Flowserve MASTER STATION IV EEP-SN4001 User manual

Experience In Motion
USER INSTRUCTIONS
Installation
Operation
Maintenance
MASTER STATION IV:
EEP-SN4001
FCD LMENIM5010-00-AQ - 03/19

Limitorque
®Master Station IV EEP-SN4001 FCD LMENIM5010-00-AQ – 03/19
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Limitorque
®Master StationI V EEP-SN4001 FCD LMENIM5010-00-AQ – 03/19
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Contents
1 Introduction 6
1.1 Overview 6
1.2 User Role Overview 6
1.3 Login 7
1.4 Main Menu 8
1.5 System Technical Data 9
2 Function Flowchart 10
3 Quick Startup 13
4 Electrical Connections 14
4.1 MSIV Rear Panel Connections 14
4.2 Master Station Wiring Requirements 17
4.3 Master Station Network Topologies 18
5 System Status 20
5.1 Main Menu 20
5.2 System Status 21
5.2.1 Network Status 21
5.2.2 MOV Status 22
5.2.3 MSIV Status 22
5.2.4 MOV Data 23
6 System Control 24
6.1 Main Menu 24
6.2 System Control 24
6.2.1 MOV Control 25
6.2.2 Emergency Shutdown 26
7 System Configuration 28
7.1 Main Menu 28
7.2 System Configuration 28
7.2.1 System Settings 29
7.2.2 Redundant Configuration 32
7.2.3 Change MOV Tags 33
7.2.4 User Administration 34
7.2.5 DCS Configuration 36
7.2.6 MOV Network Configuration 52
7.2.7 File Manager 53
8 Diagnostics 57
8.1 Main Menu 57
8.2 Diagnostics 58
9 Troubleshooting Guide 61
9.1 Front Panel Indicators 61
9.2 Network Status Screen 61
9.3 Blank Display 62
9.4 Network Communications 62

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Figures
Figure 1.1 - Introduction 7
Figure 1.2 - Enter User Name 7
Figure 1.3 - Login 7
Figure 1.4 - Main Menu 8
Figure 2.1 – MSIV Functional Flowchart 11
Figure 4.1 – MSIV Rear Panel Electrical Connections 14
Figure 4.2 – Debug Port Connection: DB9 Male 15
Figure 4.3 – DCS Serial Port Connection: DB9 Female 16
Figure 4.4 – Modbus Redundant Loop Topology 18
Figure 4.5 – Hot Standby Redundant Wiring Diagram. Refer to Fig. 4.4 for cable shield wiring
(applies to both Active and Standby Modules) 19
Figure 5.1 – The Main Menu Screen 20
Figure 5.2 – System Status 21
Figure 5.3 – Network Status 21
Figure 5.4 – MOV Status Screen 22
Figure 5.5 – MSIV Module Status 22
Figure 5.6 – MOV Data 23
Figure 6.1 – System Control Menua 24
Figure 6.2 – MOV Control Menu 25
Figure 6.3 – Control Relays 25
Figure 6.4 – Emergency Shutdown 26
Figure 6.5 – Emergency Shutdown in Progress 26
Figure 6.6 – Emergency Shutdown Termination 27
Figure 7.1 – System Configuration Menu 28
Figure 7.2 – System Settings Menu 29
Figure 7.3 – Software Version Information 30
Figure 7.4 – Language Selection Menu 30
Figure 7.5 – System Clock Settings 31
Figure 7.6 – Time Zone Settings 31
Figure 7.7 – Screen Saver Settings 32
Figure 7.8 – Redundant Configuration Menu 32
Figure 7.9 – Configuration Transfer Lockout 33
Figure 7.10 – MOV Tag List 33
Figure 7.11 – User Administration Menu 34
Figure 7.12 – Delete User Menu 34
Figure 7.13 – User Settings Menu 35
Figure 7.14 – Change Password Menu 35
Figure 7.15 – DCS Configuration Menu 36
Figure 7.16 – Configure DCS Serial Port 36
Figure 7.17 – Configure DCS Ethernet Port 37
Figure 7.18 – Configure DCS Data Table Menu 37
Figure 7.19 – FC 02 Read Input Status 38
Figure 7.20 – FC 03 Read Holding Registers Menu 41

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Figures (Continued)
Figure 7.21 – FC 03 Example Data Table 41
Figure 7.22- Modbus FC 05/15 Coils 44
Figure 7.23 – FC 05/15 Sample Data Table 45
Figure 7.24 – Modbus holding registers – one per MOV shown 47
Figure 7.25 – FC 06 sample data table with “Two Per Mov” selected 47
Figure 7.26 – General DCS Settings (defaults shown) 51
Figure 7.27 – MOV Network Configuration 52
Figure 7.28 – Active MOVs 52
Figure 7.29 – Polling Priority, Active MOVs 53
Figure 7.30 – File Manager Menu 53
Figure 7.31 – Import Configuration File 54
Figure 7.32 – Export Event Log 55
Figure 7.33 – Update Software Menu 55
Figure 7.34 – Restore Factory Defaults 56
Figure 8.1 – Main Menu 57
Figure 8.2 – Diagnostics Menu 58
Figure 8.3 – Event Log 58
Figure 8.4 – Comm/FC Logger 59
Figure 8.5 – Debug Serial Port 59
Figure 8.6 – Polling Statistics 60
Figure 9.1 – Rear Panel On/Off Switch, Fuse, and Power Input Terminals 62
Tables
Table 4.1 – Network Channel A Connection 15
Table 4.2 – Network Channel B Connection 15
Table 4.3 – Hot-Standby Wiring Connections for Redundant Modules 19
Table 7.1 – Status Bit Definitions 38
Table 7.2 – Function Code 02 Example Message Breakdown 40
Table 7.3 – Function Code 03 Example Message Breakdown 42
Table 7.4 – Function Code 03 Holding Registers 42
Table 7.5 – DDC coil assignments, Modbus 05 command usage for Digital Outputs 45
Table 7.6 – Function Code 05 Example Message Breakdown 46
Table 7.7 – Function Code 15 Example Message Breakdown 46
Table 7.8 – Function Code 06 First command message breakdown 48
Table 7.9 – Function code 06 message breakdown 48
Table 7.10 – Function code 06 message breakdown 49
Table 7.11 – Function code 16 message breakdown 49
Table 7.12 – Valid Command Register Operations 50

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1 Introduction
1.1 Overview
The next generation master station is designed by Flowserve Limitorque specifically for use
with the Limitorque line of electric actuators equipped with Modbus DDC. The Master Station IV
(MSIV) acts as a single-source controller for up to 250 actuators.
The MSIV is a plug-and-play solution that provides complete control, monitoring, and diagnos-
tics of Limitorque electric actuators through a simple touch-panel display serving as a Human
Machine Interface (HMI).
1.2 User Role Overview
The MSIV requires users to login. Four user role levels are configurable for each user: 1) View,
2) Control, 3) Configure, and 4) Administrator. Each role includes the rights of the lesser roles
(i.e. Control includes View’s rights, and Configure includes Control’s rights and View’s rights).
VIEW: the user can view the network status and the activity log. No control
or configuration functionality is available.
CONTROL: in addition to the View rights, the user has the ability to control
MOVs.
CONFIGURE: in addition to the Control rights, the user has the ability to configure
the Master Station and the Network.
ADMINISTRATOR: in addition to Configure rights, the user has the ability to add or
delete users, as well as modify user settings.
These roles can be changed by an Administrator user. See section the User Administration
section for details.

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1.3 Login
When the MSIV completes the boot process, it loads the introduction screen (Figure 1.1).
Figure 1.1 - Introduction
Touching any part of the screen will load the Enter User name screen (Figure 1.2).
NOTE: If the screen is blank and the green power LED is illuminated, the MSIV is in screen saver mode.
Touch the display to exit the screen saver mode.
Figure 1.2 - Enter User Name
Once the user name has been entered, the Enter Password screen will be displayed (Figure 1.3).
NOTE: Each user name must have a unique password.
Figure 1.3 - Login

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Passwords and user names are set via the User Administration menu, under System Configuration.
The correct password entry for the respective user name will advance the screen to the Main Menu (Figure 1.4).
If passwords are lost or forgotten, please contact your Limitorque service coordinator at 1-434-528-4400.
1.4 Main Menu
Once logged in, the user will see the Main Menu (Figure 1.4).
Figure 1.4 - Main Menu
From here, the menu options are displayed based on the current user role. Each button represents a separate logical
section of the Master Station.:
SYSTEM STATUS (ALL USERS): View information related to the network status, status of the Master Station, and MOV
status.
SYSTEM CONTROL (CONTROL, CONFIGURE, AND ADMINISTRATOR): Access to MOV control and emergency
shutdown functions.
DIAGNOSTICS (CONFIGURE AND ADMINISTRATOR): Activate event logging, communication data analysis, or polling
statistics.
REBOOT: Restart the MSIV
SHUT DOWN: Shut down the MSIV
EXIT: Log out of the MSIV user mode.

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1.5 System Technical Data
1. Power supply
1.1. Nominal: 24VDC to 48VDC (+/- 10%).
1.2. Absolute minimum: 21.6VDC.
1.3. Absolute maximum: 52.8VDC.
1.4. Maximum current draw is 2.0 amps.
2. Operating environment
2.1. It is recommended to install and operate the MSIV in an indoor, climate-controlled environment,
ideally in temperature range of 10 Celsius to 30 Celsius.
2.2. Absolute minimum operating ambient temperature: 0 degrees Celsius
2.3. Absolute maximum operating ambient temperature: 40 degrees Celsius
2.4. Humidity: maximum 85% RH non-condensing
3. Storage
3.1. Store the MSIV in a cool, dry area, out of direct sunlight.
3.2. Minimum storage temperature: -20 degrees Celsius
3.3. Maximum storage temperature: 60 degrees Celsius
3.4. Humidity: maximum 95% RH non-condensing
4. Human machine interface
4.1. 6.5” diagonal touch panel LCD
4.2. 640x480 resolution
4.3. Multiple language support: English, Spanish, and Chinese
5. Communication Protocols
5.1. MSIV to Field Units
5.1.1. Modbus RTU
5.1.1.1. EIA-485 (RS-485) physical layer
5.1.1.2. Bi-directional redundant loop or multi-drop network topologies
5.1.1.3. Maximum communication rate of 38.4 Kbaud
5.2. MSIV to DCS
5.2.1. Modbus RTU
5.2.1.1. TIA-232 (RS-232) physical layer
5.2.1.2. If RS-485 or RS-422 physical layers are required, an external converter can be specified.
5.2.1.3. Maximum communication rate of 115.2 Kbaud
5.2.2. Modbus TCP/IP
5.2.2.1. 10/100Mbit ethernet physical layer
6. System Redundancy
6.1. A completely modular, redundant system can be setup using two EEP-SN4001 modules.
6.2. Wire the modules in parallel to the same Modbus RTU actuator network and configure one module as
Active and one as Standby.
6.3. The Standby module will monitor network communications and if the Active module fails, the Standby
module will become active and take over the actuator network communications.
7. Electromagnetic Compatibility (EMC) Compliance
7.1. EN 61326-1:2013
7.2. EN 55011:2009+A1(2010) Class A
7.3. EN 61000-4-2:2009
7.4. EN 61000-4-3:2006+A1(2008)+A2(2010)
7.5. EN 61000-4-4:2004+A1(2010)
7.6. EN 61000-4-5:2006
7.7. EN 61000-4-6:2009
7.8. EN 61000-4-8:2010
7.9. EN 61000-4-11:2004

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2 Function Flowchart
The following flowchart graphics illustrate the main functional categories of the MSIV.

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Figure 2.1 – MSIV Functional Flowchart
System Configuration branch continued on next page…

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…System Configuration branch continued…

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3 Quick Startup
1. Connect earth ground (#18AWG minimum) wiring, MOV network cables (Belden #3074F/#9841/#3107), and DC
power cabling.
2. Apply power to the MSIV and turn the power switch to the ON position.
3. Wait for the MSIV to display the start-up screen.
4. Touch the screen once and wait for the login prompt.
5. Enter default username “FLOW”. Press Enter.
6. Enter default password “100”. Press Enter.
7. Select “System Configuration” then “Redundant Configuration”.
8. Set the requested mode to “Disabled”, startup mode to “Active”, and redundancy mode to desired setting.
9. Press the “Back” button and in the “System Configuration” page select “User Administration”.
10. Set up user accounts.
11. Select “MOV Network Config” and set up the MOV network.
12. Select “DCS Configuration” and set up the DCS communications.
a. For remote DCS control, the three primary registers of interest are:
i. 46001: Register for HS Status (Ready Only): 0=idle, 1=standby, 2=hot
ii. 46002: Register for Host System to toggle (Write Only): 3=toggle state
iii. 46191: Register for Internal Program Execution Heartbeat (Read Only): Updates every scan, 8-bit integer.
13. Tap the “Back” button to return to the “System Configuration” screen.
14. Select “Redundant Config” and change the requested mode to “Active”.

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4 Electrical Connections
4.1 MSIV Rear Panel Connections
Figure 4.1 – MSIV Rear Panel Electrical Connections
The following list defines the connections shown in Figure 4.1 above.
1. ON/OFF SWITCH: Used to switch the MSIV DC power supply ON or OFF.
2. FUSE: Housing of the fuse used to protect the DC power input. Use a 5x20mm, 2.5 amp, 250V
fuse.
3. EARTH GROUND: Chassis ground using a #10-32 grounding screw. The Master Station MUST be attached
to a good quality electrostatic local earth ground. An effective, low-impedance (less than
5 ohms) connection is required.
4. MOV CHANNEL A: Connections for channel A of the MOV network using #6-32 terminal screws. See table
4.1 for connection details.

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Table 4.1 – Network Channel A Connection
Connector MX/QX UEC-3-DDC
DATA-A1(+) 13 TB4 D-S
DATA-A1*(-) 14 TB4 D-S*
Shield N/C
5. MOV CHANNEL B: Connections for channel B of the MOV network using #6-32 terminal screws. See table
below for connection details.
Table 4.2 – Network Channel B Connection
Connector MX/QX UEC-3-DDC
DATA-A2(+) 5 TB3 D-M
DATA-A2*(-) 4 TB3 D-M*
Shield 3
6. DEBUG SERIAL: RS-232 serial port. Used for MSIV diagnostics. See figure 4.2 below for RS-232
connection information. The Debug serial port is configured as a DTE, DB9 Male
connector.
Figure 4.2 – Debug Port Connection: DB9 Male

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7. DCS SERIAL PORT: RS-232 serial port. If RS-422 or RS-485 is needed, an external converter should be
used. The DCS serial port is configured as a DTE, DB9 female connector (depending on
the DCS system, a null modem DB9 cable may need to be used for communicating with
this port).
Figure 4.3 – DCS Serial Port Connection: DB9 Female
8. MOV TCP/IP: Ethernet connector for future development (not currently placed). Intended for use with
actuators that are equipped with Modbus TCP/IP add-on adapter.
9. WEB ETHERNET: Ethernet port for future development.
10. USB PORTS: Can be used for updating MSIV software. Note: the rear panel has 3 USB ports physically
installed, but only the top 2 ports are available for the user.
11. DCS TCP/IP: Ethernet port for DCS communications. RJ45 connector. Supports Modbus TCP/IP
protocol as specified by the Modbus Organization’s “MODBUS MESSAGING ON TCP/IP
IMPLEMENTATION GUIDE V1.0b” publication.

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4.2 Master Station Wiring Requirements
Regarding the network cable which connects the field units to the Master Station, a shielded, twisted-pair cable must
be used. In particular, Belden 3074F, 3105A or 9841 cable should be used. The use of other cables may result in a
reduction of internodal distances or increased error rate, and is the user’s responsibility.
BELDEN 3074F SPECIFICATIONS
• Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 4000’ (1.2km)
For loop mode, this is the total length between operating field units. If a field unit loses power, the relays internal to
the field unit connect the A1 Channel to the A2 Channel, which effectively doubles the length of the cable (assuming
a single field unit fails). To ensure operation within specifications in the event of power failure to field units, this
consideration must be added. Example: to ensure operation within specification when any two consecutive field units
lose power, the maximum length of cable up to 19.2 kbps should not exceed 4000’ (1.2 km) per every four field
units.
Key Specifications
• Resistance/1000 ft = 18 AWG (7 x 26) 6.92 ohms each conductor (13.84 ohms for the pair)
• Capacitance/ft = 14 pF (conductor-to-conductor)
• Capacitance/ft = 14 pF (conductor-to-shield)
BELDEN 3105A SPECIFICATIONS
• Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 4000’ (1.2 km)
For loop mode, this is the total length between operating field units. If a field unit loses power, the relays internal to
the field unit connect the A1 Channel to the A2 Channel, which effectively doubles the length of the cable (assuming
a single field unit fails). To ensure operation within specifications in the event of power failure to field units, this
consideration must be added. Example: to ensure operation within specification when any two consecutive field units
lose power, the maximum length of cable up to 19.2 kbps should not exceed 4000’ (1.2 km) per every four field
units.
Key Specifications
• Resistance/1000 ft = 22 AWG (7 x 30) 14.7 ohms each conductor (29.4 ohms for the pair)
• Capacitance/ft = 11.0 pF (conductor-to-conductor)
• Capacitance/ft = 20.0 pF (conductor-to-shield)
BELDEN 9841 SPECIFICATIONS
• Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 3500’ (1 km)
For loop mode, this is the total length between operating field units. If a field unit loses power, the relays internal to
the field unit connect the A1 Channel to the A2 Channel, which effectively doubles the length of the cable (assuming
a single field unit fails). To ensure operation within specifications in the event of power failure to field units, this
consideration must be added. Example: to ensure operation within specification when any two consecutive field units
lose power, the maximum length of cable up to 19.2 kbps should not exceed 3500’ (1 km) per every four field units.
Key Specifications
• Resistance/1000 ft = 24 AWG (7 x 32) 24 ohms each conductor (48 ohms for the pair)
• Capacitance/ft = 12.8 pF (conductor-to-conductor)
• Capacitance/ft = 23 pF (conductor-to-shield)

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4.3 Master Station Network Topologies
Figure 4.4 – Modbus Redundant Loop Topology
Additionally, a redundant system can be setup using by using 2 modules. Wire the modules in parallel to the same MOV
RS-485 network as shown below. The redundant modules can be located at any position in the network, but Configure
one module as Active and one as Standby as explained in section 7.2.2 Redundant configuration. The 2 redundant
modules should be connected to the same electrical node of the RS-485 network, and the wiring should adhere to the
Belden wiring specifications regarding max distance between network nodes and repeaters.

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Table 4.3 – Hot-Standby Wiring Connections for Redundant Modules
MSIV Module Connector MX/QX Network UEC-3-DDC Network
Hot Active
Channel A Data (+) 13 TB4 D-S
Channel A Data*(-) 14 TB4 D-S*
Shield (GND) N/C
Standby
Channel B Data(+) 5 TB3 D-M
Channel B Data*(-) 4 TB3 D-M*
Shield (GND) 3
Figure 4.5 – Hot Standby Redundant Wiring Diagram. Refer to Figure 4.4 for cable shield wiring (applies to both
Active and Standby Modules)

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5 System Status
5.1 Main Menu
Upon successful login as a user assigned to any role level, the System Status button on the Main Menu screen will
be present. Simply touching the System Status button will advance the HMI display to the System Status screen. Be
selecting Exit, the user will end the session and log out.
Figure 5.1 – The Main Menu Screen