rotork p3 User manual

Publication PUB059-002-00 Issue 06/15
P3 - Pakscan Master Station
Technical Manual

P3 - Pakscan Master Station Technical Manual
2 of 136 Publication PUB059-002-00 Issue 06/15
KNOW YOUR MASTER STATION
Port 3 Port 4
Port 3 Port 4
1 2 3 45
1 2 3 45
Host Ethernet
Ports for A
master station
Connection to
wireless module
Port 1
Port 2
P
3
PS731
Keyswitch
Auto
A
B
P
3
P
3
PS720
IIE Loop
Standby
Port A
Port B
P
3
PS720
IIE Loop
Standby
Port A
Port B
P
3
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
PS700
CPU/PSU
Port 1
Port 2
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
Option 1
Option 2
Switch
A
B
CЄ
Option 2
Option 1
CPU/PSU
rotork
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rotork
P3 Wireless
Comms
PS721
P3 Wireless
Comms
PS721
rotork
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These modules not fitted on single master stations
Main
Chassis
Host Comms
Serial Ports for A
master station
Host Comms
Serial Ports for B
master station
A side P3
CPU Main
Module
Optional
Wireless
Module
Optional
Current Loop
Module
Key Switch and
LTD Module
Optional
Current Loop
Module
Optional
Wireless
Module
B side P3
CPU Main
Module
Power Connector
Power Connector
View from below
Current
Loop
Connection
Terminals
Current Loop
Connection
Terminals (Single
Master Only)
Alarm and
ESD
Terminals
Alarm and
ESD
Terminals
Host Ethernet
Ports for B
master station

Contents
Issue 06/15 Publication PUB059-002-00 3 of 136
CONTENTS:
KNOW YOUR MASTER STATION.............................................................................2
TABLE OF FIGURES:.................................................................................................5
INTRODUCTION.........................................................................................................7
1. MOUNTING AND CONNECTING THE MASTER STATION..............................9
1.1 Mechanical Fixing ................................................................................................................9
1.2 Host Serial Communications Connections.......................................................................12
1.3 Ethernet Communications Connections...........................................................................12
1.4 Power Connector and Fuses .............................................................................................12
1.5 Alarm and Hardwired ESD Connector...............................................................................13
1.6 Current Loop Connections ................................................................................................13
1.7 P3W Coordinator Connections..........................................................................................14
1.8 P3W Repeater and P3W WMA AC Power Connections ....................................................15
1.9 P3W Repeater and P3W WMA 24VDC Connections..........................................................16
1.10 P3W WMA Modbus Connections.....................................................................................17
1.11 Setting up the P3W Repeater and P3W WMA..................................................................18
1.12 Front Panel LEDs .............................................................................................................21
2. THE FIELD CURRENT LOOP NETWORK.......................................................23
2.1 Loop Checks.......................................................................................................................24
2.2 Connecting Up....................................................................................................................25
3. THE FIELD WIRELESS NETWORK.................................................................27
3.1 Wireless Site Survey..........................................................................................................28
3.2 Wireless Specification .......................................................................................................28
3.3 Connecting Up....................................................................................................................28
4. CONFIGURING SERIAL COMMUNICATIONS................................................31
4.1 Setting Port 1 and 2 for RS-232 or RS-485........................................................................31
5. CONFIGURING ETHERNET COMMUNICATIONS..........................................35
5.1 Default Ethernet Settings...................................................................................................36
5.2 Ethernet Security................................................................................................................37
6. SETTING UP THE MASTER STATION BY THE KEYPAD..............................39
6.1 Using the Keypad...............................................................................................................39
6.2 The Screen Display............................................................................................................40
6.3 Setting the Current Loop Option Module Parameters ......................................................41
6.4 Setting the Wireless Option Module Parameters..............................................................45

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4 of 136 Publication PUB059-002-00 Issue 06/15
6.5 Setting the Master Host Communications Parameters.....................................................47
6.6 The Other Settings.............................................................................................................49
6.6.1 Security..........................................................................................................49
6.6.2 ESD...............................................................................................................49
6.6.3 Date and Time................................................................................................49
6.6.4 Master Station Parameters.............................................................................50
7. INTERNAL WEB PAGES .................................................................................51
7.1 Making an Internet / Intranet Connection..........................................................................51
7.2 Connecting a Computer Directly to the Master Station....................................................52
7.3 Adjusting the Network Settings of the Computer.............................................................52
7.4 Web Page Structure ...........................................................................................................54
7.4.1 User Levels....................................................................................................54
7.4.2 Overview of Web Page Layout........................................................................54
7.5 The Web Pages in Detail....................................................................................................56
7.5.1 Log In Screen.................................................................................................56
7.5.2 Master Station................................................................................................57
7.5.3 View Configuration .........................................................................................59
7.5.4 System Diagnostics........................................................................................60
7.5.5 Master Station Data Logger [ms datalogger]...................................................62
7.5.6 Master Station Host Analyser [host analyser]..................................................64
7.5.7 Pakscan 2 Loop Diagnostics [diagnostics] ......................................................65
7.5.8 Pakscan Wireless Diagnostics [diagnostics]....................................................68
7.5.9 Pakscan 2 Loop Option Module Event Logger [Event Log]..............................70
7.5.10 Pakscan Wireless Option Module Event Logger [Event Log]...........................71
7.5.11 FCU Menu......................................................................................................72
7.5.12 FCU Control –IQ / IQT Actuator.....................................................................73
7.5.13 FCU Control - Integral Actuator (2-wire loop only)...........................................82
7.5.14 FCU Control - General Purpose Field Control Unit (2-wire loop only) ..............86
7.5.15 Admin.............................................................................................................90
7.5.16 Users .............................................................................................................90
7.5.17 Master station Configuration...........................................................................93
7.5.18 Host Port Configuration................................................................................102
7.5.19 Alarms..........................................................................................................107
7.5.20 Time.............................................................................................................109
7.5.21 General........................................................................................................110
7.5.22 Network........................................................................................................111
7.6 Setting Up the Master station Configuration Using the Web Pages ..............................113
7.6.1 Masterstation Config - Modbus Address .......................................................113
7.6.2 Masterstation Config - Pakscan 2 Current loop option...................................113
7.6.3 Masterstation Config - Pakscan 3 Wireless option.........................................114
7.6.4 Host port settings .........................................................................................114
7.6.5 Network IP address settings.........................................................................115
8. MAKING THE SYSTEM WORK .....................................................................117
8.1 Commissioning the Wired System..................................................................................117
8.2 Commissioning the Wireless network.............................................................................118
8.3 Monitoring and Controlling the Actuators from the HMI or web pages.........................119

Contents
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9. LONG TERM DATALOGGER (LTD)..............................................................121
9.1 Removing the memory card and copying data...............................................................122
9.2 Viewing the data with the LTD Viewer software..............................................................124
9.2.1 Messages.....................................................................................................125
9.2.2 Messages –Filter Options............................................................................125
9.2.3 Reports ........................................................................................................128
9.2.4 FCU Data.....................................................................................................129
10. RESETTING THE MASTER STATION TO DEFAULT VALUES....................130
11. REPLACING THE P3 MASTER STATION BATTERY...................................132
GENERAL SAFETY INFORMATION......................................................................133
TABLE OF FIGURES:
Fig 1: The Pakscan 3 Single Master Station –option: Current loop............................................7
Fig 2: The Pakscan 3 Hot Standby Master Station - option: Current loop...................................7
Fig 3: The Pakscan 3 Single Master Station –option: Wireless..................................................8
Fig 4: The Pakscan 3 Hot Standby Master Station –option: Wireless........................................8
Fig 5: The P3W (Pakscan 3 Wireless) coordinator –PS722. .....................................................8
Fig 6: Pakscan 3 surface mounting dimensions.........................................................................9
Fig 7: Pakscan 3, 19-inch rack mounting dimensions...............................................................10
Fig 8: View below the Pakscan P3 master station showing the Connectors .............................10
Fig 9: P3W coordinator, P3W WMA and P3W Repeater mounting details................................11
Fig 10: Serial Communication connections................................................................................12
Fig 11: PS710 CPU module connector terminal functions..........................................................13
Fig 12: PS720/PS730/PS731/PS732 Current Loop connections................................................13
Fig 13: PS721 to PS722 connections (Master station to P3W Coordinator)................................14
Fig 14: Power module for P3W Repeater and P3W WMA..........................................................15
Fig 15: Connections from DC power supply to P3W WMA or P3W repeater ..............................16
Fig 16: Connections from Modbus device to P3W WMA............................................................17
Fig 17: P3W WMA operation.....................................................................................................19
Fig 18: P3W Repeater and P3W WMA database.......................................................................20
Fig 19: CPU LEDs (Light Emitting Diodes) ................................................................................21
Fig 20: Pakscan P3 Wired Network...........................................................................................23
Fig 21: Pakscan P3 Current Wired Loop System Block Diagram (hot standby master station)....25
Fig 22: Pakscan P3 Current Wired Loop System Block Diagram (single master station).............26
Fig 23: A typical P3 wireless network ........................................................................................27
Fig 24: Pakscan P3 Wireless network Block Diagram (hot standby master station)....................29
Fig 25: Pakscan P3 Chassis, CPU and Key Switch modules removed.......................................31
Fig 26: Port Function Switches shown in RS-232 position .........................................................32
Fig 27: Port Termination Switches shown in Off position............................................................32
Fig 28: Cross connection switch settings on the backplane behind the Switch Module...............33
Fig 29: Hot Standby Serial Communications..............................................................................34
Fig 30: Hot Standby Ethernet Communications.........................................................................35
Fig 31: Hot Standby, Dual Redundant Ethernet Communications..............................................36
Fig 32: Pakscan P3 Main module connection to laptop and keypad detail..................................39
Fig 33: Connecting a Laptop to the Pakscan P3 Main Module...................................................52
Fig 34: Changing the Network Connections TCP/IP Properties –Windows XP ..........................53
Fig 35: Web Page Menu Layout................................................................................................55

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Fig 36: Web page Log In Screen...............................................................................................56
Fig 37: Web page Header Navigation........................................................................................56
Fig 38: Master Station Overview web page and Option 1 data, if a Wireless module is fitted......57
Fig 39: System Configuration Overview web page.....................................................................59
Fig 40: System Diagnostics web page wired only and option 1 data, if wireless fitted.................60
Fig 41: Master Station Data Logger pop-up...............................................................................62
Fig 42: Close up of Master Station Data Logger Information......................................................62
Fig 43: Saving the master station log file...................................................................................63
Fig 44: Host Analyser pop-up....................................................................................................64
Fig 45: Pakscan 2 Loop Diagnostics web page .........................................................................65
Fig 46: Pakscan Wireless Diagnostics web page.......................................................................68
Fig 47: Wired Option Module Event Logger pop-up ...................................................................70
Fig 48: Wireless Option Module Event Logger pop-up...............................................................71
Fig 49: FCU Menu web page ....................................................................................................72
Fig 50: IQ and IQT actuator FCU Control web pages.................................................................73
Fig 51: Wired IQ / IQT Parameters pop-up................................................................................74
Fig 52: Wired IQ / IQT Alarms pop-up .......................................................................................75
Fig 53: Wired and Wireless IQ / IQT Torque Profile pop-up .......................................................75
Fig 54: Wired IQ / IQT FCU Event Log pop-up ..........................................................................76
Fig 55: Wireless IQ / IQT Parameters pop-up............................................................................77
Fig 56: Wireless IQ / IQT Alarms pop-up...................................................................................78
Fig 57: Wireless IQ / IQT FCU Event Log pop-up......................................................................79
Fig 58: Wireless IQ / IQT Downloads pop-up.............................................................................80
Fig 59: Wireless Neighbour tables pop-up.................................................................................80
Fig 60: Q actuator FCU Control Web page................................................................................82
Fig 61: Q Parameters pop-up....................................................................................................83
Fig 62: Q Alarms pop-up...........................................................................................................84
Fig 63: Q FCU Event Log pop-up..............................................................................................84
Fig 64: GPFCU Control web page.............................................................................................86
Fig 65: GPFCU Parameters pop-up ..........................................................................................87
Fig 66: GPFCU Alarms pop-up..................................................................................................88
Fig 67: GPFCU Event Log pop-up.............................................................................................88
Fig 68: Administrator Level........................................................................................................90
Fig 69: Users web page............................................................................................................90
Fig 70: Add User web page.......................................................................................................91
Fig 71: Modify User web page...................................................................................................92
Fig 72: Master station configuration web page: General Settings...............................................93
Fig 73: Web page Field unit distribution bar...............................................................................97
Fig 74: Master station configuration web page: Pakscan 2 Loop................................................98
Fig 75: Master station configuration web page: Pakscan 3 Wireless........................................100
Fig 76: Host Port Configuration web page...............................................................................102
Fig 77: Modbus Message Generator web page .......................................................................105
Fig 78: Modbus Message Example web page .........................................................................106
Fig 79: Alarm Reporting Set up web page...............................................................................107
Fig 80: Time Settings web page..............................................................................................109
Fig 81: General web page.......................................................................................................110
Fig 82: Ethernet Network Settings web page...........................................................................111
Fig 83: Detailed Actuator Condition HMI pages.......................................................................119
Fig 84: Hot standby master station with Long Term Datalogger (LTD) .....................................121
Fig 85: Front view of the LTD..................................................................................................122

Introduction
Issue 06/15 Publication PUB059-002-00 7 of 136
Port 1
Port 2
P
3
PS731
Keyswitch
Auto
A
B
P
3
P
3
PS720
IIE Loop
Standby
Port A
Port B
P
3
PS720
IIE Loop
Standby
Port A
Port B
P
3
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
PS700
CPU/PSU
Port 1
Port 2
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
Option 1
Option 2
Switch
A
B
CЄ
Option 2
Option 1
CPU/PSU
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Port 1
Port 2
Port 1
Port 2
P
3
P
3
PS720
IIE Loop
Standby
Port A
Port B
PS700
CPU/PSU
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
Option 1
Option 2
Switch
A
B
CЄ
Option 2
Option 1
CPU/PSU
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INTRODUCTION
Pakscan 3 is a complete field network control system from Rotork. With the addition of a wireless
(P3W) network the user now has the choice of proven current loop technology of the Pakscan IIE
system or the flexibility of a meshed wireless network. The P3W master station is supplied with a
P3W Coordinator module; this module is powered by the master station and facilitates the
communications between the master station and the wireless network. Most types of Rotork actuators
can be connected to a Pakscan current loop provided they are fitted with the necessary field unit.
Information on the respective actuator field units can be found in the appropriate manuals. In this
guide, the type of actuator is not considered, though reference is made to both the integral and IQ
actuator types of field unit. The type of field unit does not affect the setting up of the system. The IQ
and IQT range of actuators integrate fully with the wireless network. The network range can be
extended using a P3W Repeater module, this module is externally powered and it extends the network
range by receiving and retransmitting network messages. Other actuators or devices can be added to
the wireless network using a Pakscan 3 Wireless Modbus Adaptor (P3W WMA). This module is very
similar to the P3W Repeater, but has a RS-485 serial port for communication. The Pakscan 3 master
stations are delivered either as loose items for mounting by the user, or contained in an enclosure
provided by Rotork. The master station will generally be either a single unit, or a hot standby pair.
This manual provides a guide to setting up the Pakscan master, the various P3W Wireless modules,
the loop communications, wireless communications, and the host connections for the most commonly
found applications.
Fig 1: The Pakscan 3 Single Master Station –option: Current loop
Fig 2: The Pakscan 3 Hot Standby Master Station - option: Current loop
This manual relates to Pakscan 3 Master Stations fitted with
PS720 Current Loop modules and/or the PS721 and PS722
Wireless modules

P3 - Pakscan Master Station Technical Manual
8 of 136 Publication PUB059-002-00 Issue 06/15
A master station fitted with the wired network only requires the PS720 module that fits in to the back
plane. A master station fitted with wireless requires a module to be fitted to the back plane (in option
1) and connected to this module, a P3W coordinator module (PS722).
Fig 3: The Pakscan 3 Single Master Station –option: Wireless
Fig 4: The Pakscan 3 Hot Standby Master Station –option: Wireless
Fig 5: The P3W (Pakscan 3 Wireless) coordinator –PS722.
One required for single channel master stations, two for hot standby
master stations. The P3W repeater (a device for extending the
range of wireless) and the P3W WMA look identical to this.
Port 1
Port 2
P
3
PS730
Keyswitch
ch
Aut
o
A
B
P
3
P
3
P
3
PS720
P
3
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
mm
PS700
CPU/PSU
Port
1
Port
2
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
Option1
Option 2
Switch
A
B
CЄ
Option 2
Option 1
CPU/PSU
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P3
Wireless
Comms
PS721
P3
Wireless
Comms
PS721
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rotork
P
3
P
3
P
3
3
PS700
CPU/PSU
Port 1
Port 2
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
Option 1
Option 2
Switch
A
B
CЄ
rotork
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P3 Wireless
Comms
PS721
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1. Mounting and Connecting the Master Station
Issue 06/15 Publication PUB059-002-00 9 of 136
1. MOUNTING AND CONNECTING THE MASTER STATION
The Pakscan 3 master station (single or hot standby) provides front access for all the user
connections, including power feed and the field network connections –either loop wires to the Current
Loop module (PS720) or network connection to the P3W coordinator (PS721 and PS722). The host
communication links use plug in D-type connectors for the serial communications and RJ45
connections for the Ethernet links.
The field wiring for the current loop, P3W coordinator and the master station alarms are taken
to screw terminals on plug in connectors that are fitted from below their appropriate module.
Power wiring is connected using an IEC connector in the bottom of the master station module
PS710. Two connections are required for a hot standby system.
Serial communications (RS-232 or RS-485) plug into 9 way female D-type connectors on the
front of the mounting chassis.
Ethernet connections use RJ45 connectors on the bottom of the master station module
PS710. The connector on the front is intended for connection to a service laptop computer.
1.1 Mechanical Fixing
Room should be left around the module for all the connections and cables, allowing for a suitable
bending radius on each lead. Power wiring should be suitably fused or protected with miniature circuit
breakers (MCBs) external to the master station.
The master station may be mounted on a flat surface using the mounting brackets provided. Also, the
extension brackets allow it to be mounted in a 19-inch rack. In either case it should be located in a
way that permits easy access to the pushbuttons and easy viewing of the display panel(s).
Before mounting the master station, set the communications link
switches, as discussed in section 3.
178
45
88
482
467
438
140
4 holes 6.5
All dimensions in mm
Allow 30 mm minimum space for cabling
Port 1
Port 2
Port 1
Port 2
P
3
P
3
PS720
IIE Loop
Standby
Port A
Port B
PS700
CPU/PSU
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
Option 1
Option 2
Switch
A
B
CЄ
Option 2
Option 1
CPU/PSU
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Fig 6: Pakscan 3 surface mounting dimensions.
(Both single and hot standby master stations may be surface mounted)
P
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10 of 136 Publication PUB059-002-00 Issue 06/15
All dimensions in mm
178
38
102
482
466
4 slots 6.5
Allow 30 mm minimum space for cabling
Port 1
Port 2
P
3
PS730
Keyswitch
Auto
A
B
P
3
P
3
PS720
IIE Loop
Standby
Port A
Port B
P
3
PS720
IIE Loop
Standby
Port A
Port B
P
3
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
PS700
CPU/PSU
Port 1
Port 2
PS710
Pakscan
P
3
Status
Pri/Stby
Power
Alarm
Option 1
Option 2
Switch
A
B
CЄ
Option 2
Option 1
CPU/PSU
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140
133
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Fig 7: Pakscan 3, 19-inch rack mounting dimensions.
(Both single and hot standby master stations can be panel or rack mounted)
Fig 8: View below the Pakscan P3 master station showing the Connectors
(The B side connections are similar)
Port 3 Port 4 1 2 3 4 5
1 2 3 4 5 6
IEC Power
Connector
Ethernet
Ports
Hard Wired
ESD
Serial
Ports
Current
Loop
Fuses
(Hot Standby)
(Single)
Wireless
module
1
2
3
4
5
6
7
8