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

Manual 4028 - Rev. 0 - 08/2008

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i ns t ruc t ion manua l FasTrak TM

1.0

2.0

3.0

4.0

5.0

6.0

1.11.21.3

2.12.22.32.42.52.62.72.8

3.13.23.3

4.14.24.34.44.54.64.74.84.94.104.11

5.15.25.35.4

3456

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3434

353637

3839

DescriptionSpecificationsModel selectionManufacturer’s identification

General safety instructionDevice Safety instrctionInstallationMaintenanceSpecial instructions for FT positioners of explosion protection type Ex iaElectromagnetic interferencePneumatic safetyElectrical safetyCorrect use

InstallationPneumatic connectionsPower board connectionsMechanical feedback linkage mounting

Using Remote Control SoftwareRemoteControl sw connectionStarting softwareThe main pageQuick Buttons‘Tuning’ & standard ‘System setup’Main variables and statusCFG PanelHART PanelThe Graph windowThe MenuSystem Calibration : Self Tune

Using Digital InterfaceInstallationConnectionMenuSetup Wizard

DimensionCertification

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1.0 Descrption

The FasTrak™ positioner is a high-capacity, high-precision digital-pneumatic valve controller that replaces aconventional positioner. The FasTrak™ has several advanced control and diagnostic features:

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

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1.1 Specifications

• ConnectionPOWER: 2 wire from signal (min 3.5 mA, 12-30 Vdc)ELECTRICAL CONNECTION:• Signal 1/2” NPT (or metric M20x1.5 on request)• Auxiliary input/output 1/2” NPT

(or metric M20x1.5 on request)PNEUMATIC CONNECTION: 1/2” NPT femaleCOMUNICATION PROTOCOL: Hart, TTL RS232

• InputANALOG: 4÷20 mA – Hart

TM protocol configurable

split rangeON OFF: 2x configurable digital inputs (optocoupler 24 Vdc)

• OutputANALOG: 4÷20 mA passive loopON OFF: 2x configurable digital outputs (optocoupler 24 Vdc)

• Stroke MovementFEEDBACK ANGLE OF ROTATION: 30°÷120°(<30° with lower resolution)ADJUSTABLE SPEED: range 0÷300 seconds, individually configurable for each directionCHARACTERISTIC CURVE:• Linear• Equal percentage• User definedCONTROL PARAMETER: individually configurablefor each directionTRAVEL CONTROL: Min. and Max limits, settablestroke limits, adjustable pressure on seat

• Air supplyINSTRUMENT AIR: free of oil, water and dust to ISO 8573-1 SUPPLY PRESSURE: 2.5÷10 barAIR CONSUPTION: 1.5 Nm3/h at 6 bar

• Performance Data (for angle >30°) according to IEC 61514-2HYSTERESIS+DEADBAND: ±0.15%REPEATIBILITY: ±0.15%SENSITIVITY: ±0.1%

LINEARITY: ±0.3%INFLUENCE OF AMBIENT TEMPERATURE:≤0.3% for every 10°CFLOW CAPABILITY: 180Nm3/h at 6bar (CV 2.3)ACTION: configurable single or double

• Environmental capabilitiesHAZARDOUS PROTECTION: ATEX II 2G Ex ia IICT6/T5/T4AMBIENT:• protection IP66 (NEMA4)• operation temperature -30°C to +80°CVIBRATIONS: compliant with ISA-S75.13CE MARK: CE conformity and EMC

• MaterialAluminium, copper free for external side with stainless steel feedback shaft

• Weight3.25 kg

• OptionsREMOTE FEEDBACK SENSOR UNIVERSAL LINKAGE FOR:• Linear long stroke actuator (70-1500 mm)• VDE/VDI 3845 for rotary applications• Lever for side yoke or top mounting applicationDIRECTLY MOUNTED PNEUMATIC ACCESSORIES:• gauges• look up valve• special boosterCAPTURED OR HIGHLY SILENCED EXHAUSTHIGH SPEED COMUNICATION KITHIGH CORROSION RESISTANCE VERSION

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1.2 Model selection

• Signal0 4÷20 mAH 4÷20 mA HartD Digital high speed

• Feedback1 standard2 Linear kit3 VDE-VDI (Namur) kit4 Remote5 Special

• HousingO ordinaryI intrinsically safeC corrosion resistantS special

• CertificationE European (CE or CE-ATEX)S Special

• Display0 blind cover1 with display

• Connection Electrical Air supply Air portsS 1/2” NPT 1/2” NPT 1/2” NPTM M20 1/2” NPT 1/2” NPT

• Exhaust1 standard IP662 conveyed3 high silenced

• Circuit options1 supply/output gauges2 lock-up device with supply/output gauges 3 special

FT

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1.3 Manufactorer’s identification

Every positioner FT is provided with a nameplate with its serial number. The year ofmanufacturing is indicated by the first twodigits of the serial number (*).P080000 year of manufacturing 2008

(*) The serial number is shown in the HART panel as Dev. ID see page 31

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2.0 General Safety Instructions

In order that you can make the best use of thisdocument and to ensure safety during commissioning,operation and maintenance of the equipment, pleasenote the following explanation of the symbols used: aswell as the instructions in this document, you must alsofollow applicable accident prevention and safetyregulations.

Please read this document carefully before installationand commissioning.

Symbol definitions

DANGERindicates an imminently hazardous situation which, if notavoided, will result in death or serious injury. (High levelof risk).

WARNING indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury. (Mediumlevel of risk).

CAUTIONindicates a potentially hazardous situation which, if notavoided, could result in minor or moderate injury. (Lowlevel of risk).

NOTEindicates a potentially harmful situation which, if notavoided, may result in damage of the product itself or ofadjacent objects. (Damage to property).

This chapter provides important instructions for yoursafety. Proper and safe operation of the FT positionerrequires:• proper transportation and storage• mounting, electrical and pneumatic installation and

commissioning by qualified personnel• correct operation according to the instructions in this

manual• correct use• careful maintenance

Every positioner FT is provided with a name plate with

its serial number. The year of manufacturing is indicatedby the first two digits of the serial number.

P081968 year of manufacturing 2008

In order to keep the device in a safe condition andensure safe operation, please carefully read and followthe instructions given in the sections marked with therespective symbols.The device must be shut down and secured reliablyagainst unintentional restart if it must be assumed thatsafe operation is no longer ensured. Possible reasonsfor this assumption can be:• visible damage of the device• failure of the electrical function• exposure to a storage temperature of more than 85 °C

for a longer time period• exposure to considerable strain or wear during

transport.Only the manufacturer is authorized to repair the device.If the device is damaged or faulty do not continue use.

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2.1 Device safety instructions

Observe the accident prevention rules of the H&Sorganizations. The non-observation of the followingsafety instructions and of the instruction manuals canresult in serious injury. Installation must be carried byour qualified person.

2.2 Installation

• The electrical connections must be made according tothe diagram and label.

• To achieve optimum performance from the FTPositioner, it is recommended that shielded cables beused when installing the positioner.

• The use of a ground strap between the FT positionerhousing and a suitable earthed point is necessary.

• When changing electrical connections inside the FT positioner housing, observe ESD handlingprecautions. The use of a conductive, earthed, wriststrap is recommended.

• The pneumatic connections must be done accordingto the diagram and label, do not allow the FTPositioner supply pressure to exceed 10 bar.

• The supply circuit must be protected ito prevent thevoltage or current exceeding the stated limits.

• The equipment must be provided with cable entries andfiller plugs certified according to the required certification.

• The actuator must be installed and used according tothe design specification.

• The fluid must be chemically compatible with thegaskets and lubricant used in the installation.

• If the FT positioner is to be installed in a hazardousarea, ensure that electrical barriers are used betweenthe FT positioner and the electrical power sources.

• To prevent injury always ensure that the air supply isremoved from the FT positioner before the ModeSelection Plate is changed.

• Only trained personnel should permitted to alter thesoftware control parameters stored within the FTpositioner. Incorrect settings may lead to personalinjury and or property damage.

2.3 Maintenance

Before making changes to the pneumatic configuration,make sure that the compressed air supply is isolated

from the FT positioner and to avoid unpredictablemovement of the actuator always remove the electricalpower to the FT positioner electronics before changingelectrical connections.

• Must be done by qualified person • Cleaning must be done with a humid cloth• Clean, dry air. No oil, no grease

Product DisposalThe disposal of this product should be carried out in away that conforms to the 2007 Weee Directive, and anyother locally applicable directions and regulations.

2.4 Special instructions for FTpositioners of explosion protectiontype Ex ia

In a hazardous area the FT positioner is to be installedwith electrical barriers between the FT positioner andthe electrical power sources.

The type plate is attached to the positioner. It indicatesthe degree of explosion protection and the certificatevalid for your positioner. For details please refer toenclosed “Certificates”. Additional electrical informationare shown the internal electronic board label.

The FT positioner’s mechanical enclosure andcomponents are suitable for installation in hazardousatmospheres with “protection constructional safety”,

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specifically tailored to the interests of non-electrical,according to the marking.

II 2G c IIC T6

The FT positioner’ s electronic circuit and componentsare certified such that when used with the specifiedwiring device, the signal will not create any sparks andthe surface temperature will not rise according to themarking.

II 1G Ga Ex ia IIC T6/T5/T4

The complete FT positioner is suitable for installation inpotentially explosive atmospheres 94/9/CE ATEXdirective.

I II 2G Ex ia IIC T6/T5/T4

Equipment group II surface industry, category 2 for usein zone 1 with explosive atmospheres caused by gases,vapours or mists, Group II and class of ignitability C inconformity to types of protection standardized EN60079-0. The component is considered to be suitable forinstallation with temperature classification:

• with FT positioner supplied via connector J3, 4-20 mAloop, only, with no connection to connectors J6, digitalinput & J1 digital output or connector J10, analoguefeedbackT5 in ambient temperature -20° to +80°C T6 in ambient temperature -20°to +60°C

• with FT positioner supplied using all of the inputsT4 in ambient temperature -20° to +80°C T5 in ambient temperature -20° to +60°C

WARNING• Any user-made changes or manipulations of the

device are prohibited! Only the manufacturer and anexpert explosion protection are authorized to modifythe device.

• Before re-using a FT positioner that has already beenused in another installation always reset the device tothe factory setting. Never start the autoadjustmentfunction before having restored the factory setting!Otherwise, hazardous situations may occur due to

improper settings.• Do not use the (J7) communication interface when the

positioner is installed and used in the hazardous area.

WARNING• Do not use flammable gas nor oxygen or oxygen-

enriched gas as a pressure medium.• Use cable entries and cables approved for a service

temperature corresponding to the maximum ambienttemperature increased by 10 K or corresponding tothe minimum ambient temperature, respectively.

2.5 Electromagnetic interference

• Do not lay signal lines close to power lines. Powerlines produce interference in their near vicinity, whichmay affect measured value transmission on the signalline.

• When changing electrical connections inside the FT positioner housing, observe ESD handlingprecautions. The use of a conductive, earthed, wriststrap is recommended.

• It is recommended that the lid is rest closed in normaloperation.

WARNINGAlways observe the specifications and specialrequirements for your positioner stipulated in theapplicable certificate.

2.6 Pneumatic safety

• Observe the accident prevention rules of the H&Sorganizations.

• Observe the safety instructions for the pneumaticactuator used.

NOTE• Take suitable precautions to ensure that even in the

case of malfunction the positioner’s max. admissibleoperating pressure is not exceeded. Otherwise, thepositioner and/or the actuator may be damaged.

• The positioner must be supplied with instrument air freefrom oil, water and dust according to ISO 8573-1, Class 3- Purity: max. particle size 5 μm, max. particle density5 mg/m3.- Oil content: max. concentration 1 mg/m3.

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- Pressure dew point: maximum value 10 K belowoperating temp.- Before using these products with fluids other than airor for non-industrial applications, consult STI.

Before connecting the air pipes, blow them out toremove dust, splinters and other particles.

2.7 Electrical safety

WARNING• Observe the common safety regulations and the

accident prevention rules of the H&S organizations.• Observe the common standards and safety

regulations for the installation and operation ofelectrical systems.

• When connecting the device, observe all electricalspecifications in these operating instructions or in thedrawing.

• For the electrical installation of explosion-protecteddevices, observe all standards, regulations anddirectives governing explosion protection and applicablefor the construction and use of explosion-protectedsystems, the directives for explosion protection (EN60079), and the special requirements and specificationsfor your devices. In particular make sure that:- Used in situations that comply with the certificationconditions stated in this handbook.- Maintained only by qualified personnel with adequatetraining on hazardous area instrumentation.- This product is not intended for use in life supportsystems.- The use of a ground strap between the FT positionerhousing and a suitable earthed point is necessary.- The supply circuit must be protected to preventcurrent exceeding the limit fixed.- The equipment must be provided with cable entries andfiller plugs certified according to the required certification.

2.8 Correct use

The FT positioner is an electro-pneumatic positioner forpneumatic final control elements. It is designed for beingattached to linear and rotary actuators following theinstructions in this manual. The positioner may be usedonly for the applications listed in these operatinginstructions. Any other use is considered as incorrect.The signal current circuit and the input and output

circuitry must meet the explosion protectionrequirements stipulated in the certificates

DANGEROnly those persons familiar with the installation,commissioning, operation and maintenance of the FTpositioner or similar instruments who have the requiredqualification and have read and understood theoperating instructions are authorized to work on thepositioner.These persons must be sufficiently trained andexperienced and know the relevant standards andregulations to be able to judge their assigned tasks andrecognize potential hazards. Only persons who arequalified or have been trained adequately and who havethe required certificates are authorized to work onexplosion-protected devices.

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3.0 Installation

Remove the FT positioner from its packing, thepneumatic and electric port are protected by plasticplugs. These plugs must be removed and all ports notconnected must be plugged with tight plugs suitable forthe pressure rating and area classification.

3.1 Pneumatic connections

Pressure line and port A and port B are 1/2” NPTfemale. The full flow performance of FT positionerrequire that the piping between FT and actuators has tobe 1/2” without any restriction and short as possible, thepressure line pipe has to be sized to avoid significantpressure drop during the actuator stroke.

During piping connection be careful to keep the internalside of piping and fittings free from thread sealingmaterial and any other contaminant.

The FT positioner is suitable to operate from 2.5 to 10bar but the line pressure must be set lower than actuatordesign pressure.

No load or bending moment are allowed by the piping onFT connections.The FT positioner is suitable for rotary or slidingactuators; double acting with or without spring or singleacting.The port “A” is fully vent in case of power fail and/orsignal 0%.

Double acting:the port “A” must be connected to the actuator airchamber that has to vent at 0 signal position.

The port “B” must be connect to the other actuator airchamber, that has to be pressurized at 0 signal position.

Port “A” connected to the stem side port on slidingactuator that has to extend stem on power fail and 0signal.

Port “A” connected to the port opposite of stem side onsliding actuator that has to retract stem on power fail and0 signal.

Double acting with spring:the port “A” must be connected to the actuator port thathas lower volume on air fail (volume minimized by springaction).The port “B” must be connect to the other actuator airchamber, that has to be pressurized at 0 signal position.

Single acting:the port “A” must be connected to the actuator air chamber.

The port “B” must be plugged.

Important: to set as single acting the plate (see page 14)FT must be moved to read single. The factoryconfiguration of the FT is double acting.

To check that the correct connections have beenmade, the system supply can be pressurised withoutany power signal. With no power rest that thevalve/actuator moves to the 0% signal position.

PORT “B” PORT “A”

Air Supply

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3.2 Power board connection

ENCODER Supply (Red)

ENCODER Signal (White)

ENCODER Return (Black)

4 - 20mA Set Point

4 - 20mA Return

Analogue F/B +ve

Analogue F/Back Return

Digital Inputs

Return

+ 24V

Dgital Outputs

Return

HART MODEMConnection

DisplayOption

FactoryUse Only

PO

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NT

IOM

ET

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FO

RFA

CTO

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US

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NLY

SERIALCOMMS

MODE SELECTPLATE

M3 x 16 Screws

0V TX

RX MODE

TO SELECT MODELoosen both M3x16 Screws and

slide plate to set for Actuator Type

SINGLE ENDED DOUBLE ENDED

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4-20mA input signal:Input port J3 should be connected to HART compliant 4-20mA signal source.

Input signal is used to:• Provide power to the positioner• Inform the positioner about the “desired position”.

The HART communications signal is superimposed on the 4÷20mA signal. The signal generator and theintrinsically safe barrier must be compliant with the HART protocol .

NOTE

1. UNSPECIFIED EXCEPT THAT IT MUST NOT BESUPPLIED FROM NOR CONTAIN UNDERNORMAL OR ABNORMAL CONDITIONS ASOURCE OF POTENTIAL WITH RESPECT TOEARTH IN EXCESS OF 250 VOLTS RMS OR 250VOLTS DC

2. A POSITIVE ATEX CERTIFIED SHUNT ZENER

DIODE SAFETY BARRIER OR GALVANICISOLATOR FOR GROUP IIC ia, WHOSE OUTPUTUo LESS THAN OR EQUAL TO 30V Io LESS THANOR EQUAL TO 120mA Po LESS THAN OR EQUALTO 0.65W AND IS SUITABLE FOR USE WITHSMART TRANSMITTERS.

3. THE ASSOCIATED APPARATUS (Co), LESSTERMINAL (Ci), GIVES THE TOTAL EXTERNALCABLE CAPACITANCE PERMITTED FOR EACH

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SEPARATE I.S. CIRCUIT. THE ASSOCIATEDAPPARATUS (Lo), LESS TERMINAL (Li), GIVESTHE TOTAL EXTERNAL CABLE INDUCTANCEPERMITTED FOR EACH SEPARATE I.S. CIRCUIT.

Refer to “Hart Application guide, HCF-LIT-34” forimportant information about Intrisically safe barrier andHart signals.

Designing an IS System Using Shunt-diode Barriers

Designing an IS direct-current loop simply requiresensuring that a field device has sufficient voltage tooperate, taking into account zener barrier resistance,the load resistor, and any cable resistance.When designing an IS loop using shunt-diode barriers,additional requirements must be considered:• The power supply must be reduced by an additional 0.7 V

to allow headroom for the HART communication signaland yet not approach the zener barrier conduction voltage.

The series resistance for the same zener barrier may beas high as 340 Ω. To calculate the available voltageneeded to power the positioner, use the followingequation:Power Supply Voltage – Zener Barrier Resistance XOperating Current (mA) = Available Voltage

Example: 26.0 V – 340 Ω 22 mA = 13.0 V

Any cable resistance can be added as a seriesresistance and will reduce the voltage even further. Inaddition, the power supply to the zener barrier must alsobe set lower than the zener barrier conduction voltage.For example, a 28 V, 300 Ω zener barrier would typicallybe used with a 26 V power supply.

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Analog feedback:

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

NOTE

1. THE ASSOCIATED APPARATUS (Co), LESSTERMINAL (Ci), GIVES THE TOTAL EXTERNALCABLE CAPACITANCE PERMITTED FOR EACHSEPARATE I.S. CIRCUIT. EXTERNAL CABLEINDUCTANCE PERMITTED FOR EACH SEPARATEI.S. CIRCUIT. THE ASSOCIATED APPARATUS (Lo),

LESS TERMINAL (Li), GIVES THE TOTAL.2. A POSITIVE ATEX CERTIFIED SHUNT ZENER

DIODE SAFETY BARRIER OR GALVANICISOLATOR FOR GROUP IIC WHOSE OUTPUTPARAMETERS ARE LESS THAN OR EQUAL TOTHAT SPECIFIED.

3. I.S. INSTALLATION EARTH (REQUIRED FORZENER BARRIERS ONLY).

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Digital IN/OUT

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

Digital OUTPUT:Digital output is isolated by an optocoupler.The output ismade by a transistor with a series resistor of 1Kohm.When the output is energized the impedance is less that4 Kohm, when deenergized the impedance is greaterthan 100Kohm. The optocoupler requires an externalpower source to be energized via J1 pins 1 & 4.

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Intrisically safe data :

High speed serial connection :

A special interface cable is needed : STI code 81569

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Electrical connection:

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3.3 Mechanical feedback linkage mounting

The FT has been designed to work on feedback rotationangle between 30° and 120°. Any feedback linkage mustbe able to generate a rotation angle between 30° and120° on full actuator/valve stroke.

Any backlash, linearity error, elasticity of feedbacklinkage will affect the positioning performance

The feedback shaft has about 120° max reading angleon 360°. There are no mechanical stops on the shaft,there is no chance to damage the positioner by over-rotation during installation.

The feedback shaft is 8mm diameter and fully cylindrical.It can be initially connected with any orientation to thefeedback linkage. The alignment of linkage angle insidethe 120° reading range can be done by rotating thefeedback shaft with respect to linkage. The reading angleis shown on the RC sw or displayed on the handhelddigital interface.

• By RC software:on CFG panel looking position sensor window.

Unlock the connection between FT shaft and linkage.If the valve/actuator is not on hard limit 0% signalposition drive it pressurizing port B by position sensoradjustment verify that the valve/actuator move to 0%signal position.

WARNINGWhen the send button is pressed the system can move.

Rotate the FT shaft slowly in the same direction(clockwise or counter-clockwise) that linkage would rotateto move valve/actuator. On each complete FT shaft turnthe scroll bar index will move on 120° shaft rotation,moving always in the same direction (left to right or rightto left ). Rotate the FT shaft until the scroll bar index startto move outside of the red/orange zone. Lock theconnection between FT shaft and linkage. Now usingposition sensor adjustment it is possible drive thevalve/actuator to check that both hard limit are in the rightposition. Both have to be out of the red/orange zones.

• By digital interface:hand held see the command tree pag. 44

Unlock the connection between FT shaft and linkage.If the valve/actuator is not on hard limit 0% signalposition drive it pressurizing port B by position sensoradjustment (command 5).

Rotate the FT shaft slowly in the same direction(clockwise or counter-clockwise) that linkage wouldrotate to move valve/actuator.

On each complete FT shaft turn the variable will changebetween 0 and 4095 on 120° shaft rotation, movingalways in the same direction (0 to 4095 or 4095 to 0).

If the variable moves from 0 to 4095 rotate the FT shaftuntil the variable is 500 ± 250 then lock the connectionbetween FT shaft and linkage.

If the variable move from 4095 to 0 rotate the FT shaftuntil the variable is 3600 ± 250 then lock the connectionbetween FT shaft and linkage.

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Now using position sensor adjustment it is possible drivethe valve/actuator to check that both hard limit are in theright position. Both have to be between 250 and 3850.

An other alternative method to set the mechanicallinkage in right position is:

1. with the positioner connected to the PC and withoutmechanical linkage rotate the FT shaft slowly untilscroll bar index reaches the central position.

2. evaluate the angle between the actual position and

the position at 50% of stroke of the actuator, theangle is measured on seat of lever where the FTshaft will be mounted.

3. rotate the FT shaft from central position to an angleabout equal at angle measured to previous point withdirection that bring the FT shaft in the position that ithas if the mechanical linkage is connected.

4. connect the mechanical linkage to the FT shaft.5. Now using position sensor adjustment it is possible

drive the valve/actuator to check that both hard limitare in the right position.

4.0 Using remote control software

Sw installation• Insert the CD (or download the installation file)• Run setup.exe• Follow the instructions on the screen.

4.1 RemoteControl sw connection

HART interface connection:Connect your HART interface at the same cables of the4-20mA input signal (J3).

If the 4-20mA signal generator is not HART compliantcommunication problems may be expected.

HART interface connection:Connect your HART inter

DANGERThe TTL High speed interface is not Intrisically Safe.Use this type of interface only in a Safe Area or take allthe necessary precautions before using.

4.2 Starting the sw

• Run the sw starting from the desktop icon or from theWindows Start menu.The “Select Communication” page is displayed.

• Select the right communication port.

Only the available communication ports are displayedin the combo box.

• Select the Communication mode (TTL or HART).

• Disable “AutoDownload and Refresh Vars” if you wantto reduce the refresh rate (and the traffic on thecommunication line).

• Press the “OK” button.

Select the right communication port.

Select the Communication mode (TTL or HART).

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Download buttonDownload all the parameters

from the FT positioner. At the end of the download the values displayedon the RC sw are the same as the

FT positioner.

4.3 The Main page

4.4 Quick Buttons

• “Main vars” and “Status Information” are normally refreshed automatically.• The other parameters are refreshed manually with the “Download” command.• The refresh rate depends on the communication mode (HART or TTL)• If the “Autodownload and Refresh vars” option is disabled, use the “Download” command to refresh the parameters

use the “Refresh” button (located near the “Communication Status Led” when “Autodownload” is disabled) to refreshthe main variables.

Quick Buttons

Communicationstatus led

“Tuning” &standard “SystemSetup” area

Advanced Menus

Positioner Main vars and status information

Graph buttonOpen the Graph window.

Password buttonOpen the Login window. In order tochange the parameters or to access

configuration windows, a login isrequired. The default standard

password is: 12345.

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4.5 “Tuning” & standard “System setup” area

Definitions:Limit: when a limit is configured the Requested positionis limited to this value.Example: Set the Limit at 95%. Even if the signal inputis 20mA and the theretical Request position is 100%,the applied Request position is 95%.

CutOff: When a cutoff is configured, if the Requestedand Actual position falls inside the Cutoff area theRequest position is fixed at the min (or max) value.Example: Set the cutoff at 5%. When the Request positionis less of 5% and the Actual position is less of 5% a fixedpressure is applied in order to put the actual position at 0%.

Tight (open/close) pressure: this defines the pressureapplied when a cutoff is active. (Advanced parameter).

Open/Close: Information related to “Signal Fail Action”configuration.

WARNINGThe signal Fail Action setting informs the Positionerabout what happens when the electrical power supplyfails. This behaviour is determined by the pneumaticconnection and is not software configurable.

WARNINGOn some type of valves it is mandatory to enable acutoff to ensure that the valve works properly ( to ensurefull trust on seat).

Travel control:

Open Limit [50..100 %]:Specify if a Limit or a CutOff is configured in the opendirection.

Close Limit [0..50 %]:Specify if a Limit or a CutOff is configured in the closedirection.

Tuning: A lot of parameters are configurable with different

settings for the open and close directions. This is tomaximize the performance of the system. If the Mono

flag is checked the first value of each parameter isautomatically copied into the second one.

Kp [0,1 .. 25]:Proportional gain is the multiplier of the error (differencebetween input signal and actuator actual position) and itis expressed in percent. It is active only for an errorwhich is bigger than dead band value.A different gain for each stem direction can be selected.

Ti [OFF- 10 .. 100000 ms]:Integral factor.The integral term accelerates the movement of the processtowards setpoint and eliminates the residual steady-stateerror that occurs with a proportional only controller.However, since the integral term is responding toaccumulated errors from the past, it can cause the presentvalue to overshoot the setpoint value. A small “Ti” value isequal to an aggressive integral effect. A different integralfactor for each stem direction can be selected.

Td [0..1000]:Derivative factorThe derivative term slows the rate of change of thecontroller output. Setting Td equal to “0” disable; thederivative factor. Increasing the value increases thederivative action.

Dead Band [0..10]:Dead band prevents (at expense of the accuracy) thatthe valve, in the controlled condition, keeps continuouslyhunting for the target position. The dead band settingcan be used to reduce continues cycling (“hunting”)around the target position. Increasing the value reducesthe accuracy, but can improve stability.

Velocity Limit [0..655 sec]:Velocity limit is the value expressed in seconds of thestroking time for each direction

Damping Factor [0..255]:Apply a damping effect at the signal rate of change.Increasing the damping factor causes a smooth effecton the signal rate of change.

Switched ctrl err threshold[0..100 %]:When the error is greater than this threshold:

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• the positioner tries to impose a fixed ΔP in order tomaximize the speed.

• the Integral contribution is reset to zero.

Sweep pressure [0..10 bar]:Fixed ΔP applied when the error is greater than‘Switched ctrl err threshold’.

Switched control function Enabled[ON/OFF]:Turn ON/OFF the “Switched control function”.

Normally the following settings work well: • sweep pressure equal to the line pressure

• the Switched ctrl err threshold equal to [100/min(Kp)]*[‘sweep pressure’/10]

4.6 Main vars and status

This window reports information about the status of thepositioner.The LED in the top-right position informs the user aboutthe information status:YELLOW LED blinking: the communication is running.RED LED: communication problem.

ActPos [%]:Actual position measured by the positioner.

ReqPos [%]:Input signal or the request position.The source of the requested position depends on the“service state”.While “in service” the requested position comes from the4-20mA input signal and the split range setting. While“out of service” the requested position comes from themanual setpoint setting.

ErrPos[%]:ReqPos-ActPos.

Input [mA]:Current read by the 4-20mA loop current Input channel. The user can calibrate the value displayed using the

commands in the “CFG” area.

PI [bar]:Line pressure

PA [bar]:Pressure measured at port A of the positioner.

DP[bar]:Differential pressure measured: portB-portA.

Calibration status / Status:Displays the status of the internal sensor calibration.

Calibration status / Error code:

Calibration status / Data Source:

Service State / Mode:Allow the selection of the Service State.- In Service: the Requested Position is evaluated

continually by the positioner starting from the 4-20mAsignal value.

- Out Of Service (Manual): the Requested Positioncomes from the manual setting in the window. Whenthe Service Mode is set to “Out Of Service (Manual)”the first manual setpoint is equal to the last “Actualposition” in order to minimize the movement of thesystem.

- Out of Service: special mode selected automaticallywhen the system is not calibrated. In this mode port Bis fully pressurized and port A is depressurized

WARNINGChanging from “Out of Service” to “In Service” cancause the actuator to move.When the positioner is turned ON it starts automaticallyin “In Service” or “Out of Service” based on the positionsensor calibration status.

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Position sensor:Pos. raw ADC reading (bits)This is the read value of the position sensor measuredvalue before calibration.The same value is shown in the scroll bar below.During the mechanical linkage adjustment the user canuse this scroll bar to verify the alignment: the raw ADCvalue must fall inside the range. The best condition iswhen the 50% mechanical position is near the middlevalue of the scroll bar (2048 +/- 500).

Position sensor adjustment:This button opens a window that helps the user to movethe actuator. The slide bar enables the user to select asafe speed to move in one direction or in the other.

Move the slide to the desired position and press “Send”.To increase the movement speed, move the slider farfrom the middle position.

WARNINGWhen the send button is pressed the system can move.

4.7 CFG panel

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Digital inputs/outputsRefer to the “electrical connection” for information aboutthe use of “Digital inputs/outputs” in Intrisically Safe areaand proper connection to an IS barrier.

Digital Input 1:Configure the action that the positioner will do whenDigital Input 1 is activated.• Shut down: the I/P is de-energized and the spool goes

in the default position -> Port B is fully pressurized.• Pressurize Port “A”: the I/P is fully energized and Port

A is fully pressurized.

WARNINGThe “Pressurize Port A” option is not “safety”: if the 4-20mA signal is removed, or the air closed, the systemcan move.

Digital Input 2:Same as Digital Input 1.

Digital Outputs:Open the Digital Outputs configuration window. For eachdigital outputs it is possible to select the rules of activation.

Not IN SERVICE:Digital output is activated when the system is not INSERVICE.

Position Below Limit 1:Digital output is activated when the actual position isbelow the limit specified in “Position Limit 1”.

CAUTIONDon’t use this is a virtual limit switches for a safetyapplication.

Position Above Limit 2:Digital output is activated when the actual position isabove the limit specified in “Position Limit 2”.

CAUTIONDon’t use a virtual limit switches for a safety application.

Pressure Fail:Digital output is activated when the pressure of the line( PI ) is below the limit specified in Min PI Pressure.

Position error:Digital output is activated when the system is IN SERVICEand the position error is >= 5% for at least 10 sec.

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SYSTEM CALIBRATIONStarts the calibration and self-tuning procedure.

The “Only HARD LIMITS” option allows the calibration ofthe travel without performing self tuning.

WARNINGWhen the “Start Calibration” button is pressed thesystem will move.

4-20mA CALIBRATIONStart the calibration of the selected option:

Loop Current ADC 4mAReads the actual value of the input current and calibratethe internal system to always read this value as 4mA.

CAUTIONBe sure that you are supplying the positioner with astable, accurate 4mA reference.

Loop Current ADC 20mAReads the actual value of the input current andcalibrates the internal system to always read this valueas 20mA.

SPLIT RANGE INPUTEnables the split range function.The values in Lower range value and Upper range valueare referred to the 4-20mA input.A minimum distance of 20% is required between Lowerand Upper value, so up to 5 split range area can beconfigured in different concatenated positioners.The result of the split range is then evaluated by the“Transfer Function Curve”.If the Low range value is equal to 0% and Upper rangevalue is equal to 100% the positioner interprets 4mA asthe 0% Request position and the 20mA as 100%.If the Low range value is equal to 0% and Upper rangevalue is equal to 50% the positioner interprets 4mA asthe 0% Request position and the 12mA as 100%.

Lower range value (%):Specifies the Lower range value.

Upper range value (%):Specifies the Upper range value.

Setpoint range function (enabled):Enable or disable the split range function.

The “Transfer Function Curve” shows the effect ofSplit Range Function in a graphical way.

INPUT CHARThe Characterization specifies the relationship betweenthe Input signal and the Requested Position.

Transfer Function:Select one of this characterization:• Linear• Standard 1-50 : equipercentage 1:50• Standard 50-1 : inverse equal percentage 1:50• User : user defined• Standard 1-25 : equipercentage 1:25• Standard 25-1 : inverse equal percentage 1:25• Standard 1-30 : equipercentage 1:30• Standard 30-1 : inverse equal percentage 1:30

Transfer Function Curve button: Open the Transfer Function Curve window

- The “Close” and “Open” label in the “Requestedposition” axis shows the effect of the “Signal FailAction” selection.

- The “4.0mA” and “20.0mA” in the “Signal Position”

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show the effect of the “Split Range” setup.- The effect of “Limit” and “CutOff” are showed on the

graph.- Only the “User Curve” can be modified, the other

curves are fixed if you want to start from a standardcurve and generate a user curve you can:• Select the starting curve• Save the Table (File Save Table).• Select “User Curve”• Load the saved Table• Modify the table

- To “Send” a “User Curve” to the Positioner press the“Send” button.

- The Signal Position steps are fixed, you can onlychange the Requested position value.

- You can change a value in the table or click_&_dragthe dot in the graph.

- If you hold down the shift key and click on two dots, thesystem will automatically do a linear interpolationbetween these two points.

Analog OutputAnalog Feedback- Selects the Analog Output (4-20mA signal out) report

the “Actuator position” or the “Reverse ActuatorPosition”.

4.8 HART panel

HART PARAMETERS

Tag:- The Tag is a 8 character label assigned by the end user

based on the location and use of the field device. It’s a8 character (6 byte) Packed ASCII string used to identify

the field device.The term originated when physical tagswere attached to instruments for this purpose.

Date:- The date is represented by three 8-bit binary unsigned

integers representing, respectively, the day, monthand year (minus 1900). It’s a date code, used by theMaster for record keeping (e.g. last or next calibrationdate).

Descriptor:- The Descriptor is a 16 character (12 byte) Packed

ASCII string used by the Master for record keeping.- The default value is a blanked string, 16 bytes long.

Message:- The Message is a 32 character (24 byte) Packed

ASCII string used by the Master for record keeping.- The default value is a blanked string, 32 bytes long.

Polling address:- In the HART Protocol, the polling address is an integer

used to identify the field device. It is used to constructthe Short Frame Address. The Polling Address is setto 0 in point to point installations.

Dev. ID:- This number is different for every device manufactured

with a given Manufacturer ID and Device Type, itcorresponds to serial number (see page 7).

HART Protocol- Show some communication parameters which may be

useful for debugging communication problem.

HART CommunicationHart Mode:- ‘Time management’ and ‘Time management

(performance)’ are two different way to manage theHart modem. If you experience of communicationproblems try changing this option.

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Using the up/down and right/left arrows on the keyboardit is possible to move in the graph’s window.It’s also possible to “zoom in”: hold the right mousebutton, define the window to be zoomed in, release theright mouse button.

By pressing the “Graph Cfg” button, the user canchoose the following signals on the graph:

4.9 The Graph window

This feature allows user to record set point and position signal waveforms for 10 seconds. Moreover, it comes withsome tools to analyze the acquired waveforms. This feature is only available on the “Remotectrl” program with a TTLconnection.

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4.10 The Menu

Menu: FileLoad:Load a saved set of parameters into the RC interface.

Save:Save the current set of parameters in a .qtp file.

Report:Create a document in .rtf format with the actualparameters (similar to the Save command but the fileformat is compatible with text editing software).

Exit:Close the application.

Menu: DeviceDownloadPerforms the same function as the quickbutton.

Upload ParamSends the displayed parameters to the positioner.

Upload Param + Calib dataThe same as the Upload Param command but additionallysends information about the calibration.

Menu: PasswordLoginPerforms the same function as quick button

ChangeChanges the password.

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4.11 The Graph window

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

Starting page

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

WARNINGThis panel is to inform the positioner about the actionand is not to specify the user desired behaviour. Thepositioner is not able to change the mechanical defaltpiston by itself.

gallod

Text Box

System Calibration: self-tune

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Position sensor alignment

This page helps you align the position sensor.

Pressing the ‘Position sensor adjustment’ button opensa window where you can find a tool that allows you tomove the valve.

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Actuator volumeSpecify the size of the actuator

Actuator TypeSpecify the type of actuator. Remember to check the position of the ‘Mode select plate’ inside the positioner.

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Booster type

“Only stroke” or “full calibration”

Select “Control parameters and stroke” if you want toperform a full SelfTune procedure.

Select “Only stroke” if you want only to update thehardware limits of your valve.

Press “Start” the perform the SelfTune.

The progress bar informs you about the “SelfTune”status.

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5.0 Using digital interface

5.1 Installation

375 Easy Upgrade Programming Utility is required to upload and download files to the 375 Field Communicator.The Programming Utility communicates with the Field Communicator and permits file movement between a PC anda 375.- Start the Programming Utility- Verify that the 375 is up-to-date, checking and updating the HART Application for 375 if it’s necessary.

Refer to the 375 Field Communicator User’s Manual for reference.

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- Select File/Import DDs from Local Source.

- In the Select Path to DD Files dialog, browse to the location of the DDP (directory \375 on the FT installation CD).- Each DDP (Device Driver Package) consists of two files. A DD binary has an .hdd file extension, and a

corresponding binary header has an .hhd file extension.- Select OK after the desired DDP(s) have been found. The Programming Utility adds the selected DDP(s) into its

database.

5.1 Connection

- Connect the FT device to the 375 (refer to the 375 Field Communicator User’s Manual if you need instructions).- Turn on the 375 Field Communicator. The 375 Main Menu is displayed with HART as the default application.- Double HART application to run the HART application.

On startup, the HART application will automatically poll for devices.If a live HART device is connected to the 375 Field Communicator, the HART Application main menu will be displayedautomatically with key parameters from the connected device.

gallod

Text Box

2

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5.3 Menu

1 Manufacturer2 Model3 Dev id4 Write protect5 Tag6 Descriptor7 Message8 Date9 Hart revision10 Fld dev rev11 Software version12 Poll addr13 Num req preamms

7 Co

mm

unic

atio

n

1 Kp opening 1.02 Kp closing 1.03 Ti opening 0 msec4 Ti closing 0 msec5 Td opening 0 msec6 Td closing 0 msec7 Dead band 0.20%8 Open velocity limit 10.00s/100%9 Open vel.lim.funct. Disabled10 Close velocity limit 10.00s/100%11 Close vel.lim.funct. Disabled12 Damping open 013 Damping close 014 Switched ctrl err 25%15 Sweep pressure 10.0bar16 Switched ctrl funct. Enabled

3.2

Tuni

ng

1 System Calibration2 0%/fail signal pos. Close3 Actuator Volume don't know4 Actuator type Double5 Booster or QE Yes6 PI 7.00 bar7 Norm.supply press. 6.50 bar8 Status9 Calib.progr./err. 10 Progr./err. Details

6 Ca

libra

tion

1 Sens. pos. reading 4512 Sens. pos. lower lim. 03 Sens. pos. upper lim. 40955

Posi

tion

sens

or

1 ActPos2 ReqPos3 Manual Setpoint 0.00%4

Man

ual

mod

e

1 In Service2 Out Service - Manual2.

1 Se

tOp

erat

ion

mod

e

1 Open cutoff/limit 95%2 Open mode CutOff3 Close cutoff/limit 5%4 Close mode CutOff3.

1 Tr

avel

Cont

rol

1 Travel Control2 Tuning

3 Sy

stem

Setu

p

1 Set operation mode2 Operation Mode In Service2 Status3 Calib.progr./err.4 Progr./err. Details5 Data source2

Syst

em S

tatu

s

1 ActPos 100.00%2 ReqPos 0.99%3 Input 4.00mA4 PI 6.00bar5 PA 6.00bar6 DP 6.00bar7 TE 13.70 °C

1 M

ain

Vars

1 Main Vars2 System Status3 System Setup4 Manual Mode5 Position Sensor6 Calibration7 Communication

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5.4 Setup Wizard

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

Setup Wizard starts from :6 Calibration ->

6.1 System Calibration

Are you sure you want to start self-tune ? Valve will move!

Calibration in progress ... step 140

Self Tune completed

Refresh parameters ... 1

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

Boosters or Quick Exhaust- NO- YES

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

Return INSERVICE- NO- YES

Select Actuator Volume1- SMALL2- SMALL3- SMALL4-MEDIUM,,,,

Select Actuator Type1- Single2- Double3- Double with spring

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6.0 Dimensions

STI S. r. l . - V ia Pasco l i 10a/b 24020 Gor le (BG) I ta lyTe l . +39 035 2928.2 - Fax +39 035 2928.247www.st iactuat ion.com - in fo@st is t rumentaz ione.com

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