rotork Pakscan IIE User guide

Publication S177E V2.0 Issue 03/05
Pakscan IIE Master Station
System Manual

Pakscan IIE System Manual
2 of 132 Publication S177E V2.0 Issue 03/05
As we are continually developing our products their design is subject to change without notice.
©The contents of this document are copyright and must not be reproduced without the written
permission of Rotork Controls Ltd.
The name Rotork is a registered trademark
Windows is a registered trademark by Microsoft Corporation
Modbus is a registered trademark by Modbus IDA
Software Level
This manual relates to Pakscan IIE master stations fitted with software
versions
V25 (5206-014) software version 5.8 or greater
Loop Driver (5206-034) software version 5.2 or greater

Contents
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Contents
Glossary of Terms...........................................................................................................................7
Abbreviations ..................................................................................................................................7
How to use this Manual ..................................................................................................................9
Software level ..................................................................................................................................9
1INTRODUCTION.................................................................................................11
1.1 Related Documents..............................................................................................................11
2EQUIPMENT DESCRIPTION..............................................................................13
3STORAGE PROCEDURE...................................................................................15
4OVERVIEW OF PAKSCAN.................................................................................17
4.1 Field Control Units...............................................................................................................17
4.2 Control and Indication.........................................................................................................18
5FUNCTIONS........................................................................................................19
5.1 Cable Fault Protection - Loopback system.......................................................................19
5.2 Current Loop Start Up Operations.....................................................................................19
5.2.1 Loop Configuration ..................................................................................................20
5.2.2 Normal Running Operation......................................................................................20
5.3 Modbus Serial and Ethernet Interfaces .............................................................................21
5.4 Local User Interface (LCD and Keypad) ............................................................................21
6INITIAL SETTING UP..........................................................................................23
6.1 Jumper Settings...................................................................................................................23
6.2 External Links.......................................................................................................................25
6.3 Display Screen Contrast .....................................................................................................26
7INSTALLATION AND CONNECTION.................................................................27
7.1 Mounting...............................................................................................................................27
7.2 Mains Power .........................................................................................................................27
7.3 Field Wiring...........................................................................................................................28
7.3.1 Screen Connections ................................................................................................29
7.4 Loop Checks.........................................................................................................................29
7.4.1 Loop Continuity........................................................................................................29
7.4.2 Screen Continuity ....................................................................................................30
7.4.3 Cable Capacitance ..................................................................................................30

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8LOCAL USER INTERFACE................................................................................33
8.1 Front Panel Indication LEDs...............................................................................................33
8.2 LCD Screen and Keypad .....................................................................................................34
8.3 Keypad Security...................................................................................................................35
8.3.1 Using a PIN..............................................................................................................35
8.4 Menu Structure.....................................................................................................................35
8.5 Master Station Status ..........................................................................................................38
8.5.1 Master Station Commands......................................................................................39
8.5.2 Master Station Alarms - Text Description................................................................40
8.6 Configuration Mode Screen................................................................................................41
8.7 Diagnostic Menus ................................................................................................................42
8.7.1 Top Diagnostic Display............................................................................................42
8.7.2 Modbus Port Diagnostic Displays............................................................................43
8.7.3 Printer port diagnostic display .................................................................................44
8.7.4 Loop Diagnostic Display..........................................................................................45
8.7.4.1 FCU Map and Failure Counts ..................................................................47
8.7.4.2 Loop Speed Test......................................................................................48
8.7.4.3 FCU Address Fault Details.......................................................................49
8.7.5 Hot Standby Inter Unit Diagnostic Display...............................................................50
8.8 Setup Menus.........................................................................................................................51
8.8.1 Top Setup Menu......................................................................................................51
8.8.2 Port Setup Menus....................................................................................................52
8.8.2.1 Alarm Linkage ..........................................................................................53
8.8.3 Data transfer to Standby Unit ..................................................................................54
8.8.4 Loop Setup Menu ....................................................................................................55
8.8.4.1 Further Loop Options ...............................................................................56
8.8.5 Unit Address Setup Menu........................................................................................57
8.8.6 Tag Setup Menu......................................................................................................58
8.8.7 Date and Time Setup...............................................................................................59
8.8.8 ESD Options Setup Menu .......................................................................................60
8.8.9 Keypad Security Options.........................................................................................61
8.9 Field Unit Menus ..................................................................................................................62
8.9.1 Actuator Field Unit Status Display...........................................................................62
8.9.1.1 IQ Actuator Second Status Page.............................................................63
8.9.1.2 IQ and IQT Historic Torque Displays .......................................................64
8.9.2 Flowpak Actuator Field Unit Status Display.............................................................65
8.9.3 General Purpose Field Unit Status Display.............................................................66
8.9.3.1 Second Page for General Purpose Field Unit..........................................67
8.9.4 IQ Analogue Input Field Unit ...................................................................................68
8.9.5 Communications Failure Display.............................................................................69
8.9.6 Field Unit Status Secondary Data ...........................................................................70
8.9.7 Field Unit Alarm – Text Description.........................................................................71
9SETTING PARAMETERS...................................................................................73
9.1 Initial Decisions....................................................................................................................73
9.2 Serial Communication Ports...............................................................................................74
9.3 Loop Data..............................................................................................................................75

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9.4 Tag Names............................................................................................................................76
9.5 Date and Time.......................................................................................................................76
9.6 ESD Configuration...............................................................................................................77
9.7 Security Access Level.........................................................................................................77
9.8 Final Checks.........................................................................................................................77
10 SETTING A HOT STANDBY PAIR PARAMETERS...........................................79
10.1 Copy Data A to B..................................................................................................................79
10.2 Changes to Terminal Connections.....................................................................................79
10.2.1 Main/Standby Connections......................................................................................79
10.3 Hot Standby Parameter Setting and Options....................................................................81
10.4 The PS300 Keyswitch..........................................................................................................81
11 INCLUDING A PS410 CONVERTER..................................................................83
11.1 Jumper functions.................................................................................................................84
11.1.1 PS410 port 2 to RS485 setup..................................................................................84
11.1.2 PS410 port 1 to RS232 setup.................................................................................85
11.1.3 LED functions ..........................................................................................................85
11.1.4 RS485 line conditioning...........................................................................................85
11.1.5 2-Wire and 4-wire RS485 communications.............................................................86
12 SETTING UP AND USING THE PS600 ETHERNET MODULE .........................87
12.1 Internal Connections ...........................................................................................................88
12.2 Connecting to the Ethernet Bridge ....................................................................................88
12.2.1 Local Ethernet Connection ......................................................................................89
12.2.2 Direct Ethernet Connection to a PC ........................................................................89
12.2.2.1 Connection using Windows XP................................................................89
12.3 Ethernet Module Status Indicators.....................................................................................90
12.3.1 LED Functionality.....................................................................................................90
12.4 Setting Up the Module.........................................................................................................91
12.4.1 Setting the Serial Connection Fields .......................................................................92
12.4.2 Setting the User Fields for the Web Browser ..........................................................93
12.4.3 Setting the Alarm Messaging Information................................................................95
12.4.4 Setting the Local Area Network Connection Parameters........................................96
12.5 Using the Ethernet Connection ..........................................................................................97
12.5.1 Master Station Overview .........................................................................................97
12.5.2 Master Station Configuration...................................................................................98
12.5.3 Network Diagnostics................................................................................................99
12.5.4 FCU Menu ............................................................................................................ 100
12.5.4.1 Field Unit Status and Control................................................................ 101
12.5.4.2 Field Unit Alarms screen....................................................................... 102
12.5.4.3 IQ and IQT Actuator Torque screen...................................................... 102
12.5.5 FCU Parameters................................................................................................... 103
13 COMMISSIONING THE SYSTEM.....................................................................107

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13.1 Checking Individual Field Units....................................................................................... 107
13.2 Checking the Loop Itself .................................................................................................. 108
13.3 Checking System Performance....................................................................................... 110
13.3.1 Setting the Loop Driver Voltages.......................................................................... 110
13.4 Diagnostic Information..................................................................................................... 111
13.4.1 Loop Configuration ............................................................................................... 111
13.4.2 Loop Communications.......................................................................................... 112
13.4.3 Loop speed reprogramming ................................................................................. 112
13.4.4 Checking Host Communications .......................................................................... 113
13.5 Final Checks...................................................................................................................... 113
13.6 Commissioning Aids ........................................................................................................ 114
14 MASTER STATION SOFTWARE VERSION ....................................................115
15 SET UP DATA RECORDS................................................................................117
15.1 Loop Map ........................................................................................................................... 118
16 TECHNICAL SPECIFICATIONS.......................................................................121
16.1 Master Station ................................................................................................................... 121
16.2 Actuator Field Units.......................................................................................................... 121
16.3 GP Field Unit...................................................................................................................... 122
16.4 2-Wire Loop ....................................................................................................................... 122
16.5 External Connections....................................................................................................... 124
16.5.1 Loop Connections and Digital I/O......................................................................... 124
16.5.2 Serial Ports........................................................................................................... 125
16.6 Printer Messages .............................................................................................................. 127
16.7 Maintenance ...................................................................................................................... 127
16.8 Master Station Dimensions.............................................................................................. 128
17 GENERAL SAFETY INFORMATION................................................................129

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Glossary of Terms
Address The unique address for a field unit on the Pakscan loop, range 1-240
Loop The digital, twisted pair 2-wire data communication link
Field Unit The Pakscan option card fitted to the actuator, or complete General Purpose field
unit
Master/Slave The method of communication used on the field loop. The master station controls
the data exchange on the highway
Node A single device (address) on the Pakscan loop
RS485 The electrical properties as defined by the IEA485 standard, 2-wire twisted pair.
RS232 The electrical properties as defined by the IEA232 standard
Abbreviations
Comms Communications
FCU Pakscan Field Unit
RAM Random Access Memory
ROM Read Only Memory
RTU Remote Terminal Unit
SW Software

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Contents
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How to use this Manual
In order to make the best use of the information in the following pages we suggest you use this
manual as follows:
 Familiarise yourself with the hardware - section 4 will show you all the parts
 Read sections 4 to 12 before attempting to commission the system
 Refer to section 6 to check the internal link settings
 Section 8 relates to the front panel LED’s, keypad and LCD screen
 Make sure you understand how to connect the system - section 7 tells you how
 Set up the Software selected parameters - also see section 9
 With a Hot Standby system check the information in section 10
 Commissioning the system is explained in section 13
 If you have RS485 Converter units, read section 11 carefully
 Ethernet connections are explained in section 12
 Record the information about your system on data sheets such as those outlined in section
15, or use Rotork MasterTools to document the system. Pakscan Ethernet systems can
also record the master station data to file from the web server application.
Software level
This technical manual relates to Pakscan IIE master stations with software version 5206-014 V5.8 or
later for the main V25 processor and version 5206-034 V5.2 or later for the loop processor.
MasterTools
The software utility, MasterTools, runs on a PC and maybe downloaded from www.rotork.com.
With this utility a complete record of the Pakscan loop, the field units and master station settings
can be made and retained either as an electronic file or the data may be printed out.

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Introduction
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1 INTRODUCTION
This document describes the procedures for setting up commissioning and running a Pakscan IIE
system. If the unit is to be stored for a period of time prior to its use, then please refer to section 3 for
information about storage of electronic equipment.
The Pakscan IIE master station hardware is a stand-alone unit requiring only the connection of power
and suitable field units to operate. This manual describes the Pakscan IIE master station only. Please
refer to the documentation relating to the field units for information on that part of the system.
The Pakscan IIE system is compatible with all Pakscan II and IIE field units and setting tools. The
Pakscan IIE is equipped with either serial communication ports, or Ethernet ports, or both through
which the master station can be controlled and operated from another device. The communication
protocol supported by these ports is Modbus RTU and Modbus TCP and details of the function codes
and data base organisation established within the master station are contained in the associated
protocol documents.
1.1 Related Documents
There are a number of documents for the Pakscan system that relate to the Pakscan IIE master
station these include:
General
(1) Field Test Unit Technical Manual (Paktester) S178E
(2) Master Station Test Unit Technical Manual (Pakreader) 5161-021
(3) Pakscan IIE RS485 Converter Technical Manual 5218-023
Serial Communications
(4) Pakscan Modbus Interface Specification S171E

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Equipment Description
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2 EQUIPMENT DESCRIPTION
The master station is an assembly of a computer card, a current loop interface card, a power supply
card, and a front panel with an LCD screen and 16-key keyboard, fitted to a standard 19-inch rack.
The rack will contain some or all of the items identified in Fig. 1.
 PS100 CPU and Display Module (two off in Hot Standby systems)
 PS210 Power Supply module (unless the hardware is supplied by 24V dc)
 PS300 Switch module for Hot Standby systems only
 PS410 RS485 Converter (optional)
 PS601/2/3/4 Ethernet port converter
The rack can accommodate two master stations, when viewed from the front these are referred to as
M/S A on the left and M/S B on the right. The 19-inch rack is always fully wired to accommodate all
variations of assembly within it. Some applications may require external links on the connectors and
terminal blocks and these will normally be fitted before despatch. It is advisable to check that any links
that may be required for a particular application are in place. When PS601 or PS602 Ethernet servers
are fitted there will be links to the Port 1 or Port 2 connectors and these will not be available for host
connections.
All master stations have their own dedicated power packs, each operating from an independent input.
In the case of a dual or hot standby system there maybe two independent supplies to the rack.
Optional additional cards may be fitted to the master station rack for converting the communications
hardware between RS232 and RS485, and in the case of a Hot Standby a switch unit is also included.
If the master station includes Ethernet connectivity then there are internal servers fitted inside the
rack. Where no cards are fitted blanking plates are used to cover the resulting space.
Two master stations may optionally be interconnected to form a dual redundant system. In this
configuration, one unit controls the loop, whilst the other acts as a 'hot standby'. Changeover between
the units can be automatic or manually triggered.
MASTER STATION A MASTER STATION B
PS210 - Power Supply
PS100 - CPU & Display ModulePS410 - RS232/RS485 Converter PS300 - Keyswitch
PS60X - Ethernet Server (Internal)
Fig 1: Pakscan IIE Master Stations in a 19 inch rack

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On the rear are the following items, repeated for both M/S A and M/S B.
 Power Connector (IEC) for use with a.c. powered units (when a 24V dc supply is used this
is replaced by a terminal block). There is a 1 Amp slow blow fuse adjacent to the power
connection.
 26 screw terminals for Field Connections, of these 25 only are used, and terminals 1 to 21
are directly linked internally to the 25 way D type connector (pins 1 to 21) above the
terminal block.
 Two 9 way D type connectors for Comms Port 1, a male and a female. This port is always
RS485, 2-wire.
 A single 9 way D type female connector for Comms Port 2. This port is always RS232.
 There are two further connectors, 9 way D type female, for Ports 3 and 4. These are only
used if the optional RS232/485 Protocol Converter Module, PS410, is fitted, as described in
section 11.
 One trailing RJ45 female socket for connection to the Ethernet server when one is fitted.
For host computer communications either serial or Ethernet connections can be used. The data format
for information exchange is Modbus RTU (for serial ports) or Modbus-TCP (for Ethernet LAN
connection). There are multiple data bases within the master station and these are explained later in
this manual.
Support for a printer to log alarms is provided. Each entry can be tagged with the time and date. There
are contact outputs for various alarm conditions, and provision for an Emergency Shutdown ('ESD')
input. Emergency Shutdown may be invoked by breaking the circuit between two terminals at the
master station causing an 'ESD' message to be broadcast on the current loop. Field units and
actuators may be set up to carry out an appropriate action, e.g. close a valve.
Fig 2: Pakscan IIE Master Stations – rear view
PORT 1
RS485
PORT 2
RS232
FIELD CONNECTIONS
PORT 3
PORT 4
RS485
PORT
EXP
PORT 3
PORT 4
RS485
PORT
EXP
PORT 1
RS485
PORT 2
RS232
FIELD CONNECTIONS
MAINS INPUT
90 - 264 Vac
FUSE 1A
MAINS INPUT
90 - 264 Vac
FUSE 1A
MASTER STATION B MASTER STATION A
Data Label
Field Terminals and D-type Connector
Comms Port 1 (2xD-type) Comms Port 2 (D-type)
Ethernet (RJ45) IEC Power Connector

Storage
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3 STORAGE PROCEDURE
On receipt the hardware should be examined for signs of damage and to ensure that the expected
equipment is present. Identify all the parts.
If the unit is to be stored for a period of time then normal conditions for keeping electronic hardware
must be provided.
The ambient conditions should remain in the following bands at all times:
Temperature: 10 - 30 degrees Centigrade
Humidity: Not to exceed 80% R.H.
The equipment should not be stacked, though it may be stored in any orientation. The original packing
should be retained. DO NOT LOSE THE MANUALS.
If it is to be kept for a prolonged period then an electrical exercise test is recommended every 6
months, for 24 hours. The master station internal battery has a shelf life of 3 years.

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Pakscan Overview
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4 OVERVIEW OF PAKSCAN
The Pakscan system is a control and monitoring
package comprising a master station, 2-wire serial
data cable wired in a ring or loop and a number of
connected actuators with Pakscan field units fitted.
The fieldbus loop can have up to 60, 120, 180 or
240 field units connected depending on the
capability of the master station, and the cable can
be up to 20 km long. The length of the 2-wire cable
(loop length) can be considered as the
circumference of a circle starting and finishing at
the master station.
The master station is a single module in a 19-inch
rack. It may have a supporting, identical, standby
unit. Details of setting a Hot Standby pair are
covered in Section 10. In essence, the Hot Standby
simply comprises two identical master stations each
of which is set identically to its partner. In some
cases two master stations are fitted into one 19-
inch rack (there is space for two). These can be
considered as two independent units.
The current loop is single fault tolerant and can
withstand either an open circuit, short circuit or
ground connection fault and still maintain
communication with all the field units. Subsequent
faults do not stop the complete system from
working and the parts that remain connected to the
master station will continue to be in communication
with it.
In addition to controlling the loop, the master station
also provides the external interface to the system.
It supports 2 serial ports for communications to host
computers, as well as providing a local user
interface. Alternatively, one of the serial ports may
be used to drive a printer to log alarms. In the
Pakscan Ethernet version one or both the serial ports are replaced with a standard 10Base-T Ethernet
ports. When a single Ethernet port is available the remaining serial port may be either RS232 or
RS485 depending on the option chosen.
4.1 Field Control Units
A range of field control units ('FCU’s') is available to cater for specific application areas. These may be
summarised as follows:
Fig 3: Pakscan IIE System Diagram

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 Integral type field control units mounted within a Rotork actuator electrical housing such
as the IQ, IQT or Q range actuator.
 Externally mounted field control unit. Various packages are available, including 'Pakbox',
weather-proof box, or rack mounting. The unit may be used for either actuator control
applications, or for general purpose applications such as pumps, blenders etc. Its
complement of I/O is 8 digital inputs, 4 changeover relay outputs, 2 analogue inputs and
1 analogue output.
4.2 Control and Indication
The field units each report information to the master station that can be viewed on the integral LCD
display, or collected from the serial communication port of the master station for use on another
display system. The reported data is already organised and requires no configuration by the user;
each field unit automatically reports all its available data.
Commands to operate the output devices may be sent over the system, the initiation of the command
can either be from the integral keypad (under the correct access code) or from the serial or Ethernet
data link. Once again the organisation of these commands is already configured and the user only has
to address the correct register to implement the command.

Functions
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5 FUNCTIONS
5.1 Cable Fault Protection - Loopback system
Communication between the master station and the field control units is via a twisted pair 2-wire cable
carrying a 20 mA current in a loop. In normal operation the current flows round the loop on one wire
and returns via the master station on the second wire. If high-speed operation with ‘doubling on’ is
selected the current returns inside the master station and the second wire is not used.
Each field control unit has the capability to connect the 2 wires together (apply a loopback circuit), and
this mechanism is used to divert the current in the event of a loop fault. With field units each side of a
loop fault 'in loopback', the system can still communicate with all field units by operating the system as
2 segments. If there are 2 loop faults, those field units between the faults will be isolated.
A loop cable fault may be an open circuit, a short circuit, or an earth fault.
5.2 Current Loop Start Up Operations
The Pakscan IIE controls the current on the loop to communicate with the attached field units. Loop
communication divides into two parts: configuration (when the master station decides whether the loop
is complete, and if not, where the faults are), and normal operation.
Fig 4: Loopback system
Master Station
Port B Port A
Add 2
Add 4 Add 3
Add 1
In OutOutIn
Master Station
Port B Port A
Add 2
Add 4 Add 3
Add 1
In OutOutIn
Normal operation Broken loop operation
Cable
Fault
LB on LB on

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5.2.1 Loop Configuration
The loop configuration phase is entered after power-up, after a loop fault is detected, or after a loop
configure command is received.
Configuration consists of the following steps:
1. Wait for all the field units to go into loopback. The time is dependent on the baud rate.
2. Issue a command from Port A to ask a field unit in loopback for its address. This finds the
first field unit.
3. Use that address to tell the field unit to remove its loopback.
4. Repeat steps 2 and 3 until no more field units are found.
5. Attempt to send a message right round the loop and receive it back at the sending end.
This tests the integrity of the complete loop.
6. If the loop is complete stop here. If the loop has a problem execute steps 7 to 10.
7. Repeat steps 2 to 4 from Port B.
8. Again wait for all field units to go into loopback.
9. Remove loopbacks one field unit at a time from Port A until only the last field unit is left in
loopback.
10. Repeat step 9 for Port B.
Loop configuration will identify and mark as out of service any field unit found which has an address
that is zero, an address that is the same as one which has already been found, or which has an
address, which is too high. An address that is too high is one outside the range selected for the master
station.
The master station has the facility to double the loop Baud rate. If this facility is enabled, via the
Keypad, the master station will issue a broadcast command to all the field units to get them to double
the baud rate they are using, once it has detected that the loop is complete.
5.2.2 Normal Running Operation
In normal operation, the master station polls each field unit for any changed data it has to report. Most
of the time, field units have no changes to report, and traffic on the loop is kept to a minimum. Field
units are polled in address order. Data that might be reported includes changes to digital inputs, alarm
changes, or significant changes to an analogue input.
If a field unit, which previously responded on the last scan, fails to respond correctly the master station
will retry twice to get a reply. On subsequent scans only a single attempt is made to get a response.
All field units up to the address preset in the master station database are polled. Thus new field units
which are powered-up on a working loop will be identified by the master station, provided they are
within the selected address range, and future scans will poll the new field unit for data.
Commands to field units (open, close, etc.) are interleaved between polls to individual field units. This
ensures they are sent as soon as a slot is available. When the current transaction is completed the
command will be next.
A check is made at the end of each scan to see if a loop fault has occurred. For a complete loop with
no loopbacks present a test message is sent round the loop; for a broken loop (loopbacks in use)