............................................ 7-8 Companion Device .......................................................................................... 7-8 SETUP WIZARD ...................................................................................... 8-1 8.1 Introduction to Setup Wizard ................
Toc-4 10. CALIBRATION SERVICES .................................................................... 10-1 10.1 10.2 10.3 10.4 11. Calibration - Range ....................................................................................... 10-1 10.1.1 Find Range Result .......................................................................... 10-2 10.1.2 GO ................................................................................................. 10-2 10.1.
Toc-5 14.3.6 Signature Selection ...................................................................... 14-22 14.3.7 Signature Setting .......................................................................... 14-23 14.3.8 Signature Measurement ............................................................... 14-24 14.3.9 Signature Graphs ......................................................................... 14-25 14.3.10 Graph Scale Setup ......................................
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1. 1-1 <1. INTRODUCTION> INTRODUCTION This User’s Manual gives instructions on handling of YVP Management Software “ValveNavi”(Model: YVP20S). This software is to be used to setup the YVP110 advanced valve positioner; therefore, it is indispensable for users to read, understand and follow the instructions on the YVP110 user’s manual (IM 21B04C01-01E) BEFORE actually starting the operation.
1.2 <1. INTRODUCTION> 1-2 Software License Agreement Following is the software License Agreement which should be agreed by users before start using the software. The agreement will be shown when you install the software. Yokogawa Electric Corporation Software License Agreement This is a legal agreement between you and Yokogawa Electric Corporation. By selecting Accept or by using the software, you agree to be bound by the terms of this agreement.
1.3 1-3 <1. INTRODUCTION> About This Software This software is intended for use only with Yokogawa YVP positioners. The positioners are intended for use with industrial compressed air systems only. Ensure that an adequate pressure relief provision is installed if application of system supply pressure could cause downstream equipment to malfunction. Installation should be in accordance with local and national compressed air and instrumentation codes.
<1. INTRODUCTION> 1-4 IMPORTANT indicates a potentially hazardous situation which, if not avoided, may result in damage to the instrument or a system failure. NOTE Indicates important facts and conditions. 1.5 Trademarks, Copyrights, and Patents YOKOGAWA and YVP are registered trademarks of Yokogawa Electric Corporation. HART is a registered trademark of the HART Communications Foundation. Pentium is a trademark of Intel Corporation.
2-1 <2. INTRODUCTION TO ValveNavi AND TO YVP> 2. INTRODUCTION TO ValveNavi 2.1 What is ValveNavi? ValveNavi is a Windows software tool that makes it easy to configure, calibrate, and operate Foundation fieldbus pneumatic control valve positioners YVP110 with internal process control and limit switches. It fully supports the Foundation fieldbus specifications. 2.2 ValveNavi Specifications Table 2.1 ValveNavi Specifications Product name YVP Management Software (R2.
2.4 2-2 <2. INTRODUCTION TO ValveNavi AND TO YVP> What is FOUNDATION® Fieldbus? The Fieldbus Foundation summarizes the technology: FOUNDATION fieldbus is an all-digital, serial, two-way communications system that serves as a Local Area Network (LAN) for factory/plant instrumentation and control devices. The fieldbus environment is the base level group of the digital networks in the hierarchy of plant networks.
2-3 <2. INTRODUCTION TO ValveNavi AND TO YVP> ● Reduced Wiring and Installation Costs FOUNDATION fieldbus’ use of existing wiring and multi-drop connections provides significant savings in network installation costs. This includes reductions in intrinsic safety barrier termination and cable costs, particularly in areas where wiring is already in place.
3-1 <3. INSTALLATION OF HARDWARE AND SOFTWARE> 3. INSTALLATION OF HARDWARE AND SOFTWARE 3.1 What you need to get started with ValveNavi To begin using ValveNavi the following tools and software are needed. • ValveNavi software on its installation CD-ROM • A PC running Windows 2000 service pack 4 , XP service pack 2, or Vista service pack 1 • National Instruments AT-FBUS, PCI-FBUS or PCMCIA-FBUS interface card and NIFBUS software V. 3.0 or later, for Vista V. 3.2.
3.2 <3. INSTALLATION OF HARDWARE AND SOFTWARE> 3-2 Reference Model Process Throughout this manual we will use a simplified Fieldbus Reference Model Process. This is an example of a simple process (It is not a practical process) that illustrates many elements of Foundation fieldbus that are required in a successful installation. Figure 3.
3.2.1 <3. INSTALLATION OF HARDWARE AND SOFTWARE> 3-3 Wiring requirements Note that there are cable requirements that must be met for reliable installations. The cable used must support the digital data signals without reflections, noise or attenuation. The type A cable should be used whenever possible and especially for long transmission distances or for segments with many branches (spurs). ● Power conditioner Use a power conditioner for each segment.
3.3 3-4 <3. INSTALLATION OF HARDWARE AND SOFTWARE> Installing NI-FBUS ValveNavi software interfaces to the fieldbus segment through an interface card that must be installed in the PC running ValveNavi. The card is supplied with NI-FBUS installation software. ValveNavi is designed to operate only with National Instruments NI-FBUS cards, which are AT-FBUS, PCI-FBUS, or PCMCIA-FBUS.
<3. INSTALLATION OF HARDWARE AND SOFTWARE> 3-5 ● Configuring the interface card to safely connect to the Foundation fieldbus segment with a host computer If the YVP positioner is connected on a segment that has a host computer, the interface card and PC must be configured as a BASIC DEVICE at a Visitor address. Open the configuration utility (NI-FBUS Interface Configuration Utility) and follow the instructions in the NI manual.
3-6 <3. INSTALLATION OF HARDWARE AND SOFTWARE> ● Configure the interface card for one to one Communication The visitor configuration described previously will not work if the only devices that are connected to the segment are YVP positioner and the NI-FBUS interface card, because there will be no link master to schedule messages. It is necessary, therefore, to configure the interface card as a link master, exactly as shown in Figure 3.3.
3.3.3 3-7 <3. INSTALLATION OF HARDWARE AND SOFTWARE> Location of DD files and .DCT file After the DDs have been successfully installed, they will appear in the installation subdirectory of NI-FBUS. The form of the directory tree will be as shown in Table 3.2. Table 3.2 NI-FBUS Installation Subdirectory Structure NIFBUS (or other install directory name) Data 594543 (YOKOGAWA's ID) 0001 (for YVP110 without software download function) 02nn.ffo* 02nn.sym 03nn.ffo 03nn.sym 04nn.ffo 04nn.
4. 4-1 <4. ValveNavi ADMINISTRATION> ValveNavi ADMINISTRATION In the previous chapter, we described the installation of the Foundation fieldbus communications software and hardware. In this chapter, we will describe the procedures for installing ValveNavi software. The ValveNavi installation procedures outlined in this chapter assume a working knowledge of Microsoft Windows, the Yokogawa YVP positioner, and of Foundation fieldbus communications and function block technology.
4.3 <4. ValveNavi ADMINISTRATION> 4-2 Trial Period To start up ValveNavi, double-click the ValveNavi icon generated on the desktop. This will open the Registration screen. Type your name and company name there. ValveNavi can be used for 60 days without entering the serial number after installation on a PC. If you are not a licensed user, leave the serial number box blank, then press OK.
4.4 4-3 <4. ValveNavi ADMINISTRATION> Licensed User Process Permanent use of this software requires a license for each computer on which it will be used. If you purchased a licensed copy of ValveNavi, you will have received a CD-ROM with a serial number. DO NOT LOSE THIS SERIAL NUMBER. KEEP IT IN A SECURE LOCATION. To start using ValveNavi as a licensed user, in the required information in the Installation dialog (Figure 4.
4.5 <4. ValveNavi ADMINISTRATION> 4-4 Logging on with Registration Once you complete the registration of the software, you will enter from the logon screen as shown in Figure 4.4. Figure 4.
4.6 4.6.1 <4. ValveNavi ADMINISTRATION> 4-5 Setting Up User Accounts System Administration, Passwords, and Privilege Levels In a plant with many users with various levels of training and responsibility, it is often desirable to restrict certain users access to a limited range of functions. Starting the ValveNavi program requires a valid account with a user name and a password for each user.
4-6 <4. ValveNavi ADMINISTRATION> The program already contains two accounts. • The first account is the administrator account, which you are using, with the logon name “Admin” (note that this is case sensitive with a capital A) and the initial password is blank (no password). Immediately use the administration program to install a password for administration to make the system secure from unauthorized use.
4-7 <4. ValveNavi ADMINISTRATION> Level 4 Allows the user to perform all operations except Download Configuration to YVP. Level 5 This level is not defined. Level 6 This level is not defined. Level 7 This level is not defined. Level 8 This level is intended for training and should be used cautiously. It grants all of the privileges of level 4 plus allows access to the Simulation State of the process controller.
4.7 <4. ValveNavi ADMINISTRATION> 4-8 Finish ValveNavi To finish ValveNavi, select Exit from File Menu. Clicking Yes to the Confirmation message will finish ValveNavi. Figure 4.
5. 5-1 <5. FOUNDATION FIELDBUS OVERVIEW> FOUNDATION FIELDBUS OVERVIEW This chapter will introduce concepts that are used in most parts of the manual. It will briefly introduce Foundation Fieldbus blocks, and some of the essential block concepts. Throughout the manual we will reference a simple process example. The example is a simple heat exchanger with two control valves, and three measurement devices.
5.1.1 5-2 <5. FOUNDATION FIELDBUS OVERVIEW> P&ID Figure 5.2 Piping and Instrumentation Diagram The piping and instrument diagram (Figure 5.2) shows, in schematic form, the physical devices and indicates the measurement and control functions that reside in each device. The coolant flow transmitter, FT 102, has only a transmitter function, but the coolant flow control valve, FV 101, has a PID control, two limit switches (DI blocks) and an AO block all located in the YVP valve positioner.
5.1.2 <5. FOUNDATION FIELDBUS OVERVIEW> 5-3 Function block links Each of the control functions is represented in the Control configuration as Foundation fieldbus Function Blocks. All the blocks in the temperature cascade are shown in Figure 5.3. They are grouped according to the physical device containing them, and they are shown with the links between the blocks (“soft wiring” connections) for data flow. Similarly, the level loop function blocks are shown in Figure 5.4. Figure 5.
<5. FOUNDATION FIELDBUS OVERVIEW> 5-4 Finally, to complete the model, ValveNavi is shown, in Figure 5.5, temporarily connected to the heat exchanger’s Foundation fieldbus wiring at an intermediate point. The Heat Exchanger Reference Model segment consists of a Heat Exchanger Host in a control center with a Foundation fieldbus trunk running to two junction boxes. One junction box has spurs to the flow and temperature control devices and the other connects to the devices controlling tank level.
5.2 5-5 <5. FOUNDATION FIELDBUS OVERVIEW> Device Operational States and Block Modes Figure 5.6 Device Operation State in Pop-up Menu The Operation State can be accessed several ways. From the Device Selection frame, right click the desired device to pop up a menu list and select Device Operation State. In the tool bar click the Device Operation State icon. Or choose Tools>Device operation State from the Menu bar.
<5. FOUNDATION FIELDBUS OVERVIEW> 5-6 ValveNavi manages the operational states of the positioner and its embedded PID controller by controlling the target modes for each of the function blocks. The actual mode of each block may be different from the target mode. The actual mode is controlled by the block itself in accordance with mode rules based on the quality of the data and modes of the linked blocks.
5.3 <5. FOUNDATION FIELDBUS OVERVIEW> 5-7 Block Modes All blocks (function/transducer/resource) have operating modes. There are eight modes defined in the Foundation fieldbus specification. Not all modes are supported by every block. For example, the Discrete Input (DI) block supports just Auto, Man, and OOS. The action of the modes are described in the following paragraphs.
5-8 <5. FOUNDATION FIELDBUS OVERVIEW> (8) Out of Service (OOS) The block is not being evaluated. The output and setpoint are maintained at last value. (9) Multiple Modes and States The AO block must go to CAS mode to connect to a PID function block in cascade. To stop the setpoint signal from the AO to the transducer block, the AO block must go into OOS mode. The following, Table 5.2, shows examples of mode operation (not showing all cases). Table 5.
5.4 5-9 <5. FOUNDATION FIELDBUS OVERVIEW> Examples of IVI Operational States Examples of operational states that are combinations of block modes are shown in the following figures. A new device or a newly configured device may start up in the out of service (OOS) state shown in Figure 5.8. Figure 5.8 Out of service at startup To transfer to the manual state which allows ValveNavi to adjust the valve position, click the Operating State icon and select Manual.
<5. FOUNDATION FIELDBUS OVERVIEW> 5-10 When the positioner has been placed in normal, it waits for the PID block to begin to send it a setpoint. It will remain in auto mode at the current valve position. When this condition exists, it is necessary to place the PID block in its normal mode. Figure 5.
<5. FOUNDATION FIELDBUS OVERVIEW> 5-11 When the positioner is receiving its position setpoint from a remote computer system such as a DCS then the normal state for the positioner will be as shown in Figure 5.12. In this example the level control valve LV201 is receiving its signal from a DCS. The AO block is shown in RCas mode. Figure 5.
5.5 <5. FOUNDATION FIELDBUS OVERVIEW> 5-12 Changing Operational States The Foundation fieldbus Application process specifies the mode handling for interoperable function blocks. It also specifies which mode a block must be in when each parameter is written. ValveNavi provides an intelligent, optimized process for managing configuration and calibration changes. For efficiency, it does not place blocks into Out Of Service mode unless the parameter requires OOS.
6. <6. QUICK TOUR OF ValveNavi> 6-1 QUICK TOUR OF ValveNavi In the quick tour we will briefly introduce each of the tools provided by ValveNavi. The chapters that describe the tools in details follow the quick tour. 6.1 Introduction ValveNavi uses an integrated valve interface, IVI, to display all valve and positioner variables and to provide access to services, such as configuration and calibration tools. The information and controls for services are arranged in frames within IVI.
6.2 <6. QUICK TOUR OF ValveNavi> 6-2 Fieldbus Device Tree All of the devices on the bus segment live list are shown as icons in the Device Selection box. Figure 6.2 Device Tree Click on the YVP device to open a communications session with the positioner. The fieldbus segment live list is continuously scanned and devices are shown when present. Devices that have communications failure are shown with a red X. The selected device is shown with a red check-mark.
6.3 6-3 <6. QUICK TOUR OF ValveNavi> Menu Bar and Tool Bar The IVI offers tools and wizards using standard Windows conventions, offering multiple paths to functions to suit a user’s preferences. Use the menu bar, the tool bar icons, or popup menus in the Device Selection frame. When the cursor is moved over an icon a Tool Tip appears to identify the icon’s purpose. 6.3.1 Menu items Pull down menus are listed below and shown in Figure 6.3. Figure 6.
6.4 6-4 <6. QUICK TOUR OF ValveNavi> Control Valve Faceplate The control valve faceplate frame encloses displays and controls for working with the positioner. Figure 6.4 IVI Positioner Faceplate Frame Figure 6.4 shows an example of the control valve faceplate frame in the IVI. The positioner’s tag is shown in the PD-Tag field. The current operating state of the positioner is shown in the Operation control button displaying, in this example, “NORMAL STATE.
6.5 <6. QUICK TOUR OF ValveNavi> 6-5 Companion Device Display Frame This Companion Device frame displays and updates real time values for transducer block mode, target position, and valve position. It is used to observe summary information from a second positioner connected in the same segment as the selected device. Figure 6.5 IVI Companion Device Frame 6.6 Status Frame Below the position bar display, the Status Frame displays Analog Output (AO) block and PID block Scheduling status.
6.7 6-6 <6. QUICK TOUR OF ValveNavi> Accessing Services in ValveNavi Services in ValveNavi are accessed by three methods that are standard Windows techniques. • By the Tools menu, after a device has been selected and opened, or • By the toolbar icon, after a device has been selected and opened, or • From the Device tree with a popup menu, by right clicking on the desired device.
6.8 <6. QUICK TOUR OF ValveNavi> 6-7 Setup Wizard This setup wizard provides, in a single tool, all the services for setting up a basic positioner. It includes a sequence for basic configuration and basic tuning. It is most useful for first time setup of the positioner. Follow the step-by-step instructions to quickly complete the basic setup and start running the valve. Figure 6.
6.8.1 <6. QUICK TOUR OF ValveNavi> 6-8 Actuator Wizard This is the setup page in the setup wizard to configure the valve actuator information contained in Transducer (TB) block. For a description of the parameters, refer to Actuator in the Configuration window. Figure 6.
6.8.2 <6. QUICK TOUR OF ValveNavi> 6-9 Tuning Wizard This tuning step in wizard allows the user to execute the combination of Search Stops and Auto Tune described in Tuning in Calibration. WARNING Tuning will stroke the valve over its entire travel. Isolate the valve from the process prior to the calibration. Figure 6.
6.8.3 <6. QUICK TOUR OF ValveNavi> 6-10 Travel Calibration Wizard This travel calibration page in the setup wizard allows the user to calibrate the 0%, 50%, or 100% position points, when necessary. For a description of all the parameters and controls, refer to Travel calibration. Figure 6.
6.8.4 <6. QUICK TOUR OF ValveNavi> 6-11 Position Control Limits - Wizard This position control limits page in the setup wizard allows the user to change the position limit setting for the valve position configuration parameters in TB block. For a description of all the parameters, refer to Position in Configuration window. Figure 6.
6.8.5 <6. QUICK TOUR OF ValveNavi> 6-12 Finish - Setup Wizard This is the final screen of the Setup Wizard that indicates that the basic setup is valid and that provides a choice of Device Operation State before completing this setup. The Wizard is not completed until the Finish button is pressed. Figure 6.
6.9 <6. QUICK TOUR OF ValveNavi> 6-13 Configuration Services This page of the general configuration of the device includes Device Info, Block Tag Info, and device installation options. Figure 6.
<6. QUICK TOUR OF ValveNavi> 6-14 6.10 Calibration Services The calibration page has a tab for adjusting the positioner to the actual stroke (range) of the valve, and for autotuning the position control algorithm. It also has a travel calibration service that provides for making further adjustments to the valve stroke. The advanced tab provides access to non-linear factors used to optimize dynamic performance. Figure 6.
<6. QUICK TOUR OF ValveNavi> 6-15 6.11 Diagnostic Services The diagnostic page provides controls to perform the actuator and positioner signature test procedures. It also displays the continuous diagnostic data that is an accumulation of valve service. Figure 6.
<6. QUICK TOUR OF ValveNavi> 6-16 6.12 Operation State The Operation State Dialog controls switching between the block modes. Three types of the state of operation are offered, and modes of each function block are set according to the selected state. Figure 6.
<6. QUICK TOUR OF ValveNavi> 6-17 6.13 Device Query The General page in Query Device provides access to device data in predefined categories. Simply select the category name from the drop down list box, then press Read to get all the parameter values in the category. For each device, there is a query window available and it is possible to open multiple query windows for multiple positioner devices at the same time. The query window can be run while accessing other windows. Figure 6.
<6. QUICK TOUR OF ValveNavi> 6-18 6.14 PID Control Dialog The PID Process Controller dialog contains the tools for managing the PID function block. It is composed of frames that group controls and displays. The PID State frame displays and controls the PID states (block modes), the setpoint and process variable, and the Device tagname. In Manual State (M), drag the PID output slider to move the valve.
6-19 <6. QUICK TOUR OF ValveNavi> 6.15 Rescan Clicking Rescan button or selecting Tools >Re-scan Devices will refresh connections to all working devices on the fieldbus segment. It will close the opened device you will lose control until you have reselected a device. You will be prompted to confirm that a rescan is acceptable. Figure 6.20 Rescan Dialog 6.16 About Clicking the About icon or selecting Help>About ValveNavi will display the version of ValveNavi and the copyright notice.
<6. QUICK TOUR OF ValveNavi> 6-20 6.17 Online Help ValveNavi uses Web based technology for its online help. Click on Help>Help Topics to start your normal browser (Internet Explorer or Netscape navigator). Figure 6.
7. 7-1 <7. INTEGRATED VALVE INTERFACE (IVI)> INTEGRATED VALVE INTERFACE (IVI) The main application screen of ValveNavi is the Integrated Valve Interface (IVI) that is displayed after a successful logon (ValveNavi Logon). It monitors the operation state and status of the valve. It provides access to all other services. Figure 7.1 IVI ValveNavi operation begins with the Integrated Valve Interface, IVI.
<7. INTEGRATED VALVE INTERFACE (IVI)> 7-2 Menu items Menu bar contains File, Setup, View, Tools, and Help menus. Toolbar icons Toolbar services are listed below, in the order of the icons shown on the Toolbar. While a function is disabled its icon is “grayed out.” Table 7.
7.1 <7. INTEGRATED VALVE INTERFACE (IVI)> 7-3 Device Selection All of the devices on the bus segment live list are shown as icons in the Device Selection box. Click on any device to open a communications session with the positioner. The fieldbus segment live list is continuously scanned, and devices are shown when present. Devices that have communications failure are shown with a red X. The selected device is shown with a red checkmark.
7.1.1 <7. INTEGRATED VALVE INTERFACE (IVI)> 7-4 The Pop-Up Menu In Device Selection The pop-up menu in device selection offers quick access to services. Figure 7.4 Device Tree Popup CAUTION Do not change Device Tag or Node Address while NI Configurator or other host software with automatic address assigning function is running. All function block linkages will be cleared. These network parameters should be changed only when configuring a positioner independently.
7.1.2 <7. INTEGRATED VALVE INTERFACE (IVI)> 7-5 Setting Device as LM or Basic Device This feature is available only when the opened device has the Link Master(LM) capability. WARNING The procedures will reboot the device. Check that the device is isolated from the operating process. Figure 7.5 Change to Basic Device Clicking Yes will set device as Link Master or Basic device.
<7. INTEGRATED VALVE INTERFACE (IVI)> 7.2 Control Valve Faceplate 7.2.1 Selected Device 7-6 The Selected Device Frame provides a dedicated view for the selected device which includes device tag and operation state, blocks actual mode, valve position and setpoint, other status, and other parameters bar graph. It encloses displays and controls for working with the positioner and control valve. Figure 7.6 Control Valve Faceplate with =% Characteristic Figure 7.
7-7 <7. INTEGRATED VALVE INTERFACE (IVI)> Table 7.1 IVI Faceplate Parameters Display parameter Display type Parameter name Remarks [PD.TAG] This indicates the YVP’s tag. PD-Tag Operational State Device Operation State may be one of the following: A right clicking on this display can change NORMAL (Automatic) the operation status. MANUAL Out Of Service If no physical device is selected, it displays OFFLINE as the operation state. Active control Setpoint Signal [AO.
7.2.5 <7. INTEGRATED VALVE INTERFACE (IVI)> 7-8 Temperature, Pressure, and I/P Graphs Internal temperature, output pressure (optional code/BP) and servo output to I/P module are displayed as bargraphs. Click View > (Bar Name) to toggle the bar on or off. 7.3 Companion Device The Companion Device frame provides a view of a device which is a companion to the selected device, such as a valve related to the selected valve.
8. <8. SETUP WIZARD> 8-1 SETUP WIZARD To install and configure a YVP positioner the Setup Wizard is recommended. It combines basic calibration and tuning functions in a single sequence. 8.1 Introduction to Setup Wizard Figure 8.1 Setup Wizard This setup wizard provides, in a single tool, all the services for setting up a basic valve positioner. It includes a sequence of wizards for basic configuration and basic tuning. It is most useful for first-time setup of the positioner.
8.2 <8. SETUP WIZARD> 8-2 Actuator Wizard Figure 8.2 Actuator Wizard In the actuator setup menu select the valve action, actuator type, relay type, and valve type. Then, click Next to begin calibration and tuning. NOTE If “linear” is incorrectly selected (when the valve is rotary), there will be large angle span error message. To correct this, you must use the Configuration Services- Actuator dialog followed by the Calibration Services- Tuning dialog.
8.3 8-3 <8. SETUP WIZARD> Tuning Wizard The positioner will automatically search for the mechanical valve travel limits and tune the valve position PID control algorithm. Click Go to begin. This will take several minutes to complete and will stroke the valve. If this is not a first time setup of the valve, you may skip this step by clicking the Skip button. WARNING Before beginning the Auto or Manual range calibration, confirm that the valve is isolated from the process.
8-4 <8. SETUP WIZARD> If Limit Searching and Auto Tuning is performed successfully, a tuning result dialog will be shown for user’s confirmation. If Accept is clicked, the new servo parameters will apply to the system. Otherwise, the original servo parameters will be restored to the device. Double acting specific parameters are applicable only for double acting actuator type. Figure 8.
8.4 <8. SETUP WIZARD> 8-5 Travel Calibration Wizard The mechanical stops on some actuators may allow the valve to move beyond its rated travel. The next wizard allows adjustment of the valve travel to correspond to the travel indicator on the actuator. In the example shown the valve has been moved to 100% travel mark on the actuator by trial and error. The YVP positioner indicates that the position corresponding to 100% rated travel is 93.5% of the measured mechanical travel.
8.5 8-6 <8. SETUP WIZARD> Position Control limits Wizard Click next to move to the Position Control Limits Wizard. If it is decided to limit the travel, set the appropriate values here. These values will alter the valve performance. Use them with caution. The values shown in Figure 8.8 are the initial values to use if there are no special requirements. The parameters are defined below. Figure 8.
8-7 <8. SETUP WIZARD> Position Upper Limit The valve position setpoint may not exceed this value. This will prevent the valve from closing. A value of 110 removes this function from the normal travel range. “Near Closed” Value The threshold below which the valve is considered “near closed.” “Near Close” term is useful for estimating when to change the valve trim. This value does not affect valve travel, and it is used only for reporting the time that valve is near the seat.
<8. SETUP WIZARD> 8-8 Servo Warning High If the operating point of the I/P module is more than this value, the timer that measures the time after the I/P module operating point error starts. Servo Warning Low If the operating point of the I/P module is less than this value, the timer that measures the time after the I/P module operating point error starts. Input a value that is less than that for Servo Warning High.
9. 9-1 <9. CONFIGURATION SERVICES> CONFIGURATION SERVICES Configuration services provide the tools to read and/or set parameters required for successful communications and control. Each set of tools is grouped in a page with a tab. CAUTION Do not turn off power for 60 seconds after writing configuration data. Data may not be saved. See positioner instruction manual. 9.
9.1.1 <9. CONFIGURATION SERVICES> 9-2 Device Info ● Tag The physical device tag (PD-Tag). The device tag is defined in Foundation fieldbus as a string of maximum 32 characters. Make sure the tag is unique in the entire control network. When a device is selected, this field is grayed out for read only. Therefore, the access to the device tag change is handled in Main Screen (IVI) by selecting the Setup menu or by right clicking the device icon in Device Selection.
9.1.2 <9. CONFIGURATION SERVICES> 9-3 Block Tag Info Each block is assigned a default tag-name that should be renamed by the user. ● RB The tag of the resource block. ● TB The tag of the transducer block. ● AO The tag of the analog output block. ● DI1 The tag of the discrete input 1 block. ● DI2 The tag of the discrete input 2 block. ● PID The tag of the PID block. ● SPLT The tag of the output splitter block. 9.1.
9.2 9-4 <9. CONFIGURATION SERVICES> Configuration - Position This is the setup page for the valve position configuration parameters in Transducer (TB) block. 9.2.1 Servo Parameters The servo parameters are normally set by autotuning in Tuning of Calibration. They determine dynamic response of the valve position control. Figure 9.
9.2.2 9-5 <9. CONFIGURATION SERVICES> Position Limit The Position Limits frame provides parameters that allow you to limit the valve, to force the valve to close tightly or open fully at specified positions, to set the trip points of the limit switches (DI Block). You can also activate a warning when a deviation lasts longer than the Time 1 or to force the valve to its failsafe position if the deviation lasts longer that time 2.
9.2.3 9-6 <9. CONFIGURATION SERVICES> Limit Switch Threshold The Limit switch thresholds apply to the Discrete Input (DI) block setpoints. ● Threshold Low The threshold for the low limit switch that communicated by the DI block. ● Threshold High The threshold for the high limit switch that communicated by the DI block. 9.2.4 Fault Control ● Error Band The position deviation limit to start deviation timer of Time 1 and Time 2.
<9. CONFIGURATION SERVICES> 9-7 ● Servo Time (duration) If the duration in which the I/P module operating point is out of the range from Servo Warning Low to Servo Warning High reaches this set time, block alarm “Servo output drift warning” is generated. If the duration in which the I/P module operating point is less than 10% or more than 90% reaches this set value, block alarm “Severe servo output drift” is generated.
9.3 <9. CONFIGURATION SERVICES> 9-8 Configuration - Actuator This is the setup page related to the valve actuator and diagnostics limit information contained in Transducer(TB) block. Figure 9.4 Configuration - Actuators 9.3.1 Valve Action This is the ACT_FAIL ACTION parameter. ● Air To Open It specifies the final failure position of the actuator as air-to-open. ● Air To Close It specifies the actuator as air-to-close. 9.3.2 Actuator Type This is the ACTUATOR TYPE parameter.
9.3.3 9-9 <9. CONFIGURATION SERVICES> Relay Type This is the RELAY TYPE parameter. ● Normal (Direct Acting Instrument) It specifies the control relay as normal type. ● (Hardware) Reverse It specifies the control relay as reverse type. This parameter is currently not available. 9.3.4 Valve Type This is the VALVE TYPE parameter. ● Linear (Reciprocating) It specifies the valve as linear (reciprocating) type. ● Rotary It specifies the valve as rotary type. 9.3.
9.3.6 <9. CONFIGURATION SERVICES> 9-10 Model And Serial Number of Valve The items in this section can be set and modified by users as a record of the information related with the valve. ● Valve Manufacture The valve manufacturer’s identification number as defined by the Fieldbus Foundation. ● Valve Model The valve model number. ● Valve S/N The valve serial number. ● Act. Manufacture The actuator manufacturer’s identification number as defined by the Fieldbus Foundation.
9.4 9-11 <9. CONFIGURATION SERVICES> Configuration - AO Block This is the setup page related to the setpoint that is received from another function block or a remote application. And I/O option contained in Analog Output (AO) Block. Figure 9.5 Configuration - AO Block 9.4.1 Limits ● Setpoint High Limit (%) Use this to limit the setpoint from another function block or remote application.
9.4.2 9-12 <9. CONFIGURATION SERVICES> Configuration - AO Block Options This setup page consists of both I/O Options and Status Options for the AO block. For each parameter, it is enabled/disabled if it is checked/unchecked. IO_OPTS and STATUS_OPTS are parameters that control options about the AO block’s signal processing and mode transitions. ● SP Tracks PV if Man Permits the setpoint to track the process variable when the target mode of the block is Man.
9.5 <9. CONFIGURATION SERVICES> 9-13 Configuration - PID Block This is the setup page for the PID process controller configuration parameters mainly in PID block. Figure 9.6 Configure PID block 9.5.1 PID Parameters ● Proportional Gain Dimensionless value used by PID block algorithm in calculating the block output. ● Integral Time The integral time constant, in second per repeat. ● Derivative Time The derivative time constant, in second.
9.5.2 9-14 <9. CONFIGURATION SERVICES> Limits ● Set Point High Limit The highest value that is allowed for the PID set point. ● Set Point Low Limit The lowest value that is allowed for the PID set point. ● Output High Limit The limit for the maximum PID output value. ● Output Low Limit The limit for the minimum PID output value. ● Deviation Alarm High Limit This is the parameter in PID block called DV_HI_LIM. It is the setting of the high deviation alarm limit.
9.5.3 <9. CONFIGURATION SERVICES> 9-15 PV Scale ● Units The engineering units code used for PID process variable. ● Upper Range (EU100) Upper limit value ● Lower Range (EU0) Lower limit value 9.5.4 Configuration - PID Options This setup page consists of both Control Options and Status Options for PID block. For each parameter, it is enabled/disabled if it is checked/unchecked. Figure 9.
<9. CONFIGURATION SERVICES> 9-16 SP-PV Track in LO or IMan Permits the setpoint to track the process variable when the actual mode of the block is LO or IMan. SP Track retained target Permits the setpoint to track the RCas or Cas parameter based on the retained target mode when the actual mode of the block is IMan, LO, Man, or ROut.
9.6 <9. CONFIGURATION SERVICES> 9-17 Configuration - Options This is the setup page for other configuration settings including characterization, pressure range and units, bumpless transfer, display language, and temperature units. Figure 9.8 Configuration - Options 9.6.1 Characterization Frame The positioner is supplied with a choice of characteristics that modify the characteristic built into the plug and actuator.
<9. CONFIGURATION SERVICES> 9-18 ● Camflex Percentage This function is used to equalize the flow rate characteristic with the Equal Percent characterization feature that is provided by mechanical positioners from Masoneilan. ● Define A custom characterization defines the relationship between the input signal and the output position of the valve.
<9. CONFIGURATION SERVICES> 9-19 ● Custom Characterization Dialog The Characterization Dialog lets the user define his own characterization. There are 9 definable points for the valve position at 10% increments of position setpoint. Use the mouse to drag the points on the curve or enter numerical values in the table to define the characterization. To configure a custom characteristic curve, enter the values in the edit boxes at the bottom of the screen and press the Tab key.
9-20 <9. CONFIGURATION SERVICES> ● Custom Linearization Dialog Select the Custom Linearization menu item in the Characterization Dialog to display the Custom Linearization dialog (Figure 9.11). Figure 9.11 Custom Linearization Dialog A custom linearization method built into ValveNavi can be used to correct non-linearity. The method automatically generates a custom characterization that matches the specific linkage used.
<9. CONFIGURATION SERVICES> 9-21 Compound Lever The compound linkage has Lever1 attached at one end to the pivot (the position sensor in the YVP) and at the other end to Link L2. In order to compute the proper correction curve, the user must enter the stroke length, first lever segment length (L1), second lever segment length (L2), the distance from the pivot to the valve stem pickup (L3), and the valve position at horizontal. Most linkages use a linkage with L3 equal to L1, i.e.
10-1 <10. CALIBRATION SERVICES> 10. CALIBRATION SERVICES Calibration Services provide tools to set valve stroke, and to tune the dynamic parameters for control of position. Each set of tools is grouped in a tab. 10.1 Calibration - Range To calibrate the position sensor to match the actual valve travel, use the Auto Stop Limits or the Manual Stop Limits function to search for the mechanical stop limits of the valve.
<10. CALIBRATION SERVICES> 10-2 10.1.1 Find Range Result Display the result of the calibration execution after GO button is pressed. 10.1.2 GO Start button to execute the selected calibration. Figure 10.2 Warning 10.1.3 Auto Stop Limits When Auto Stop Limits is selected, press GO button to execute the automatic position calibration process. The actuator will be fully exhausted, then fully filled. The position at each stop will be measured and saved.
<10. CALIBRATION SERVICES> 10-3 10.1.4 Manual Stop Limits If Manual Stop Limits is selected, press GO button to execute a manual position calibration process. The actuator moves to one stop and waits for user’s confirmation, and then moves to the other stop for the other confirmation. The position at each stop will be measured and saved. Wait until the valve has stopped moving before pressing the confirmation button. Figure 10.
<10. CALIBRATION SERVICES> 10-4 10.2 Calibration - Tuning Figure 10.5 Tuning This tab allows the user to automatically tune the positioner’s control alogorithm and examine the positioner servo parameters. The parameters display provides two views for comparison, the left half displays the original set before performing autotune, the right half will be updated after the auto tuning. The parameters can be manually modified here as well.
<10. CALIBRATION SERVICES> 10-5 10.2.1 Auto Tune Click the Auto Tune button to execute the auto tuning procedure. After clicking Auto Tune, a dialog will appear to warn that the valve will stroke. Click yes if the valve is isolated from the process and if it is safe to proceed. Observe all safety precautions. Figure 10.6 Autotune warning dialog Figure 10.
<10. CALIBRATION SERVICES> 10-6 The Progress dialog will appear to indicate progress. The procedure will fully stroke the valve and then tune for a few minutes. Click Cancel to stop tuning and the return parameters to their prior values. WARNING During this process, the valve strokes over its full range. Keep clear of moving valve and actuator parts. The parameters before tuning are shown on the left (Original). The parameters determined by auto tune are show on the right (Now).
<10. CALIBRATION SERVICES> 10-7 10.2.4 Manual parameter adjustment After auto tuning is complete, or as an alternative to auto tuning, the parameters may be manually entered in the text boxes (Now). ● Positioner Tuning Parameters The position controller is a type of non-linear PID control algorithm with 5 standard parameters listed below. See Table 10.1 Servo Tuning Parameter Ranges for the allowed and default parameter ranges. There an additional 16 advanced servo tuning parameters.
<10. CALIBRATION SERVICES> 10-8 10.3 Travel Calibration The Travel Calibration tab allows the user to adjust calibration at 0%, and 100% to match the valve’s working stroke when there is over-travel at one or both stops. Additionally, if the valve linkage introduces a non-linearity, it can be corrected by setting a correction at 50%. The corrections in this dialog are applied over corrections applied with Open Stops tool and over the Custom Linearization tools.
<10. CALIBRATION SERVICES> 10-9 Step 2 Select 0% Calibration. Move the valve by entering a value in the Current Target Position (Change To) text box, and clicking Set, until the valve is in the desired closed position. The valve can be jogged by selecting the Increment change amount (0.1 for example, in Figure 10.9) and by clicking the up or down arrow beside the Change to (%) text box. Click once and wait until the position value shows the change.
<10. CALIBRATION SERVICES> 10-10 10.3.1 Calibration Result The result display of the travel calibration execution after Apply Calib button pressed. 10.3.2 Apply Calib Start button to execute the selected travel calibration. 10.3.3 Pick Target Position for Calibration To select a position for calibration, the valve needs to be moved to that position as displayed by Current Target Position edit box (Change To).
<10. CALIBRATION SERVICES> 10-11 10.4 Calibration - Advanced Position Servo Tuning Parameters Normally dynamic position control parameters are established by the Auto Tune procedure. This is the page for manually configuring dynamic position control parameters that are contained in Transducer(TB) block. It is intended for technician use only.
<10. CALIBRATION SERVICES> 10-12 ● Internal Gain This position control parameter shows the total gain for an I/P module, control relay and valve. ● Servo Offset Initial valve of an integrator. Table 10.2 Advanced Servo Tuning Parameters Ranges Parameter Initial Value Range of Values Units Boost On Threshold 1 1.9 0 (disables); 0.1 to 10. % Boost On Threshold 2 2.9 0 (disables); 0.1 to 10. (1) ≥ (2) % Boost Off Threshold 1 1 0 (disables); 0.1 to 10.
<10. CALIBRATION SERVICES> 10-13 ● X Boost Off Threshold 1 and X Boost Off Threshold 2 (Exhaust Boost Off Threshold 1/2) This control parameter makes the boost on the exhaust side asymmetric to that on the air supply side. Based on the Boost Off Threshold 1 and Boost Off Threshold 2 values, input a difference for change. ● X Boost Value 1 and X Boost Value2 (Exhaust Boost Value 1/2) This control parameter makes the boost on the exhaust side asymmetric to that on the air supply side.
11-1 <11. PID BLOCK SERVICES> 11. PID BLOCK SERVICES The PID Process Controller dialog contains the tools for managing the PID function block. Figure 11.1 PID Process Controller Dialog The PID Process Controller dialog, like the IVI, is composed of frames that group controls and displays. The PID State frame Displays and controls the PID states (modes), the setpoint and process variable, and the Device tagname.
<11. PID BLOCK SERVICES> 11-2 11.1 States and Modes The permitted states of the PID block are: • RCas selected by the R button. In this mode, the setpoint of the PID block is set by a remote application that writes to the RCAS_IN parameter regularly. This mode is allowed only if a remote application is “soft-wired” to the RCAS_IN parameter of the PID block. • Cas selected by the C button. In this mode, the setpoint of the PID block is set by a Foundation fieldbus function block.
<11. PID BLOCK SERVICES> 11-3 11.2 Tuning Parameters Process tuning parameters may be adjusted from the PID Process controller dialog. Click Change in the Tuning Parameters frame. The Proportional Gain, Integral Time and Derivative Time may be entered without changing control mode. Using the Trend service to view the effect of tuning can be performed by selecting the View>Trend menu item. Figure 11.
11-4 <11. PID BLOCK SERVICES> 11.3 Simulation Function The simulation state is allowed only for the users of privelege level 8. ValveNavi provides a special function for testing and training. The user can connect the valve position to the input of the PID with lag of 5 seconds to allow demonstration of closed loop control. WARNING The simulation state must not be used if the valve is connected in a control loop or the if the valve is controlling process flow.
<12. TRENDING SERVICE> 12-1 12. TRENDING SERVICE The trend service may be used to observe the dynamic behavior of both the control valve and its associated process variable. It is particularly useful for tuning the PID process loop and may be used to alter the response of the positioner control algorithm after auto-tuning. Each device is provided with one trend window (ValveNavi supports up to 30 trend windows open simultaneously). Figure 12.1 Trend with Pressure Loop Figure 12.
<12. TRENDING SERVICE> 12-2 The Trend Window is opened by right clicking on a device in the Device Tree, or by selecting View>Trend in the IVI or PID dialogs. The trend window can display selected historical data for up to 12 hours. The selected parameters may be actual valve position, target valve position, PID process variable, and PID process setpoint. Click the Start menu button to start trending and click Stop to stop trend. While the trend is stopped the time axis continues to increase.
<12. TRENDING SERVICE> 12-3 12.1 Trend Selection The Trend Data Selection dialog lets you select which parameters to trend: actual valve position, target valve position, servo output signal, PID process variable, and PID process setpoint. WARNING Do not alter schedules or links of operating process control segments. Figure 12.
<12. TRENDING SERVICE> 12-4 12.2 Scope Settings • Display Window The vertical axis in the trend graphical display can be scaled by entering values in the High/ Low text boxes for vertical range. The horizontal (time) axis is adjusted by entering the trend time in the Wide text box. • Max. Record Length The maximum length for logging the trend data is 12 hours. The default is 1 hour. Any data older than the specified Max. Record Length will be discarded, dynamically. Figure 12.
<12. TRENDING SERVICE> 12-5 12.3 Saving and Opening Trend Files Use the File menu to save the trend data or load saved data for playback. For each device, there is a trend window available and it is possible to open multiple trend windows for multiple positioner devices at the same time. The trend window can be run while other windows are active. Saving a trend does not discard current trend data, but you must temporarily stop trending while performing the save.
12-6 <12. TRENDING SERVICE> 12.4 Changing Valve Position while Trending Figure 12.8 Change the Trend Position To observe the positioner dynamic response, select Change Pos from the menu bar. The positioner must be in Manual Operating state. Enter the desired value in the text box, Figure 12.8 12.5 Closing the Trend Service To close the trend click File>Exit. All unsaved trend data will be discarded.
<13. SAVING, DOWNLOADING, AND CLONING A CONFIGURATION> 13-1 13. SAVING, DOWNLOADING, AND CLONING A CONFIGURATION ValveNavi provides tools to retrieve, copy, or save YVP configuration data that can be used for offline configuration. Use them for copying a configuration from a device to its replacement, or to configure a series of similar positioners. WARNING This download may cause valve motion. Keep away from the valve and actuator or any moving parts while carrying out the download.
<13. SAVING, DOWNLOADING, AND CLONING A CONFIGURATION> 13-2 13.2 Save to File This service is to save a current configuration on the ValveNavi and available either while online with a YVP or when offline. Select the open icon, click File>Save File menu item, or right click the currently selected device or the Offline icon in Device tree. Choose a file from the popup dialog and click Open. Figure 13.
<13. SAVING, DOWNLOADING, AND CLONING A CONFIGURATION> 13-3 13.3 Download While a device is selected, configuration changes are downloaded to the device as the changes are made (when you click OK in the configuration dialog). To download configuration data from a file, you must be in OFFLINE state. In OFFLINE state, open the designated file by clicking the open file icon.
13-4 <13. SAVING, DOWNLOADING, AND CLONING A CONFIGURATION> You will be warned that the address will be changed and asked Figure 13.5 Download Device Warning WARNING Do not change tag or address of a positioner unless the valve is isolated from the process. CAUTION Changing tag or address will alter control linkages between function blocks. After changing these parameters, the control configuration must be tested and corrected. Figure 13.
<13. SAVING, DOWNLOADING, AND CLONING A CONFIGURATION> 13-5 Figure 13.7 Download Warning Dialog IMPORTANT After the download is complete, the device must remain powered for at least 60 seconds to transfer the data to permanent memory. 13.
<14. DIAGNOSTIC SERVICES> 14-1 14. DIAGNOSTIC SERVICES 14.1 General Figure 14.1 General Tab of Diagnostics This general tab of diagnostics displays the service history for continuous data. The continuous data are compared with the limits set in Actuator setup. See the Actuator page for a detailed description. To reset the continuous data to zero, first make a record of current values, then press the Reset button. All Continuous Data will be lost and cannot be recovered.
14-2 <14. DIAGNOSTIC SERVICES> To reset Valve Historian data and Device Diagnostic data to zero can be performed individually. Click reset button and carry out according to the figure 14.2. When you want the Device Diagnostics data to zero, you need to change the mode to OOS.
<14. DIAGNOSTIC SERVICES> 14-3 14.2 Self Check WARNING Performing Self Check will stroke the valve. Do not perform while the valve is controlling the process. Keep clear of moving valve parts. The Self Check page of the diagnostics tests the performance parameters that are used to determine the position control parameters. The test will run autotune but will not change any parameters.
<14. DIAGNOSTIC SERVICES> 14-4 (2) Measured Gain The Measured Gain is measured by the Auto tuning function. The unit for this parameter is rad/mA. (3) Valve TC This parameter describes the response speed of control valve system. The units for this parameter are seconds. This parameter is measured by the Auto Tuning function. The parameter indicates how fast the control relay can drive the air actuator. (4) Valve Hysteresis This parameter describes the hysteresis of the control valve.
14-5 <14. DIAGNOSTIC SERVICES> 14.3 Signature Signature function is one of the functions in diagnostic function. The aim of this function is to detect the degradation failure and to grasp the condition of the control valve or the positioner by comparing the history of signature characterization. To accomplish the aim, the positioner must have the function to measure and retain the measured data of the characteristics of the control valve and the positioner itself.
<14. DIAGNOSTIC SERVICES> 14-6 14.3.1 Actuator Signature Actuator signature will measure and save the data of static characteristic of the control valve. • Measurement Parameters The input parameter is output pressure (Equal to MEAS_PRESS_AIR); and the output parameter is the feedback signal ( Equal to FINAL_POSITION_VALUE.Value) In measuring the signature, YVP will obtain 18 data set. (Pressure data and Position data is one set.
<14. DIAGNOSTIC SERVICES> 14-7 • Measurement Setting Parameters There are three measurement setting parameters: Recommended Scan Time, Scan Time and Deviation margin. Figure 14.7 Standard Signature Setting Recommended Scan Time (sec): The value is read only and does not affect the measurement. The value is calculated from the tuning parameters. It is used as a guide for setting Scan Time (in second). Scan Time (sec): It determines the time for round trip of the measurement.
<14. DIAGNOSTIC SERVICES> 14-8 • Measurement of Spring Range and Valve Friction To view the results, click Edit on the menu bar and select the signature graph type, and then a pop-up menu will be shown. Also, you can move the cursor to the area of signature graph and make a right click for editing oreration in a pop-up menu. Select and click Result Analysis to see the measured spring range and valve friction. The valve friction means the half of valve hysteresis. Figure 14.
14-9 <14. DIAGNOSTIC SERVICES> 14.3.2 Extended Actuator Signature Extended actuator signature will measure the In-Out characteristics of the control valve in the range defined by users. The total number of data is 100 points. • Measurement Parameters The input parameter is output pressure (Equal to MEAS_PRESS_AIR); and the output parameter is the feedback signal ( Equal to FINAL_POSITION_VALUE.
14-10 <14. DIAGNOSTIC SERVICES> • Data to Obtain In measuring the extended actuator signature, YVP will obtain 100 data set. (Position data and Pressure data is one set.) There are two data acquisition mode. Position related data acquisition and time sampling related data acquisition. Normally, data will be acquired according to the addressed measuring position point. When the valve is saturated and can not reach the measurement point, then data acquisition mode is switched to time sampling.
<14. DIAGNOSTIC SERVICES> 14-11 14.3.4 Step Response Test This signature function will measure the step response characteristic of the control valve system. There are two types of step response test: single step response test and multiple step response test. The multiple step response test consists of a series of single step response test, with a new set point for each following test incremented by the step size, executed consecutively in the overall range specified by the user.
<14. DIAGNOSTIC SERVICES> 14-12 Initial Set Point (-10 to 110%): The base position for step test from which the set point will change by the amount of the step size. If the step test works as cyclical, resolution and dead band test, the value fixed at 50. Dest. Set Point (-10 to 110%): The destination position. If it is in resolution patterns step test, the value should be over 50. Step Size (0 for Single Step): The size of each step change. Used for multi step response test only.
<14. DIAGNOSTIC SERVICES> 14-13 • Data to Obtain Position data before the step change is required in order to determine the starting point. The YVP110 will collect 10 samples of data before the each step input is applied. Figure 14.13 Step Response test Graph • View of Result Analysis To view the results, click edit on the menu bar and select the step response test graph, and then a pop-up menu will be shown.
<14. DIAGNOSTIC SERVICES> 14-14 • Step Response Patterns a) Normal Step Response Test Figure 14.15.1a Normal Response Test Setting Figure 14.15.
<14. DIAGNOSTIC SERVICES> 14-15 The measured overshoot and 86% response time are displayed in the result analysis. Figure 14.15.1c Normal response Test Result Analysis b) Cyclical Figure 14.15.
<14. DIAGNOSTIC SERVICES> 14-16 Start at initial set point (50%) to dest.set point by step size changing. Then move to set point which is 100 minus dest. set point. Then back to the initial set point (50%). Figure 14.15.2b Cyclical Response Test Graph The measured accuracy, hysteresis plus dead band and repeatability are displayed in the result analysis. Figure 14.15.
<14. DIAGNOSTIC SERVICES> c) 14-17 Cyclical / Dead Band Test This test is used to determine the maximum value of marginal changes in the input level that does not move the control valve. Figure14.15.3a Dead Band Test Setting Figure 14.15.3b Dead Band Test Graph Note: YVP110 stops integral function at the Dead Band Test. Therefore, the responding actual position has deviation from Set Point.
<14. DIAGNOSTIC SERVICES> 14-18 The mesured accuracy, hysteresis plus dead band, repeatability and dead band are displayed in the result analysis. Figure 14.15.3c Cyclical Response Test Result Analysis d) Resolution Figure 14.15.
<14. DIAGNOSTIC SERVICES> 14-19 Always start at initial set point (50%). Up to 1* step size, down to 1* step size, then up to 2* step size, down to 2* step size until the destination set point. Figure 14.15.4b Resolution Response Test Graph The measured overshoot and 86% response time are displayed in the result analysis. Figure 14.15.
14-20 <14. DIAGNOSTIC SERVICES> 14.3.5 Positioner Signature This signature function measures the static characteristics of the control valve system. eter Input signal of the control valve system: Input signal of YVP110 (Equal to AO Block OUT.Value) Output signal of control valve system: Feedback signal of YVP110 (Equal to FINAL_POSITION_VALUE.
<14. DIAGNOSTIC SERVICES> 14-21 • Data to Obtain The application will apply the Input signal to the YVP110 and wait until the valve stem settles then obtain the position data. The measurement will be proceeded in round trip. Figure 14.
<14. DIAGNOSTIC SERVICES> 14-22 14.3.6 Signature Selection The general page of Diagnostics includes the interface to measure signatures. Figure 14.18 Selecting Signatures The system allows user to be able to select Measure All or any combination of signatures set in either execution or data display. When selecting Measure All, YVP will perform signature measurement in the following order.
<14. DIAGNOSTIC SERVICES> 14-23 14.3.7 Signature Setting This dialog is used for setting signature conditions. The parameters allowed to modify will differ according to the selected signature. The setting parameters are grouped by signature type. Each type of signature has its own parameters page (Extended Actuator Signature and High Resolution Signature share one page). Figure 14.
14-24 <14. DIAGNOSTIC SERVICES> 14.3.8 Signature Measurement During the signature procedure, the current measuring signature, measurement setting, real time data, real time curves, status and progress are displayed. Figure 14.20 Signature Measurement Window Title: the current execution signature. Measurement Setting: the measurement condition of the signature in progress or other message before signature starts. Temp.
<14. DIAGNOSTIC SERVICES> 14-25 14.3.9 Signature Graphs After signature measurement completes, the signature graphs dialog will be shown. Based on the user’s selection, the signature graphs dialog can display up to four types of signature graphs. Because extended actuator signature and high resolution actuator are share database, their graphs are displayed in the same graph window.
<14. DIAGNOSTIC SERVICES> 14-26 • Save Signature Graph(s) To save a group of graphs, select Save from menu File. To save one specified graph, move mouse cursor to that graph, right click, and select Save Graph from Pop-up menu. To save data of current data base in YVP to a file, select the curve from a pop-up menu, and then select Save to File. If signature type is standard actuator signature, Save to Record or Save to Baseline can also be selected.
<14. DIAGNOSTIC SERVICES> 14-27 • Show Set Points For Step Response Test only. Checking/Unchecking Show Set Points from a pop-up menu will display or hide the set points curve in step response graph. The default mode shows set points curve. • Grid Line Select a grid line figure from solid, dot, and none by clicking Grid Line from a pop-up menu. • Zoom in/Zoom out Zoom in: In the curve area of a graph window, a selected rectangle area by mouse will be zoom in.
14.3.11 <14. DIAGNOSTIC SERVICES> 14-28 SignaAug. 01, 2004-00ture Summary The Signature Summary shows measured temperature, signature setting, input/output parameters, time stamp, saved location, and user’s free signature notes. Measurement Setting: the signature’s measuring condition. Input/Output Parameters: signature input and output parameter’s properties including engineering unit, range limits, maximum and minimum measured value. Time Stamp: signature measured time.
14.3.12 <14. DIAGNOSTIC SERVICES> 14-29 Signature Notes Signature notes can be used for writing down the condition of the control valve or the positioner when performing the signature tests. Signature Notes can be entered either before signature starts or after it is performed. There are three ways to record signature notes. • Write down notes before signature starts. In Signature Page, Signature Notes edit field is used for entering notes. See Signature Selection.
<15. QUERY SERVICES> 15-1 15. QUERY SERVICES Query services are useful for viewing every parameter in every YVP. It is accessible by several methods: from the Device Query icon in the tool bar, from the IVI, or PID dialogs and by right-clicking a selected device in the device tree. As many as 30 Query dialogs can be open simultaneously to examine parameters in the selected function blocks. Click Read to update. They are not refreshed.
<15. QUERY SERVICES> 15-2 The Block Parameters tab provides access to every parameter in each selected block. For the expert technician it provides detailed information that is not available in the configuration and tuning dialogs. For interpretation of the parameters, and their units and data structure, see the YVP user’s manual. In the example shown in Figure 15.2, the parameter MODE_BLK reveals that the mode of the Transducer block is Set to OOS (out of service) now. Figure 15.
<15. QUERY SERVICES> 15-3 The Parameter Attribute window can be accessed from the Block Parameters page of Query Device by right-clicking the parameter name field. It displays the attributes of the parameter described in the DD file. Figure 15.
<16. REPORTING SERVICES> 16-1 16. REPORTING SERVICES 16.1 Configuration Report This program provides a Configuration Report feature that captures a snapshot of all configuration data currently contained in and related to the selected device. The data are organized into groups that are consistent with the format of the configuration user interface. The report can be either HTML format or TEXT format. The HTML-based is browser independent. It is best viewed with the latest browser versions.
16-2 <16. REPORTING SERVICES> ● Use Report Generation to View Saved Configuration Files Services Figure 16.2 Save Configuration Web Page Dialog Configurations that are saved for downloading (.dmp files) to devices may be viewed with the Report Generator in Offline State. Right click Offline and then click Open. Select the configuration file that has the desired data. When the Offline device loads the data, then click Generate Report to view and to print the data with your Web browser. 16.
16-3 <16. REPORTING SERVICES> Step 1 Right click on the error log text box. A menu box appears (Figure 16.4). Step 2 Click Select All. There may be many lines of errors although only one shows in the text box. Step 3 Click Copy. Step 4 Open a text document with any text editor and paste the log. Figure 16.
<17. FAILSAFE HANDLING> 17-1 17. FAILSAFE HANDLING 17.1 Introduction For the selected positioner, ValveNavi will constantly monitor the status of the actual valve position parameter FINAL POSITION VALUE in Transducer (TB) block to report and manage Failsafe events. The actual status of Failsafe is determined by the parameter RELEASE FAILSAFE in TB. To configure the Time 2 parameter to force Failsafe because of sustained deviation, refer to Position setup configuration.
<17. FAILSAFE HANDLING> 17-2 17.3 Failsafe Clear Latched The Fail Safe Status window will be updated with the Failsafe Clear Latched condition when the active condition has been cleared. The Clear Latch button will be enabled for the user to clear the latch. If the positioner is not in out of service (OOS) operation state, required for clearing the latched state, the user will be prompted to switch to OOS state. Figure 17.2 Failsafe -Clear Latched 17.
17-3 <17. FAILSAFE HANDLING> 17.5 To Exit Failsafe Failsafe cannot be cleared until the original cause is corrected. Determine the cause of failure and correct it. After the cause of the problem has been corrected, the Failsafe Dialog may show Clear (Latched). Click the Clear latch button and close the Clear (Non-latch) button. 17.5.
<17. FAILSAFE HANDLING> 17-4 To exit Failsafe for Case 1 and 3 Step 1 Restore the air supply or correct actuator problem. Check that the pneumatics are working correctly. Step2 Move the Failsafe dialog to one side of the screen to uncover the IVI display. (If the PID dialog is open, close it.) Step3 Record the Actual Position. (Shown as -39.92% in Figure 17.4) In this extreme example, the valve calibration allows for large travel between closed stop and 0% position. Figure 17.
<17. FAILSAFE HANDLING> 17-5 Figure 17.5 Set the Parameters to Values that Allow Return from Failsafe. Click Clear Latch. Click yes to the switch to OOS to Release Failsafe. Then return to Manual operation state to resume manual operation of the valve. Then follow plant procedure to return to automatic control. The Deviation Error Failsafe configuration can later be restored by resetting the T2 parameter in Configuration>Position. Figure 17.6 Clear Latch Dialog Figure 17.
17-6 <17. FAILSAFE HANDLING> WARNING Setting the T2 Parameter, to cause failsafe after a sustained position error, can cause unwanted process shutdowns. The T2 setting should be used cautiously. Care must be taken to avoid interaction with other configuration parameters, particularly High and Low Position limits. ● Deviation Error, Air to close, High or low actuator pressure (Cases 2 and 4) Table 17.
17-7 <17. FAILSAFE HANDLING> To exit Failsafe for Cases 2 and 4 Step1 Restore the air supply or correct actuator problem. Check that the pneumatics are working correctly. Step2 Move the Failsafe dialog to one side of the screen to uncover the IVI display. (If the PID dialog is open, close it.) Step3 Record the Actual Position. (Shown as 103.41% in Figure 17.8. ) In this extreme example, the valve calibration allows for large over-travel between the open stop and 100% position.
<17. FAILSAFE HANDLING> Step7 17-8 This step requires privilege level 3, 4, 8 or 9. Open the Configuration dialog. Select the Position tab. The position limit changes made in Step 5 will prevent failsafe action from occurring and will disable FOA and Position High Limit. Unless there is an important control consideration, do not change these values. Click Clear Latch. Click yes to the switch to OOS to Release Failsafe.
App-1 APPENDICES Appendix A Glossary and Acronyms FAS Fieldbus Access Sublayer FMS Fieldbus Messaging Service MIB Management Information Base SMIB System Management Information Base MAN Manual mode RCAS Remote Cascade mode LO Local Override mode IMan Initialization manual mode ROUT Remote output mode Cas Cascade mode AUTO Automatic mode OOS Out of Service mode 0xf7 See hexadecimal. This is the number 247 represented in hexadecimal notation.
App-2 Condition Monitoring A technology for measuring the performance of process equipment and valves over a period of time to predict the need for maintenance. The technology evolved to meet NRC requirements GL 89-10, and has proven valuable to other process industries. ValveNavi offer a suite of diagnostic tools to implement condition monitoring. Connector A Connector is a coupling device used to connect the wire medium to a fieldbus device or to another segment of wire.
App-3 HSE Field Device An HSE Field Device is a fieldbus device connected directly to a High Speed Ethernet (HSE) fieldbus. Typical HSE Field Devices are HSE Linking Devices, HSE Field Devices running Function Blocks (FBs), and Host Computers. HSE Linking Device An HSE Linking Device is a device used to interconnect H1 fieldbus Segments to High Speed Ethernet (HSE) to create a larger network.
App-4 Position With a reciprocating valve, the position is the distance of the plug from its seat, normally measured as a linear motion of the valve or actuator stem. With a rotary valve, the position is the angle of rotation of the valve plug measured as angular rotation of the valve shaft. Position limit The Actuator can be mechanically set to stop at a predetermined position by setting an adjustment, sometimes with a handwheel or screw stop.
App-5 User Application The User Application is based on “blocks,” including Resource Blocks (RBs), Function Blocks (FBs) and Transducer Blocks (TBs), which represent different types of application functions. User Layer The User Layer provides scheduling of Function Blocks (FBs), as well as Device Descriptions (DDs) which allow the host system to communicate with devices without the need for custom programming.
App-6 Appendix B Configuring DI Blocks to TB Channels There are two DI (discrete input) blocks in YVP. They are used to communicate the state of internal (software) limit switches. The DI modes are displayed in IVI and the internal variables can be viewed with the Query service. To activate the DI blocks, each block must be scheduled (though not necessarily linked) and each must be configured to the correct channel in the TB. In an FB configurator set the DI channel parameter.
App-7 Appendix C Setting a Failsafe Strategy The user must design a strategy for safe handling of fault conditions that will be safe and effective for each control valve. Several levels of failsafe action can be configured using YVP and ValveNavi to support the safety strategy. As levels of safety are increased, more actions are required to restart a system that has gone into failsafe.
REVISION RECORD Title: Model YVP Management Software Manual No.: IM 21B04C50-01E Edition Date Page Revised Item 1st Nov. 2001 — New publication 2nd Nov. 2002 – – 2-1 4-3 Release of R2 Change of Images Change of Compatible OS 2.3 added Change in Registration 7-4 12-3 16-1 App-6 7.1.2 added 12.2 Scope Settings added Support TEXT file Appendix B deleted 3rd 4th Aug. 2004 Mar. 2008 – 12.1 14.3 Release of R2.20 Add servo output trending.
