FY302 - AssetView IHM
Contents
1. The user must type the reference temperature and the device will be calibrated with this value Note the 40 to 85 C limits when executing the calibration SECONDARY VALUE __ Indicates the unit related to the temperature UNIT Advanced Setup TSO a FINAL VALUE If FINAL VALUE is less than this value the valve is forced to be fully CUTOFF LOW closed FINAL VALUE is the value of the desired position FINAL VALUE If FINAL VALUE is greater than this value the valve is forced to be CUTOFF HIGH fully opened FINAL VALUE is the value of the desired position Set Point Limits SP LO LIMIT Set point lower limit of the AO Block SP HI LIMIT Set point upper limit of the AO Block _Flow Char CHARACTERIZATION TYPE Valve characterization type LINEAR the real position will be represented as a linear chart with the desired position TABLE the user can characterize the real positions according to the application EP25 EP33 and EP50 the EP Equal Percentage curves provide a larger travel only for wide set point variation OO25 Q033 and QO50 the QO Quick Open curves provide a larger travel for narrow set point variation CURVE BYPASS Enables disables the curve CURVE LENGTH Indicates the number of points that will be used to define the curve After selecting the table the user must type the input and output values in percentage To configure the points that define the ch2. 32 characters DEVICE ID Indicates the identification code of the positioner This code can have up to 32 characters MANUFACTURER Identifies the positioner manufacturer DEVICE TYPE Identifies the positioner type for a specific manufacturer MAINBOARD SERIAL NUMBER Indicates the main board serial number MODULE SERIAL NUMBER Indicates the serial number of the positioner transducer module ORDERING CODE Indicates the positioner ordering code Actuator ACT MAIN ID Indicates the identification number of the actuator manufacturer ACT MODEL NUM Indicates the identification number of the actuator model ACTUATOR SERIAL NUMBER Indicates the actuator serial number Valve VALVE MAIN ID Indicates the identification number of the valve manufacturer VALVE MODEL NUM Indicates the identification number of the valve model VALVE SERIAL NUMBER Indicates the valve serial number FY302 AssetView HMI FY302 Configuration Page There are a few parameters in the FY302 transducer block that can be used in the predictive and proactive maintenance Some of them can be read online while other parameters reguire that the process to stop or the plant control to be set to manual It is possible to detect performance decreasing comparing the current parameters with standard values and therefore determine the predictive and proactive maintenance The user can check the general diagnostic status in the FY302 Diagnostic Page Operationa
3. Block parameter will be Manual for the Analog Output block and Auto for the Resource Transducer and Display blocks CAS If this mode is selected the value of Mode Block parameter will be Cas for the Analog Output block and Auto for the Resource Transducer and Display blocks Deviation Alert DEVIATION ENABLED Enables checking the difference between the current valve position and the desired set point If this difference exceeds the dead band for more than a given time period an alert will be generated and will remain active until this difference decreases DEVIATION TIME This time period is in seconds The valve must exceed the dead band during this time period before generating an alert DEVIATION DEAD BAND Indicates the magnitude of the valve deviation value in percentage An alert is generated when the valve exceeds this value during a given time period The user can check the status of this diagnostic alarm in the FY302 Diagnostic Page in Deviation Limit Exceeded Reversal Alert REVERSAL It indicates the number of times that the valve changes the direction according to the movement The reversal total is increased when the valve changes the direction When the total of movement exceeds the specified limit an alarm is generated REVERSAL ENABLED Enables checking the difference between the reversal total and an established limit An alert is generated when the reversal total exceeds this limit If it is false the coun
4. because the maintenance will focus on the devices that really need maintenance and in that way it will be possible to plan and reduce the plant idle time Configuring the process to manual or off line it is possible monitoring and testing the performance to evaluate the general operation condition of the positioners and control valves 33 User s Manual The positioners service and calibration are executed to assure the control precision and the best valves performance These procedures are executed when the process stops or in Manual mode and it is not necessary to remove the valves from the process The analyses and the services suggested by the analysis results are reported right after the tests and all of the results can be saved in the maintenance database For example the analysis can indicate valve stuck After analyzing the tests it is possible to create a time reference between the calibrations or maintenance of the positioners actuators and valves For the positioners the tests may indicate the actions needed such as gain adjustments improvement of the air system or tuning adjustment The frequency criterion and the analyses system are essential for the information acknowledgement so the information stored can be useful for the proactive maintenance After the calibration it will be necessary to check the valve signature and verify the dynamic response If the result is not acceptable it will be necessary to analyze the valv
5. of reversals is increased when the valve changes the direction and the movement exceeds the dead band Indicates the equivalent number of full strokes The travel is increased when the number of changes exceeds the dead band value It is used to indicate that the diaphragm needs to be replaced and the actuator needs overhaul Valve Performance CLOSING TIME OPENING TIME Valve Position POSITION Temperature Indicates the time period in seconds that the valve spent to go from fully opened to fully closed This time is used to indicate a problem with the actuator diaphragm leak and problem with the pneumatic tube Indicates the time period in seconds that the valve spent to go from fully closed to fully opened This time is used to indicate a problem with the actuator diaphragm leak and problem with the pneumatic tube Indicates the current valve position HIGHEST TEMPERATURE Indicates the highest temperature value measured by the positioner temperature sensor LOWEST TEMPERATURE Indicates the lowest temperature value measured by the positioner temperature sensor CURRENT TEMPERATURE Indicates the temperature value measured by the positioner temperature sensor Advanced Status Shows the status of the continuous diagnostic including the conditions of the mechanical module MAGNET NOT CENTRALIZED OR Automatic alarm the magnet is not centralized or it was NOT DETECTED not detected SLOW VALVE MOVEMENT OR A
6. on Web technology It is recommended to generate the charts before and after maintenance to register the status of the positioner the valve the actuator and the database The database will be analyzed later to assist the user to decide the period of time needed between maintenances delaying the following maintenance and reducing the idle time of the device AssetView and the Proactive Maintenance 34 Because of the resources available in the positioner and the online monitoring it is possible to implement the proactive maintenance determining the problems and their causes The potential diagnostic of the field devices allows monitoring and conditions register such as valve stress Through the diagnostics the plant technicians execute the proactive maintenance based on the Online information before the problem occurs not waiting for the maintenance planned avoiding and reducing the idle time of the plant The proactive maintenance in the FY302 is implemented by configuring the alarms in the FY302 Configuration Page such as Reversal Deviation and Travel After configuring the alarms the user can view the alarms in the FY302 Diagnostics Page according to the previous configuration such as Reversal Limit Exceed Deviation Limit Exceed and Travel Limit Exceed The alarms that were not configured by the user are also displayed in the Diagnostics Page such as Slow Valve Movement or Low Air Supply Base not Trimmed Output Module not Init
7. 9 User s Manual 30 Temperature Calibration FY 302 This procedure executes the Temperature Calibration Check if the temperature measured is correct if not type the correct value on cal temperature field Temperature Measured 12 07669 oc Cal Temperature Submit NEAT CLOSE Figure 45 Calibrating the temperature Verify if the temperature is correct Otherwise it can be changed in the Cal Temperature field Click Next and the following window will appear Temperature Calibration FY 302 Location UNIT Vl Date Thu Sep 18 2008 10 43 41 000 Who oubmit FINISH Figure 46 Temperature Calibration Data Click OK and complete the information about the calibration indicating the location of the calibration the date and the person responsible for it OVERRIDE Selecting this method the user can verify the desired position according to a previous Set Point The message box will appear warning the user about the safe procedures Override FY 302 This procedure must be executed offline or when the process stops because valve movements can interfere in the plant operations The valve will travel between the completely open point and the completely closed point to reach the best adjustment This procedure will set the Mode Block of the Analog Output block to Manual Asset iew will restore the Mode Block of this block to the previous value at the end of this procedure The con
8. ATE SET DEVICE NEEDS MAINTENANCE SOON INPUT FAILURE PROCESS VARIABLE HAS BAD STATUS OUTPUT FAILURE MEMORY FAILURE LOST STATIC DATA LOST NV DATA READ BACK CHECK FAILED DEVICE NEEDS MAINTENANCE NOW POWER UP OUT OF SERVICE GENERAL ERROR CALIBRATION ERROR CONFIGURATION ERROR Indicates error in the hardware and software components associated to the block Indicates the error in the link configuration Indicates that the device is on simulation mode Indicates that the device is being operated manually Indicates that the device is in safe fault state condition Internal diagnostic according to the user configuration or device internal checking has detected that the device will need maintenance soon Condition of the process variable is BAD Indicates a failure in the output that could be due to the electronic or the mechanical module Indicates an electronic failure according to the internal checking process such as an incorrect checksum detected in the main memory Indicates that the device lost data from the flash or the EEPROM memory Indicates that the device lost data from the RAM memory Indicates a discrepancy in the reading of return value This may have been caused by a hardware failure Internal diagnostic according to the user configuration or device internal checking has detected that the device needs maintenance Indicates that the device has finished the initial operation procedure
9. Address 4 http w sssetview com br defavik hem sige uns zi ti a fs Aria i internat FY 302 AV01 WBS Device List DF audit Trail Report B attu a Maintenances i E fe Fieldbus Manworke E Wa pri 734 A e E Wa ori 367 i EOE ristdbus 5 EH A Fieldbus 6 Calibration OR Fieldbus 3051 F br i a s ES Fieldbus 8 SI la r Neue FY302 Bt e Device Library Device View Graphics USER INFORMATION y F rij EI A tiga e Email not registered MAIN PAGE LIBRARY NOTES REPORT MAINTENANCE DIAGNOSTIC E Done TONO tntemert Figure 1 FY302 Home Page The following sub sections will describe each one of the pages developed for the device maintenance FY302 Identification Page This page displays relevant information about the positioner The user can easily identify and specify the positioner in the physical plant User s Manual FY 302 IDENTIFICATION CALIBRATION CONFIGURATION DEVICE VIEW DIAGNOSTIC DISPLAY o Device Hardware Revision Device ID OOOS020008 SMAR FYSO2 006800709 Firmware Revision Manufacturer Device Serial Humber Device Type Mainboard Serial Number Device Revision Module Serial Number DD Revision Ordering Code Actuator Valve Act Main ID INN Valve Main ID Act Model Mum pore ei Valve Model Mum Rane una Actuator SH puta Valver SM ne Figure 2 Identification Page Device TAG Indicates the associated tag to the positioner in the physical plant The tag can have up to
10. AssetView HMI Slijijicilj JAN 09 AssetView HMI SEs USER S MANUAL FY302 AssetView HMI Z Smar AssetView Microsoft Internet Explorer File Edit View Favorites Tools Help lt a Back m A A Search ij Favorites PMedia lt 4 BD S a AH Address http www assetview com br default htm Go Links ii r 7 z bs Area Demo AT7V FY 302 Eh Device List X Controller List Audit Trail Report Status ar Maintenances E o Fieldbus Network G pr1 307 E G prt 367 B Fieldbus 9 Calibration S Fieldbus 10 Er 8 Fieldbus 11 3051 z EY 302 S Fieldbus 12 Configuration smar FY302 DFI 305 e Device Library Device View Graphics Display USER INFORMATION e F _ bob_engineer Engineer nd m v o Email not registered MAIN PAGE LIBRARY NOTES REPORT MAINTENANCE DIAGNOSTIC ASVFY302ME Specifications and information are subject to change without notice Up to date address information is available on our website web www smar com contactus asp FY302 AssetView IHM FY302 ASSETVIEW HMI FY302 Home Page This manual describes the pages developed for FY302 maintenance using AssetView The figure below shows the options from FY302 initial page E Smar Asset View Mirerosalt Internet Explorer zi xj File Edit View Favorites Toos Help Back O A Gh sevih zjFavortes Meda 4 D ob fg z
11. EL LIMIT LOW TRAVEL LIMIT HIGH Valve characterization type LINEAR the real position will be represented as a linear chart with the desired position TABLE the user can characterize the real positions according to its application EP25 EP33 and EP50 the EP Equal Percentage curves provide a larger travel only for wide set point variation Q025 Q033 and QO50 the QO Quick Open curves provide a larger travel for narrow set point variation Enables disables the curve Indicates the number of points that will be used to define the curve If FINAL VALUE is less than this value the valve is forced to be fully closed FINAL VALUE is the value of the desired position If FINAL VALUE is greater than this value the valve is forced to be fully open FINAL VALUE is the value of the desired position Odometer lower limit Odometer upper limit The user can check the general diagnostic status in the FY302 Diagnostic Page In the Characterization Type parameter select the Table option and the table will appear To configure the points that define the characterization curve click the link Curve X Curve Y as indicated below Travel Limit Low z Travel Limit High EE Characterization Type Table F Travel Control P Final Value Cutoff Low Final Value Cutoff High CURVE Sr CURYE T Submit Figure 6 Characterization Curve FY302 AssetView HMI Type the points of the curve and click Submit t
12. Indicates that the function block is out of service An error has occurred and could not be classified as one of the errors below An error occurred during the device calibration or a calibration error has been detected during the device operation An error occurred during the device configuration or a configuration error has been detected while operating the device 11 User s Manual ELECTRONIC FAILURE MECHANICAL FAILURE I O FAILURE DATA INTEGRITY ERROR An electronic component has failed A mechanical component has failed I O failure has occurred Indicates that data stored in the system may be no longer valid because the checksum of the data in the RAM memory has failed when compared to the data in the non volatile memory SOFTWARE ERROR The software has detected an error that may have been caused by a deviation to a wrong routine an interruption a lost pointer etc ALGORITHM ERROR The algorithm used in the transducer block generated an error such as a data overflow FY302 Graphics Page 12 This page allows the user to configure the FY302 graphs Select the type of the graph type the delay time to get the desired position Delay and click New Graph k t Manufacturer SMAR GRAPHICS i pa Device Type FY302 E Device Tag FY 302 AV01 Diagnostic Graphics Type Select a Graph z Delay nama New Graph Delay is the period of time for AssetView to set the desired position The
13. POSITION Figure 10 Characterization Graph Click Compare to compare characterization charts On the Type Graph menu select Characterization Select the moment for the valve position VP1 and another moment for the valve position VP2 Click Compare to conclude See the example below Diagnostic Graphics Type Graph Characterization sj M Use Marker Event Moment 1o 7f2o0o07 16 08 00 z Event Moment 10 T2007 16 09 00 s upi O D IM vpz O D JIT TT T D STI TT Figure 11 Comparing Graphs STEP RESPONSE This chart will show the behavior of the current valve position and the desired position related to the time It is an easier way to check the tuning between the servo PID and the positioner The user can analyze the behavior of the valve response such as stuck and stress lt helps the preventive and predictive maintenance because the user can save the curves and compare them later 13 User s Manual 14 Performance results are related to the chosen characterization type Servo gains Servo reset parameters and the valve inertia slow or fast valve response After configuring the Delay set the value for the Setpoint and click Write to start This chart allows the user observe it ranging in time during the analysis Diagnostic Graphics Setpoint WALVE POSITION P Figure 12 Step Response Graph Click Compare to compare the valve response charts On the Type Graph menu select Step Respo
14. See the example below Diagnostic Graphics Type Graph Valve Signature J Use Marker Event Moment 10 7 2007 16 32 00 zj Event Moment 10 7 2007 17 15 00 A M outi T out2c M ny M out1 2 7 out2 2 M In 2 OUT 1 1 OUT 2 1 IN 1 OUT 1 2 OUT 2 2 IN 2 OUT1 BACK 1 OUT 2 BACK 1 IN BACK 1 OUT 1 BACK 2 OUT 2 BACK 2 IN BACK 2 Figure 15 Comparing Graphs HYSTERESIS This chart will show the hysteresis behavior of the valve when moving the valve from fully closed to fully opened and vice versa It lets the user analyze the behavior of the valve response such as stuck and stress It helps the preventive and predictive maintenance because the user can save the curves and compare them later Performance results are related to the chosen characterization type Servo gains and Servo reset parameters 15 User s Manual 16 Remember that the response curve will depend on the response inertia of the valve analyzed For slow valves the time configured must be longer because it takes longer for the valve to reach the desired position Diagnostic Graphics Typeil Hysteresis Delay New Graph YALYE POSITION anne YP BACK Figure 16 Hysteresis Graph Click Compare to compare the valve response On the Type Graph menu select Hysteresis Select the moments to be compared and click Compare to conclude See
15. Select the Deviation option to show the error values for each point written in the device Click Compare to compare the valve response On the Type Graph menu select As Found As Left Select the moments to be compared and click Compare to conclude See the following example 17 User s Manual Diagnostic Graphics As Found As Left x M 11 7 2007 16 36 00 x 11 7 2007 17 09 00 x ni ni DEVIATION 1 1 DEVIATION 2 Figure 20 Comparing Graphs 18 FY302 AssetView HMI FY302 Calibration Page This page displays configuration data used in the calibration procedures FY 302 CALIBRATION A CONFIGURATION DEVICE VIEW DIAGNOSTIC DISPLAY IDENTIFICATION RECONCILE OPERATION MODE NOTE Actual Valve Settings User Calibration LOWER POS CALIBRATION POINT Tepe Rotary UPPER POS CALIBRATION POINT SETUP Fault State 3 SETUP REPORT Fault State Time 3 PRESSURE SENSOR CALIBRATION TEMPERATURE CALIBRATION Air To air to Close nl ae arr Se MN O ERRIDE CALIBRATION INFORMATION Tuning Settings Rate Down Servo Pid Deadband 5 Z e Rate Up Servo Pid Bypass Mot Bypass aj EP Backup Restore Sensor Data Backup z TR TUNING NOTES Temperature Calibration Secondary Value 25 49704 oc Secondary Value Unit ADVANCED SETUP Set Point Limits Flow Char Cutoff Low SP Lo Lim Characterization Type Table s Cutoff High SP Hi Lim CURVE X CURVE Y Figure 21 Calibration Page Devi
16. aracterization curve click the link Curve X Curve Y as indicated in the following figure ADVANCED SETUP Set Point Limits Flow Char Cutot Low FE SP Lo Lim 2 Characterization Type Table si Cutoff High ba SP Hi Lim sa CURVE X CURVE Y P oubrmit Figure 22 Configuring the Characterization Curve The table with the points will open 21 User s Manual 22 FY 302 CONFIGURATION s CALIBRATION CONFIGURATION DEVICE VIEW DIAGNOSTIC DISPLAY IDENTIFICATION Table Settings Curve Bypass True zj Curve Length CurvexX MW Curve y b b m b kb b bo b b submit Figure 23 Points Table Type the curve points and click Submit to send the values to the device Click Calibration link to return to the calibration page User Calibration Whenever the positioner is installed to a valve it is necessary to execute the auto calibration procedure setup before connecting it to the process The setup procedure will move the valve searching for the physical limits of the position The user must install the positioner when the valve is isolated from the process and air is directly applied to it using a manual regulator Match the arrow of the magnetic part with the arrow of the positioner transducer module when the valve is at 50 0 This procedure is crucial for the properly operation of the positioner For further details consult the FY302 manual The set
17. ate that the diaphragm needs to be replaced and the actuator needs overhaul TRAVEL ENABLED Enables checking the difference between the odometer and an established limit An alert is generated when the odometer exceeds this limit TRAVEL LIMIT Indicates the odometer value limit An alert is generated when the odometer exceeds this limit Enter an odometer value lower than the limit to acknowledge the alert TRAVEL DEAD BAND Indicates the magnitude of the valve movement value in percentage This value is used to increase the odometer The user can check the status of this diagnostic alarm in the FY302 Diagnostic Page in Travel Limit Exceeded User s Manual Sensor Pressure Alert An alert is generated every time the input pressure exceeds the limit The user can check the general diagnostic status in the FY302 Diagnostic Page HIGH LIMIT LOW LIMIT Indicates the maximum limit of the input pressure Indicates the minimum limit of the input pressure An alarm will be generated when the input pressure is lower than Low Limit Supply pressure too low and another one will be generated when it exceeds High Limit Supply pressure too high limit These alarms only will be generated when the sensor pressure is installed Travel Control The valve travel conditions will be based on the parameters below CHARACTERIZATION TYPE CURVE BYPASS CURVE LENGTH FINAL VALUE CUTOFF LOW FINAL VALUE CUTOFF HIGH TRAV
18. bration Data The valve will move to the lower position The message shown in the figure below appears Wait until the valve stabilizes the position and click Ok to continue Lower Pos Calibration Point FY 302 aYvO1 Wait until the valve stabilizes in the position NE NM ME Figure 26 Stabilizing the Position Check the current physical position of the lower limit which is indicated in the actuator scale and type this value in the New Position text field Lower Pos Calibration Point FY 302 AYOL Type the position of the valve according to the scale of the actuator NA ME Figure 27 Valve New Position Suppose that the value read in the actuator scale is 10 0 After the user types this value and click Ok the positioner will correct the lower position set at around 0 Negative values for the position will execute the correction in the opposite direction of the movement 23 User s Manual 24 Verify the scale and indicate if the correction was successful or the calibration procedure must be executed again Lower Pos Calibration Point FY 302 AYO1 Do you want to run this procedure again YES x mn Figure 28 Checking the Calibration If the correction was successful click No Otherwise if the calibration is not suitable click Yes The user can execute the correction It is possible to lie to the positioner about the value read from the actuator scale In this way the positioner
19. ce Operation Mode Indicates the operation mode for the device If this mode is selected the value of the Mode Block parameter will be Out of Service for the Resource Transducer and Analog Output blocks If this mode is selected the value of the Mode Block parameter will be Auto for the Resource Transducer Display and Analog Output blocks If this mode is selected the value of the Mode Block parameter will be Manual for the Analog Output block and Auto for the Resource Transducer and Display blocks If this mode is selected the value of the parameter Mode Block will be Cas for the Analog Output block and Auto for the Resource Transducer and Display blocks 19 User s Manual 20 Valve Settings TYPE FAULT STATE FAULT STATE TIME AIR TO VALVE ACT Tuning Settings RATE DOWN RATE UP KP TR SERVO PID DEAD BAND SERVO PID BYPASS BACKUP RESTORE The user configures the valve type linear or rotary Safe fault value in percentage Indicates the time before the valve changes to the safe fault value in seconds Air condition to open or close Action type direct or reverse The options are Invert SP tracks PV if Man SP tracks PV if LO SP tracks RCas or Cas if LO or Man Increase to close Faultstate Type Faultstate restart Target to Man PV for BKCal Out Low Cutoff Configures the set point step down rate in percentage related to the time Configures the set point step up rate in perc
20. delay must be configured according to the valve movement inertia Figure 9 Graphics Page Remember that this procedure must be executed when the process stops or the plant control is set to manual Movements of opening and closing may interfere in the process AssetView will set the Resource and Transducer Mode blocks to Auto to draw the chart The mode block values will be restored at the end of this process CHARACTERIZATION This chart will show the behavior of the current valve position compared to the desired value AssetView will generate the desired value The user can analyze the behavior of the valve response such as stuck and stress It will be easier to set the positioner parameters in the Calibration page such as the Servo Gain and the Servo Reset according to the application tuning and the positioner dynamic response This chart helps the preventive and predictive maintenance because the user can save the curves and compare them later Performance results are related to the chosen characterization type Servo gains and Servo reset parameters FY302 AssetView HMI Remember that the response curve will depend on the response inertia of the valve analyzed For slow valves the time configured must be longer because it takes longer for the valve to reach the desired position See the example below Diagnostic Graphics Type Characterization s Delay New Graph VALYE
21. e actuator and positioner valve conditions to find the best parameterization If the control valves tested continue to report control problems the valve designs should also be analyzed The design will be based on the minimum medium and extreme conditions of the process This phase must be conducted by an application engineer or an expert technician The great advantage of the digital technology is the qualitative information not only the process values in addition to the online monitoring of the valve operation conditions and to the online analysis of the performance curves and deviations The technology used in the FY302 positioner provides powerful diagnostic algorithms and through AssetView it also provides powerful resources for the predictive analyses The positioner has characterization resources tables QO and QE curves input and output pressure monitoring temperature monitoring travel control strokes control reversals control input signals set point deviation etc With AssetView it is possible to do online diagnostics safely without interrupting the process It is possible to configure the travel limits strokes reversals and alarms With these features the user can track the device condition and prevent problems in the process The information are read and saved in the tool history for a specific configuration helping to plan and execute the maintenance The AssetView can be accessed from anywhere because it was built
22. e at the end of this procedure The control loop must be in Manual NE NM METI Figure 30 Configuring the Mode Block Click OK and complete the information about the calibration indicating the location of the calibration the date and the person responsible for the calibration FY302 AssetView HMI Upper Pos Calibration Point FY 302 AYO1 Fill in the fields below who 7 13 2007 9 54 06 NE NA METI Figure 31 Calibration Data The valve will move to the upper position The message shown in the following figure appears The user must wait until the valve stabilizes the position and click Ok to continue Upper Pos Calibration Point FY 302 AYO Wait until the valve stabilizes in the position NE NE ME Figure 32 Stabilizing the Position Check the current physical position of the upper limit which is indicated in the actuator scale and type this value in the New Position text field Upper Pos Calibration Point FY 302 A YO1 Type the position of the valve according to the scale of the actuator O NA METI Figure 33 Valve New Position Suppose the value read in the actuator scale is 90 0 After the user types this value and click Ok the positioner will correct the upper position set at around 100 Negative values for the position will execute the correction in the opposite direction of the movement Verify the scale and indicate if the correction was successful or the calibration
23. entage related to the time Servo PID proportional gain Servo PID integral time Set the Servo PID dead band It should not be changed by the user Enables disables the Servo PID Enables save and restore the calibration setup and important configuration data It is recommended to run the backup process with the option Sensor Data Backup after the auto calibration process setup Calibration Information MIN SPAN Indicates the smallest difference allowed between the calibration upper position and the calibration lower position UNIT Indicates the calibration unit always in percentage METHOD Indicates the calibration method When leaving the factory the device is calibrated according to the manufacturer criteria If the user calibrates the positioner it will indicate that the user executed the calibration LOCATION Indicates the location of calibration such as a laboratory area 1 etc DATE Indicates the date of the executed calibration WHO Indicates the person responsible for the executed calibration Position Scale EU 0 Indicates the lower limit for the input scale of the position variation EU100 Indicates the upper limit for the input scale of the position variation UNITS INDEX Indicates the engineering unit percentage radian rad or millimeter mm FY302 AssetView HMI Temperature Calibration CAL TEMPERATURE Indicates the last temperature calibration value of the positioner temperature sensor
24. ialized or not Connected etc
25. igurations according to the application needs and print reports for later analysis With AssetView the user can act and control the process stability and its variation by viewing the entire process control then optimizing the use of devices and assuring a continuous improvement for the system operation The main goals are to provide a low cost maintenance guarantee the continuous and operational functionality of the devices with performance levels accepted by the application process control minimize the efforts for the corrective maintenance and adapt the system for a safe and reliable operational expansion The use of the AssetView starts during the devices commissioning and the process startup when the user creates the database to be used as reference The initial database is periodically compared to the current data In this initial process the network tuning is optimized according to the processes The charts and trends will be used The diagnostics online monitoring allows the user to easily detect the status of the positioners and control valves In the Calibration Page the user can execute the Auto Setup and calibrate the position assuring the operation performance of the positioners and control valves Preventive and Predictive Maintenance for Positioners The status of the positioners and valves must be followed periodically through the Diagnostics Page for predictive maintenance purposes The tracking can minimize maintenance costs
26. l Statistics OEs are data stored in the device that inform its usage abnormal behaviors or number of times that a specific condition occurred such as total valve travel odometer total of reversals and maximum deviation limit between the valve position and the set point Using the FY302 Configuration Page the user can set limit conditions for the operational statistics If a specific OE reaches the limit value the device notifies the system and this notification is highlighted in the Diagnostic Page FY 302 CONFIGURATION A iP m F CALIBRATION DEVICE VIEW DIAGNOSTIC DISPLAT IDENTIFICATION RECONCILE OPERATION MODE NOTE Actual Deviation Enabled Reversal Enabled Deviation Time Reversal Limit Deviation Deadband Reversal Deadband Travel Enabled High Limit Travel Limit Low Limit Travel Deadband Travel Control Travel Limit Low Final Walue Cutoff Low Travel Limit High Characterizatian Type Table s CURYE X CURVE Y Submit Figure 3 Configuration Page Final Value Cutoff High User s Manual Device Operation Mode Indicates the operation mode for the device OOS If this mode is selected the value of Mode Block parameter will be Out of Service for the Resource Transducer and Analog Output blocks AUTO If this mode is selected the value of Mode Block parameter will be Auto for the Resource Transducer Display and Analog Output blocks MAN If this mode is selected the value of Mode
27. n this case the process will be finalized with Time Out and the lower and upper values of the HALL sensor will be practically the same which indicates no movement Another example is the voltage condition of the PIEZO sensor that must be between 30 and 60V in a stable condition and a fixed position If the voltage is out of this range the mechanical calibration will be necessary at the PIEZO sensor Report FY 302 A 01 The Setup Report shows the information according to the last setup procedure NE TNE METI Figure 40 Setup Report Click Ok The figure below shows the Setup Report options Setup Report FY 302 AY01 Digital Hall Value Value Highest Cal Hall Value Lowest Cal Hall Value DA Output Value Value Values Highest Cal DA Value Status Lowest Cal DA Value Figure 41 Report Data 27 User s Manual 28 Pot DC VALUE Digital Hall Value VALUE HIGHEST CAL HALL VALUE LOWEST CAL HALL VALUE DA Output Value VALUE HIGHEST CAL DA VALUE LOWEST CAL DA VALUE STATUS Piezo VALUE STATUS The constant DC value for piezo sensor Indicates the current value of the HALL sensor according to the current position Upper value of the HALL sensor calibrated during the Setup process or Upper Pos Calibration process Lower value of the HALL sensor calibrated during the Setup process or Lower Pos Calibration process Indicates the current value of the D A converter Upper value of
28. nse Select the moment to be compared and click Compare to conclude See the example below Diagnostic Graphics Type Graph Step Response M Use Marker Event Moment 11 7 2007 14 44 00 Event Moment 11 7 2007 14 48 00 w M vpi M4 spi O M yvp2M spz O Figure 13 Comparing Graphs VALVE SIGNATURE This chart will show the behavior of the position related to the output pressure The desired value will be generated by AssetView This chart allows the user to analyze the behavior of the valve response according to the air pressure For example the user can save the chart during the installation or commissioning and then compare the current chart with the one saved before It will be possible to check if more pressure is necessary to establish the same position If it is true it means that there is a mechanical stuck FY302 AssetView HMI NOTE The chart Valve Signature will be plotted only if the FY302 has the pressure sensor Performance results are related to the chosen characterization type Servo gains Servo reset parameters and input pressure See the example below Diagnostic Graphics OI OUT 2 MI ff OUT 1 BACK a a NE INBACK Figure 14 Valve Signature Graph Click Compare to compare the valve response charts On the Type Graph menu select Valve Signature Select the moment to be compared and click Compare to conclude
29. o send the values to the device Click Configuration link to return to the configuration page FY 302 CONFIGURATION PR ts mr n F CALIBRATION CONFIGURATION DEVICE VIEW DIAGNOSTIC DISPLAY IDENTIFICATION Table Settings Curve Length Curvey True aj Cure Bypass Curvex 0 Submit Figure 7 Points Table FY302 Diagnostics Page This page displays the device status FY 302 DIAGNOSTIC o CALIBRATION CONFIGURATION DEVICE VIEW DISPLAY IDENTIFICATION Strokes Reversals Travel Highest Lowest Current In Status T ENE Device F 302 FY 302 Valve Totals Retrieving data Retrieving data Retrieving data Temperature Retrieving data a Retrieving data oc Retrieving data ac Closing Time Opening Time Position Sensor Pressure Retrieving data psi Description Default Value Set Good F 302 TRD FY 302 TRD Valve Performance Retrieving data sec Retrieving data sec Valve Position Retrieving data Retrieving data psi Retrieving data psi Bridge Channel DFI 367 Fieldbus 11 ACE DFI 367 Fieldbus 11 ACE Figure 8 Diagnostic Page User s Manual 10 Valve Totals STROKES REVERSALS TRAVEL odometer Indicates the number of times that the valve fully opens and closes Indicates the number of times that the valve changes the direction according to the movement The number
30. procedure must be executed again Upper Pos Calibration Point FY 302 AY O1 Do you want to run this procedure again YES Figure 34 Checking the Calibration If the correction was successful click No Otherwise if the calibration is not suitable click Yes The user can execute the correction It is possible to lie to the positioner about the value read from the actuator scale In this way the positioner will be calibrated higher according to the user necessities 25 User s Manual 26 It is possible to save the calibration in the EEPROM memory of the positioner transducer module which is recommended Click Yes to save the calibration data Upper Pos Calibration Point FY 302 AYO01 It is recommended to save the calibatrion data to the EEPROM memory of the sensor module Do you want to save the changes YES NO Figure 35 Saving Calibration Data SETUP When this method is selected a message box appears warning the user that this procedure must be executed when the process stops or the plant control is set at manual Opening and closing movements may interfere in the process Please refer to the FY302 manual for setup details FY 302 A O1 This procedure must be executed offline or when the process stops because valve movements can interfere in the plant operations The valve will travel between the completely open point and the completely closed point to reach the best adju
31. select the access type of the selected parameter monitoring or action ALPHA NUM Indicates if the alphanumeric field will be used for mnemonic or for value FY302 Device View Page The user can monitor the device s data opening the Device View page 32 FY302 AssetView HMI FY 302 DEYVICEVIEW CALIBRATION CONFIGURATION DIAGNOSTIC DISPLAY IDENTIFICATION Read Back 99 97987 Out Rate Inc 2 rs Gain DA Output a Rate Dec sd bys Reset sp e e CONTROL BLOCK Mode Block DA Status Lin Type Good MonCascadenNonSpecific MotLimited Table Se S T T Hall Walue 34778 FeedBack Rel Fos YPiezo po Setup Deviation Limit Excedeed Closing Time 22412 Travel poo NA Temp Value 2E6 48177 e vaseline Highest Templo lec Temp Cal E ec Lowest Temp 26 92196 oc Figure 51 Device View Page Diagnostic and Maintenance for Positioners With AssetView the user can take advantage of the digital information provided by fieldbus and HART protocols The AssetView is a powerful tool for configuring the parameters of positioners and control valves assisting the control system management and the predictive maintenance It provides the information about the network online performance tests charts and trends positioners configuration calibration performance monitoring and online diagnostics The user can also analyze the data stored from several periods as found as left reconcile conf
32. stment This procedure will set the Mode Block of the Resource and the Transducer blocks to Auto Asset iew will restore the Mode Block of these blocks to the previous value at the end of this procedure The control loop must be in Manual NE NM METI Figure 36 Configuring the Mode Block Click OK and the valve will move searching for the lower and upper physical position Depending on the valve inertia this process may take a few minutes FY 302 A4 01 Progress 0 Sow Valve Position Figure 37 Valve Movement The progress bar indicates the procedure progress The user can also verify the setup status A message box will appear indicating that the Setup process is completed FY302 AssetView HMI Microsoft Internet Explorer x A Setup is complete Figure 38 Concluding the Calibration At the end of the setup it will be possible to save the data FY 302 A O1 It is recommended to save the calibration data to the EEPROM memory of the sensor module Do you want to save the changes YES E m m Figure 39 Saving Calibration Data SETUP REPORT This option provides an analysis of the data stored during the last Setup process The data has information about the HALL and the PIEZO sensors It is useful to report a problem during the Setup process There are cases where the Setup process is executed and the valve is stuck or the input pressure is too low to allow the valve movement I
33. ter will not be increased Reversal Count REVERSAL LIMIT Indicates the reversal total limit An alert is generated when the reversal total exceeds this limit Enter a reversal value lower than the limit to acknowledge the alert REVERSAL DEAD BAND Indicates the magnitude of the valve movement value in percentage This value is used to increase the reversal total The user can check the general diagnostic status in the FY302 Diagnostic Page See the following example FY302 AssetView HMI FY 302 CONFIGURATION 4 CALIBRATION DEVICE VIEW DIAGNOSTIC DISPLAY IDENTIFICATION RECONCILE OPERATION MODE NOTE Reversal Alert Deviation Enabled True Feversal Enabled True m Deviation Time se ss Reversal Limit Deviation Deadband FE Feversal Deadband 5 Figure 4 Reversal Alert The user can check the alarm generated in the FY302 Diagnostic Page Valwe Position Position sile psa Temperature Advanced Status Highest Temperature a Travel Limit Exceeded Lowest Temperature 3 5627 e Reversal Limit Exceeded Current Temperature a 98043 Figure 5 Advanced Diagnostics Note that the variable Reversals in the Valve Totals area exceeded the limit specified The alarm is indicated in red in the Advanced Status area Travel Accum Alert TRAVEL odometer It indicates the equivalent number of full strokes The travel is increased when the number of changes exceeds the dead band value It is used to indic
34. the D A converter calibrated during the Setup process or Upper Pos Calibration process Lower value of the D A converter calibrated during the Setup process or Lower Pos Calibration process Status of the D A converter value Indicates the value of the PIEZO sensor voltage Indicates the status of the PIEZO sensor voltage PRESSURE SENSOR CALIBRATION Selecting this method the user can calibrate the pressure sensors when they are installed in the positioner These installations depend on the positioner version When this method is selected a message box appears warning the user that this procedure must be executed when the process stops or the plant control is set at manual Opening and closing movements may interfere in the process Pressure Sensor Calibration FY 302 This procedure must be executed offline or when the process stops because valve movements can interfere in The valve will travel between the completely open point and the completely closed point to reach the best This procedure vill set the Mode Block of the Transducer blocks to Auto Asset iew will restore the Mode Block of this block to the previous value at the end of this Select the Pressure Sensor and the Trim Point the plant operations adjustment procedure The control loop must be in Manual Sensor Pressure Input kal Sensor Trim Point cal Point Hi MEAT CLOSE Figure 42 Checking the Sensor Pressure In the same windo
35. the example below Diagnostic Graphics Type Graph Hysteresis al M Use Marker Event Moment 11 7 2007 15 54 00 a Event Moment iirT2007 10 29 00 al upi O D Myp2T D vP1 YP1 BACK Figure 17 Comparing Graphs TRAVEL DEVIATION This chart will show the behavior of the error accumulated in the process between the current valve position and the desired position related to the time It allows the user analyze the behavior of the valve response such as stuck and stress It helps the preventive and predictive maintenance because the user can save the curves and compare them later The value that appears in the histogram is the arithmetic average of 10 acquisitions In stuck conditions the error accumulated tends to increase because the instantaneous error increases This fact can be verified since the servo PID action increases FY302 AssetView HMI Diagnostic Graphics Typet Travel Deviation z Delay lis New Graph 1050 1200 1350 Figure 18 Travel Deviation Graph AS FOUND AS LEFT This chart allows the user to store the device status before executing a calibration procedure The user can save the chart of the set point related to the Primary Value After executing the calibration generate the chart again with the same characteristics to analyze the deviation Diagnostic Graphics Type s Found As Left sj Delay New Graph Deviation Valve Position Figure 19 As Found As Left Graph
36. trol loop must be in Manual NEAT CLOSE Figure 47 Configuring the Mode Block Click Next to start the process Select the set point value and click Ok FY302 AssetView HMI Override FY 302 FINISH ABORT Figure 48 Selecting the Set Point DYNAMIC VALUES Selecting this method the user can verify the dynamic values of the device FY 302 CALIBRATION IDENTIFICATION Dynamic Yalues Figure 49 Dynamic Values 31 User s Manual FY302 Display Page The user can save the data shown in the device s display FY 302 DISPLAY CALIBRATION CONFIGURATION DEVICE VIEW DIAGNOSTIC IDENTIFICATION Update Update None LCDI Block Tag 1 mo Inc Dec 1 Parameter 1 ss sd Decimal Point Number 1 Sub Index 1 2A Access 1 Monitoring Mnemonic 1 Alpha Mum 1 Mnemonic iz Submit Figure 50 Display Page Display Options BLOCK TAG Shows the tags list for the available instantiated blocks PARAMETER Shows the list of available parameters to be displayed in the LCD for the selected block in the Block Tag option SUB INDEX OO Indicates the sub index of the selected parameter MNEMONIC Indicates the mnemonic of the selected parameter in the Parameter option INC DEC Indicates the value to be added or subtracted when acting in the parameter via local adjustment DECIMAL POINT NUMB Indicates the number of digits after the decimal point that will be shown in the LCD ACCESS The user can
37. up procedure is necessary even before the lower or upper position calibration LOWER POS CALIBRATION POINT This method is used when the user wants to calibrate the 0 and the 100 limits differently from the physical limits set during the setup process Use this procedure in applications that involve Splitter Range conditions When this method is selected a message box appears warning the user that this procedure must be executed when the process stops or the plant control is set at manual Opening and closing movements may interfere in the process FY302 AssetView HMI Lower Pos Calibration Point FY 302 AYOL This procedure must be executed offline or when the process stops because valve movements can interfere in the plant operations The valve will travel between the completely open point and the completely closed point to reach the best adjustment This procedure will set the Mode Block of the Resource and the Transducer blocks to Auto Asset iew will restore the Mode Block of these blocks to the previous value at the end of this procedure The control loop must be in Manual a a MET Figure 24 Configuring the Mode Block Click OK and complete the information about the calibration indicating the location of the calibration the date and the person responsible for the calibration Lower Pos Calibration Point FY 302 AYOL Fill in the fields below Who Tfisfz0o0F 9 41 59 NE NA ME Figure 25 Cali
38. utomatic alarm there is a slow valve movement or low LOW AIR SUPPLY air supply TEMPERATURE OUT OF RANGE Automatic alarm the temperature is out of range BASE NOT TRIMMED Automatic alarm the base is not trimmed OUTPUT MODULE NOT Automatic alarm the output module is not connected to INITIALIZED OR NOT CONNECTED the circuit board or it was not initialize DEVIATION LIMIT EXCEEDED This alarm indicates the Deviation Limit configured in the configuration page was exceeded TRAVEL LIMIT EXCEEDED This alarm indicates the odometer counter limit configured in the configuration page was exceeded REVERSAL LIMIT EXCEEDED This alarm indicates the Reversal Limit configured in the configuration page was exceeded Sensor Pressure SENSOR PRESSURE IN SENSOR PRESSURE OUT1 SENSOR PRESSURE OUT2 Sensor Pressure Status SENSOR PRESSURE STATUS Status FY302 AssetView HMI Indicates the input pressure sensor reading Indicates the pressure sensor reading of the output 1 Indicates the pressure sensor reading of the output 2 Indicates the status of the input pressure sensor Shows the continuous diagnostic of the device status including the condition of function block electronic and the mechanical module All of the alarms are automatic that is the device will notify the user even if the alarm has not been configured BLOCK CONFIGURATION ERROR LINK CONFIGURATION ERROR SIMULATE ACTIVE LOCAL OVERRIDE DEVICE FAULT ST
39. w is possible select the sensor that will be calibrated and the respective calibration upper or lower Click Next to continue FY302 AssetView HMI A message will appear indicating the pressure values The selected pressure and calibration will be shown according to measured pressure Click Next to confirm that the pressure and calibration are correct Otherwise do the corrections click Submit and then Next Pressure Sensor Calibration FY 302 Pressure value must be between 10 and 100 psi Input Sensor Pressure o psi Cal Trim Point High 0 psi Submit M It is recommended to save the calibration data to the EEPROM memory of the sensor module Do you want to save the changes NEAT CLOSE Figure 43 Sensor Calibration Data It is possible to save the calibration in the EEPROM memory of the sensor module just select the option Click Next and a window will appear to complete the information about the calibration location the date and the person responsible for the calibration Pressure Sensor Calibration FY 302 Location UNIT Vi Date Wed Sep 17 2008 14 33 27 000 Who Submit The Mode Block will be restored to previous configuration Figure 44 Sensor Calibration Data Click Ok to finish the configuration TEMPERATURE CALIBRATION Selecting this method the user can calibrate the temperature sensor Click the Temperature Calibration option and the following window will appear 2
40. will be calibrated lower according to the user necessities It is possible to save the calibration in the EEPROM memory of the positioner transducer module which is recommended Click Yes to save the calibration data Lower Pos Calibration Point FY 302 AYO It is recommended to save the calibatrion data to the EEPROM memory of the sensor module Do you want to save the changes YES m m zn Figure 29 Saving Calibration Data UPPER POS CALIBRATION POINT This method is similar to the Lower Pos Calibration procedure described above It is used when the user wants to calibrate the 0 and the 100 limits differently from the physical limits set during the setup process Use this procedure in applications that involve Splitter Range conditions When this method is selected a message box appears warning the user that this procedure must be executed when the process stops or the plant control is set at manual Opening and closing movements may interfere in the process Upper Pos Calibration Point FY 302 AWOL This procedure must be executed offline or when the process stops because valve movements can interfere in the plant operations The valve will travel between the completely open point and the completely closed point to reach the best adjustment This procedure will set the Mode Block of the Resource and the Transducer blocks to Auto Asset iew will restore the Mode Block of these blocks to the previous valu
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