rotork Master Station Quick guide

Safe Use, Installation and Maintenance Manual
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Master Station Safe Use, Installation and Maintenance Manual
Rotork Master Station
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1. Introduction_________________________________________________________________________________________ 4
2. Know your Rotork Master Station_____________________________________________________________________ 6
3. Rotork Master Station Technical Datasheet ___________________________________________________________ 12
4. Health and Safety __________________________________________________________________________________ 14
5. Installation _________________________________________________________________________________________ 15
6. Basic Commissioning ________________________________________________________________________________ 17
7. Environmental______________________________________________________________________________________ 26
8. Fuses_______________________________________________________________________________________________ 26
9. Vibration and Shock ________________________________________________________________________________ 26
10. EMC _______________________________________________________________________________________________ 26
11. Safet y ______________________________________________________________________________________________ 27
12. Storage ____________________________________________________________________________________________ 27
Section Page
Table of Contents
This information is needed to avoid a safety hazard, which might cause bodily injury.
This information is necessary to prevent damage to the product or other equipment.
This manual contains important safety information. Please ensure it is thoroughly read and understood before
installing, operating or maintaining the equipment.
This manual is produced to enable a competent user to install, operate, adjust and inspect the Rotork Master Station.
These user instructions are provided subject to the following conditions and restrictions:
This document contains information of a proprietary nature belonging to Rotork. Such information is supplied solely for the
purpose of assisting users of the Rotork Master Station in its installation, operation and maintenance.
The text and graphics included in this document are for the purpose of illustration and reference only. The specifications on which
they are based are subject to change without notice.
Information in this document is subject to change without notice.
This work and the information it contains are the property of Rotork. The information it contains shall not be
reproduced or disclosed, in whole or in part without the prior written consent of Rotork.
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Master Station Safe Use, Installation and Maintenance Manual
The Rotork Master Station provides an intelligent interface between a host Modbus system and the connected Field Control Units (FCUs). It
performs the functions of running the field network, data aggregator, data viewer and managing the host Modbus database.
The Modbus database presented to the host is independent of the field network protocol, giving a common open industry standard
interface to the host for process control information.
The host Modbus connection is Ethernet (TCP) as standard, with the connections on the CPU module itself. For applications that require a
serial host connection a Host Serial Add In Module (AIM) is required to provide the serial connection.
In addition to the Modbus host database, the Master Station has a local display where the user can interrogate configuration, status and
alarm data from FCUs or the Master Station. For remote access, the Master Station has built-in web pages mirroring the localdisplay.
There are two different field networks available as AIMs for the Master Station and up to four AIMs can be fitted to the Master Station.
The field network AIMs run the individual field networks, distributing commands and collecting data from the FCUs to populate the host
database. Two different field network AIMs (Modbus and Pakscan Classic) are available and one serial host RTU AIM is available.
• Pakscan Classic field network AIM
The Pakscan Classic redundant loop network has been the network of choice for actuator control for over 30 years. Using robust current
loop technology, 20 km loop lengths and 240 FCUs are possible.
• Modbus Open field network AIM
Open Modbus field network with standard highway or redundant loop options. Other manufacturers' devices integrated into network by
use of a field device description file.
• Host Serial AIM
Open Modbus serial connection for host controllers.
The Rotork Master Station can be supplied in three different configurations:
Single: A single sided Master Station comprising one display, one PSU module, one CPU module and up to four AIMs.
Dual: A dual sided Master Station comprising two displays, two PSU modules, two CPU modules and up to eight AIMs total.
Each side can have different hardware configurations and remains separate from the other side.
Hot Standby: A dual sided Master Station comprising the same options as a single sided Master Station with a complete duplicate of
modules for the second side. This enables switching between each side with no impact to network communications.
1. Introduction
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1. Introduction continued
General Purpose
Field Control Unit
2-Wire Current Loop
CLASSIC
HOST ETHERNET
NETWORK
Off-site Connection
Plant Controller
DCS/SCADA
Asset Management
Laptop
Work Station
SPT
55
Mixer Compressor Solenoid
Valve
Pressure
Transmitter
M
Motor Operated
Valve
Control
Valve
E/H
Electro-hydraulic
Valve
Including 3rd Party
Field Devices
20 km distance
Redundant loop
Single or dual
highway,
or redundant
loop topology
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Master Station Safe Use, Installation and Maintenance Manual
2. Know your Rotork Master Station
Alarm LED
Green: no alarms are present
on the system.
Red: any alarm condition
in any FCU or the Master
Station. This alarm does not
prevent operation of the
Master Station.
Status LED
Flashing Green: power upsequence.
Solid Green: indicates all applications
are running correctly after a power up.
Red: Ethernet host communications
lost or communication error between
Master Station and a FCU.
Hot Standby and Dual
Rotork Master Station
Single
Rotork Master Station
Primary button
Hot Standby
In hot standby configuration, the primary button
can be used to set that side of the Master Station as
the controlling hardware. The active controlling side
of the Master Station can easily be identified by an
illuminated button. The non-controlling side will not
be illuminated.
Single and Dual
In single and dual Master Station configuration, the
primary button has no function, but the backlight
will remain illuminated to show the units are actively
controlling.
Power LED
Green: power on,
off: power off
Touch screen display
Hot Standby and Dual
Each side of a hot standby or dual Master Station has a display
module to interface with that side of the Master Station.
Single
A single Master Station has one display module for the left side.
The right side is blanked off.
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2. Know your Rotork Master Station continued
Hot Standby
The hot standby Master Station contains a duplicate set of
modules on the right hand side. The position of AIMs fitted
on the right must match the modules fitted on the left.
Dual
The dual Master Station has two separate sides that can
accommodate different modules. A dual Master Station
operates as two single Master Stations.
Single
The single Master Station has one set of modules installed
on the left side of the Master Station chassis.
Single
Rotork Master Station
Option Slot 1, 2, 3, 4
Four slots are available for AIM
installation. Empty slots will have a
blank cover fitted.
PSU module
Side A
AIM
Slot 1
Side A
AIM
Slot 2
Side A
AIM
Slot 3
Side A
AIM
Slot 4
Side B
AIM
Slot 1
Side B
AIM
Slot 2
Side B
AIM
Slot 3
Side B
AIM
Slot 4
CPU module
Hot Standby and Dual
Rotork Master Station
Hot Standby
Side A
Hot Standby
Side B
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Master Station Safe Use, Installation and Maintenance Manual
Example build details
The example below has three optional AIMs fitted; Pakscan Classic field network, Modbus RTU field network and Host Serial. Refer to the
model code of your unit for confirmation of the AIMs fitted to your unit.
User connections
Master Station provides front access for all the user connections, including power, and field network connections to the Pakscan Classic
module (P4720) or Modbus RTU module (P4724).
• CPU alarm, CPU ESD and Pakscan Classic field wiring connections are via screw terminals on removable connectors. Connectors are
supplied pre-installed on each applicable module.
• Modbus RTU field connections are via 9-way D type connectors on the bottom of the Modbus RTU module (P4724). Both sockets are
female on the Master Station.
• Power wiring is connected using an IEC-C13 connector on the bottom of the PSU module (P4740). Two power connections are
required for a dual or hot standby system.
• Ethernet host is connected using standard RJ45 connectors on the bottom of the CPU module (P4710). The top connector is intended
for temporary connection to a service laptop computer and marked clearly as a service port.
• Optional Serial host via RS-232 or RS-485 is connected using 9-way D type connectors on the bottom of the Host Serial module
(P4727). Both sockets are female on the Master Station.
2. Know your Rotork Master Station continued
LED for power
indication
Mains on / off
switch
CPU module
service
connection
Pakscan Classic
network field
connection
Mains AC
connection
Modbus RTU field connections
Blank AIM cover
Optional Host Serial AIM
connections
CPU module host connections
CPU module Alarm and ESD connection
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Single Rotork Master Station
2. Know your Rotork Master Station continued
For RS-232 Serial Data
Connect to Host Serial 2.
9-way Female D-type
RS-232 Connections
1
2
3
4
5
6
7
8
9
Signal Common
Data In
Data Out
Optional
For RS-485 Serial Data
Connect to Host Serial 1.
9-way Female D-type
RS-485 Connections
Signal Common
Data +
Data –
1
2
3
4
5
6
7
8
9
Optional
Pakscan Classic Loop
Connect field wiring to
supplied P4720 connector.
Port A OUT
Port A IN
Screen
Port B OUT
Port B IN
Screen
5
4
6
2
1
3
CONNECTOR
1
6
Host Connections
Field Connections
Ethernet
Connect to CPU Ethernet 1. CPU
Ethernet 2 is available for redundancy
(managed RSTP switch required).
Alarm and ESD
Wiring as shown.
If ESD is not
required, fit a
link between
pins 4 and 5.
5
4
Alarm
Emergency
Shutdown
PS710 CONNECTOR
1
2
3
Mains Power
Connectors
Connect to PSU. Mains
power 100 – 240 VAC.
Protective Earth must be
connected to 'E'.
CONNECTOR
Modbus RTU
9-way Female D-type
RS-485 Connections
Signal Common
Data +
Data –
1
2
3
4
5
6
7
8
9
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Master Station Safe Use, Installation and Maintenance Manual
2. Know your Rotork Master Station continued
Hot Standby Rotork Master Station
CONNECTOR
Modbus RTU
9-way Female D-type
RS-485 Connections
Signal Common
Data +
Data –
1
2
3
4
5
6
7
8
9
Pakscan Classic Loop
Connect supplied 'Y' loom to side A and
side B Pakscan Classic modules. Connect
field network to 'Y' loom connector.
Port A OUT
Port A IN
Screen
Port B OUT
Port B IN
Screen
5
4
6
2
1
3
CONNECTOR
1
6
Host Connections
Field Connections
For RS-232 Serial Data
Connect to side A Host
Serial 2 and another cable
to side B Host Serial 2.
1
2
3
4
5
6
7
8
9
9-way Female D-type
RS-232 Connections
Signal Common
Data In
Data Out
Optional For RS-485 Serial Data
Connect to side A
Host Serial 1 and
another cable to side
B Host Serial 1. Serial
connection to both
sides from one cable is
possible with bespoke
wiring.
9-way Female D-type
RS-485 Connections
Signal Common
Data +
Data –
1
2
3
4
5
6
7
8
9
Optional
Ethernet
Connect to side A CPU Ethernet
1 and connect another cable to
side B CPU Ethernet 1. Ethernet 2
ports are available for redundancy
(managed RSTP switch required).
Alarm and ESD
Wiring as shown.
If ESD is not
required, fit a
link between
pins 4 and 5.
5
4
Alarm
Emergency
Shutdown
PS710 CONNECTOR
1
2
3
Mains Power
Connectors
Connect to PSU. Mains
power 100 – 240 VAC.
Protective Earth must be
connected to 'E'.
Connect to both
sides of the
Master Station.
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2. Know your Rotork Master Station continued
Dual Rotork Master Station
CONNECTOR
Modbus RTU
9-way Female D-type
RS-485 Connections
Signal Common
Data +
Data –
1
2
3
4
5
6
7
8
9
Host Connections
Field Connections
Ethernet
Connect to CPU Ethernet 1.
CPU Ethernet 2 is available for
redundancy (managed RSTP
switch required).
Alarm and ESD
Wiring as shown.
If ESD is not
required, fit a
link between
pins 4 and 5.
5
4
Alarm
Emergency
Shutdown
PS710 CONNECTOR
1
2
3
Mains Power
Connectors
Connect to PSU. Mains
power 100 – 240 VAC.
Protective Earth must be
connected to 'E'.
For RS-485 Serial Data
Connect to Host Serial 1.
9-way Female D-type
RS-485 Connections
Signal Common
Data +
Data –
1
2
3
4
5
6
7
8
9
Optional
For RS-232 Serial Data
Connect to Host Serial 2.
1
2
3
4
5
6
7
8
9
9-way Female D-type
RS-232 Connections
Signal Common
Data In
Data Out
Optional
Pakscan Classic Loop
Connect field wiring to
supplied P4720 connector.
Port A OUT
Port A IN
Screen
Port B OUT
Port B IN
Screen
5
4
6
2
1
3
CONNECTOR
1
6
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Master Station Safe Use, Installation and Maintenance Manual
3. Rotork Master Station Technical Datasheet
Rotork Master Station Features
Power supply,
AC frequency
and current
consumption
AC
100 – 240 V~ (±10%), 50 / 60 Hz (P4740)
Power consumption: Max. 50 VA (single Master Station) Max. 100 VA (hot standby and dual Master Stations)
Power supply type must be specified at time of order.
Power connection
Standard: AC, IEC-C13 Connector (Schurter v-lock compatible)
Located at the front of the Master Station, behind the display, one on either side for hot standby and dual
Master Stations.
Housing
Standard: 19” rack mount and panel mount fixings
Box dimensions (without fixings): width 440 mm, height 177 mm (4U), depth 237 mm
Single Master Station with 7” touch screen interface
Option: Dual Master Station, second independent Master Station in same housing (2 displays).
Hot standby, second redundant standby Master Station in same housing, linked to primary Master Station (2 displays).
Communication
between
Master Station
and FCUs
Standard: There is no standard communication module. The field network must be specified at time of order.
Option: The Master Station has 4 AIM (Add In Module) slots that can be fitted with host or field network modules. Only
one host AIM can be fitted; only one Modbus RTU AIM can be fitted; up to two Pakscan Classic AIMs can be fitted.
There are two field network AIM types.
Pakscan Classic (P4720).
Modbus RTU (P4724).
Both field network protocols are described briefly below:
Pakscan Classic (P4720):
• Redundant loop topology.
• Does NOT require external repeaters or external termination.
• Network total length up to 20 km.
• No limitation for distance between FCUs within the 20 km limit.
• A single network can control 240 FCUs.
• Data transfer via robust current loop network.
• Network baud rate ranges between 110 to 2400.
• Network scan rate (60 FCUs on 4 km loop) less than 1 second.
• Twisted pair instrumentation cable (1 pair).
• Communications parameters set up using handheld tool via network or using actuator menu.
• Ideal for isolating duty applications.
Modbus RTU (P4724):
• Standard open Modbus protocol.
• Compatible with any manufacturer's Modbus device.
• Single highway, dual highway or redundant loop topology.
• Single and dual highway option standard Modbus topology.
• Redundant loop 1.2 km maximum distances between FCUs.
• Network Baud rate up to 115k200.
• A single network can control up to 240 FCUs.
• Ideal for isolating duty applications.
FCU connectivity
The maximum number of FCUs that can connect to a Master Station is 240. When ordering a Master Station, select the
appropriate maximum FCU count for the application. It is possible to order Master Stations for 60, 120, 180 or 240 FCUs.
The following devices can be connected to the Rotork Master Station:
Any Rotork electric actuator with a:
• Pakscan Classic (current loop) network interface card (A, AQ, Q, IQ, IQT, SI, EH, CVA, CMA, ROMpak, CK).
• Modbus network interface card (Q, IQ, IQT, SI, EH, CMA, ROMpak, CK).
Any Rotork switch box or pneumatic / hydraulic actuator fitted with a:
• Pakscan Classic General Purpose Field Control Unit (GPFCU).
Any Rotork Modbus enabled device such as:
• Bifold Orange controller
Any third party manufacturers Modbus device:
• Contact Rotork for details of how to integrate
Communication
between the
Master Station
and the Host
Standard: 2 off RJ45 Ethernet (10/100/1000 Mbps) connections supporting Modbus TCP, located on each CPU module
(module P4710).
Other services on the Ethernet connection are:
Web server (built in web pages).
Option: Host Serial AIM (module P4727).
Serial communications via, 2 off 9-way D-type connections supporting Modbus RTU.
Individually configurable RS-232 to RS-485 via DIP switches.
Termination for RS-485 enabled via HMI or web pages (resistor network 120 Ω passive with 1 kΩ biasing).
Termination stays in place on power down.
Baud rate 2,400 to 115,200.
A hot standby system contains duplicate modules so the number of host connections is doubled. With the standard
CPU and optional Host Serial AIM installed, a total of four host connections of each type is available.
Service port Standard: 1 off RJ45 Ethernet port (10/100/1000 Mbps) for temporary connection to a computer. Intended for service or
configuration use only. Supports the same Ethernet services as the host connection.
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3. Rotork Master Station Technical Datasheet continued
Rotork Master Station Features continued
Redundancy
Standard: A single Master Station consists of a Master Station rack into which the following units can be connected:
Display module; PSU module (P4740); CPU module (P4710)
Up to four total AIMs:
Field Network: Pakscan Classic (P4720)
Field Network: Modbus RTU (P4724)
Host Serial AIM (P4727)
In a single unit all of these modules will be arranged on the left side of the Master Station rack.
Leaving the right side free.
The single Master Station has redundant host connections to the CPU module and the field networks
can be redundant loops.
Option: For full redundancy, the hot standby Master Station contains a primary (side A, left) set of modules as described
above and identical redundant standby (side B, right) set of modules. The primary side ensures the standby side is
continually updated with the status of all the connected FCUs such that it can take over control of the field
network in the event of a failure of the primary module or if the request to change masters is received. The
standby will also take over the communications to the host network.
Change over time is less that 500 ms for the field network communications.
User interface
Standard: No specialist software required to configure system.
Can be configured fully via Local touch screen Interface or built in web pages.
Each Master Station contains at least 1 local touch screen interface – 2 in the case of a hot standby or dual unit.
• Size: 7.0” • Resolution: 1024 x RGB x 600
The local and web based interfaces have an identical structure, creating a consistent user interface across
both platforms. The user interface is focused towards quick device setup, interrogation and issue resolution.
Both interfaces enable:
Viewing of status, alarms and settings for the Master Station, field network, host network and FCUs.
Configuration of settings for the Master Station, field network, host network and FCUs.
Viewing of host communication logs.
Viewing of Master Station datalogger and FCU event logs.
In addition, the web interface enables:
Saving of Host analyser and Master Station datalogger files.
Upgrading the Master Station software.
Saving of Master Station alarm logs.
Example Data
From actuators
to the
Master Station
This is not a complete list of data available. For a full list of data refer to PUB059-052 Master Station Full Configuration Manual.
Input Data: Digital position indication (OPEN / CLOSE / MID)
Analogue position indication
Position of control selector switch (LOCAL / STOP / REMOTE)
Direction of operation indication
Indication of undesired torque trip (mid travel, directional)
Analogue Torque value indication
Motor stall indication
General Fault indication
Output Data: Operation commands to actuators (OPEN / CLOSE / STOP / ESD / SETPOINT)
Relay operation commands to General Purpose Field Control Units (GPFCU) and Actuators
From Master
Station to the
Host (available
over Modbus
interface)
This is not a complete list of data available. For a full list of data refer to PUB059-052 Master Station Full Configuration Manual.
Input Data: Data from FCUs; Master Station status information
Communication status of the FCUs; Alarm status of the FCUs
Output Data: Operation commands to actuators; ESD command to Master Station
Operating Conditions
Enclosure Standard: IP20
Environment
Standard: Operating temperature: 0 to +50 °C (+32 to +122 ºF)
Storage temperature: -10 to +70 °C (+14 to +158 ºF)
Humidity: 5% to 95% RH, non-condensing
Vibration: 5-150 Hz, acceleration 0.7 gn peak
Shock: 2 gn peak
Located: indoors
Weight Hot standby and dual configuration: approx. 7 kg; Single configuration: approx. 6 kg
Approvals
Standards
Electromagnetic Compatibility (EMC) BS EN61326-1-2013
(Intended for use in an industrial electromagnetic environment)
Low Voltage Directive (LVD) BS EN 61010-1:2010
(Safety requirements for electrical equipment for measurement, control, and laboratory use)
Useful Documentation
Manual PUB059-050 Safe Use, Installation and Maintenance Manual
PUB059-052 Full Configuration manual
Product
information
PUB059-047 Sales Flyer
PUB059-048 Sales Brochure
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Master Station Safe Use, Installation and Maintenance Manual
4. Health and Safety
This manual is produced to enable a competent user to install the Rotork Master Station. Only persons competent by virtue of their
training or experience should install, maintain and repair the Rotork Master Station.
Under no circumstances should replacement parts be used in the Master Station, other than those supplied or specified by Rotork.
Work undertaken must be carried out in accordance with the instructions in this and any other relevant manuals.
If the Master Station is used in a manner not specified in this manual and any other Rotork manual, the protection provided by the
Master Station may be impaired.
The user and those persons working on this equipment should be familiar with their responsibilities under any statutory provisions
relating to the Health and Safety of their workplace. Due consideration of additional hazards should be taken when using the Master
Station with other equipment. Should further information and guidance relating to the safe use of the Rotork Master Station be
required, it will be provided on request.
The electrical installation, maintenance and use of the Master Station should be carried out in accordance with National Legislation and
Statutory Provisions relating to the safe use of this equipment, applicable to the site of installation.
For the UK: Electricity at Work `Regulations 1989 and the guidance given in the applicable edition of the IET Wiring Regulations BS
7671 should be applied. The user must be fully aware of their duties under the Health and Safety Act 1974.
For the USA: NFPA70, National Electrical Code®is applicable.
For Canada: CEC, Canadian Electrical Code, is applicable.
Or any applicable local regulations or legislative requirements
The mechanical installation must be carried out as outlined in this manual and also in accordance with relevant standards such as British
Standard Codes of Practice.
The Master Station must only be installed in areas appropriate to its certification and must not be installed in hazardous area locations.
Under no circumstances should any modification or alteration be carried out on the Master Station as this could invalidate the Master
Station warranty and certification.
Care must be taken to ensure the voltages and currents do not exceed those specified for the Master Station and the correct polarity
is applied.
Galvanically isolated input or output signal circuits are provided by certain products. A competent person must decide upon the safety
status of such circuits when connected to other devices, and treat them accordingly.
CAUTION: Service Altitude
The Master Station installation altitude must be restricted to less than 2000 m as defined by IEC61010-1 (Safety
requirements for electrical equipment for measurement, control and laboratory use).
WARNING: Emergency Shutdown
Emergency Shutdown (ESD) functionality is configurable within the Master Station. An ESD command issued from the
Master Station may cause connected devices to move without prior warning. As default the ESD function is switched
off.
WARNING: Operation of devices connected to the Master Station
The Master Station is an actuator controller, therefore the user should ensure that any necessary additional safety
measures are considered for each actuator connected to the Master Station.
CAUTION: Enclosure Materials
The Master Station is manufactured from aluminum, metal filled plastic, printed circuit boards, glass display,
stainless steel screws.
The user must ensure the operating environment and any materials surrounding the Master Station cannot lead to a
reduction in the safe use of, or the protection afford by, the Master Station. Where appropriate, the user must ensure
the Master Station is suitably protected against the operating environment.
WARNING: Actuators connected to the Master Station may start and operate when remote is selected. This will be dependent on
remote control signal status and actuator configuration.
CAUTION: Do not use solvents for cleaning.
Clean the front panel with a damp lint-free cloth and mild detergent.
WARNING: Electro-static discharge
It is important to wear appropriate anti-static protection equipment when removing, handling or installing Master
Station modules (AIMs) to prevent damage from electro-static discharge.
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5. Installation
Mechanical Fixing
Appropriate clearance space should be maintained around the Master Station, allowing for a suitable bending radius on connecting cables
and allowing for the doors to be fully raised to ensure easy access or removal of AIMs.
The equipment can be used as:
• Panel mounted: positioned on a vertical surface using the panel-mount option kit. The brackets are provided with 7 mm x 11 mm
slots for appropriately sized (6 mm) fixing bolts.
• Rack-mounted: in a standard 19" rack using the rack-mount option kit. The brackets are provided with 7 mm x 11 mm slots
for appropriately sized (6 mm) fixing bolts. The two bracket positions permit flush or protruded (by 40 mm) mounting of the
Master Station.
• Free standing: on a horizontal surface.
In all cases the Master Station should be located in a way that permits easy access to the touch screen interface and disconnection of the
power supply.
CAUTION: Do not obstruct the air cooling outlet and inlet vents on the top and underside. Free flow of air around the
Master Station must be maintained, especially at high ambient temperatures.
All dimensions in mm
Hot Standby Master Station, wall mounted
Side view with bracket in
wall mounting position
Single Master Station rack mounted
Side view with bracket in
19" rack mounting position
Bottom view
Hot Standby Master Station, wall mounted
Doors open
Hot Standby Master Station, rack mounted
Side view with bracket in
19" rack mounting position
Doors open
482
465
133 22
177
440 232
6
232
137
177
177 58
177
482
465
440
440
236
177
236 30Allow
minimum space for cabling
Mounting position for
protruding Master Station
7
11
11
145
37
30Allow
minimum space for cabling
88
7
45
Mounting position for
protruding Master Station
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Master Station Safe Use, Installation and Maintenance Manual
5. Installation continued
Nameplate
Every Master Station includes a nameplate detailing serial number and model number. The serial number uniquely identifies the Master
Station and can be used by the Rotork factory to trace the manufacturing details of the unit. This is a useful reference for upgrades
and spares enquiries. The model number defines the build configuration of the Master Station, whether it is hot standby, dual or single
configuration, the power supply rating, how many FCUs can be connected and which Add In Modules (AIMs) are fitted.
All dimensions in mm
Hot Standby Master Station, wall mounted
Side view with bracket in
wall mounting position
Single Master Station rack mounted
Side view with bracket in
19" rack mounting position
Bottom view
Hot Standby Master Station, wall mounted
Doors open
Hot Standby Master Station, rack mounted
Side view with bracket in
19" rack mounting position
Doors open
482
465
133 22 177
440 232
6
232
137
177
177 58
177
482
465
440
440
236
177
236 30Allow
minimum space for cabling
Mounting position for
protruding Master Station
7
11
11
145
37
30Allow
minimum space for cabling
88
7
45
Mounting position for
protruding Master Station
Location of
Nameplate
311B2BB1B2BB1
Z3660866770 Brassmill Lane, Bath, England
www.rotork.com
The red text below indicates the decoding of the model number 311B2BB1B2BB1: a Master Station with hot standby, AC PSU, Pakscan
Classic field network, 120 channels (FCUs).
Enclosure Left Hand Side Right Hand Side
Rack PSU LH Option 1 LH Option
2 LH CPU LH Option 3 LH
Option
4 LH
Option
1 RH
Option
2 RH
CPU
RH
Option
3 RH
Option
4 RH
PSU
RH
1 Single 1 AC 1 Classic Field 1 1 60 Channels 1 1 11 1 1 1 1
2 Dual 2 Future 2 2120 Channels 2 2 2 2 22 2 B
3Hot Standby 3 Future 3 3 180 Channels 3 3 3 3 3 3 3
4 Modbus Field 4 4 240 Channels 4 4 4 4 4 4 4
5 Future 5 5 Future 5 5 5 5 5 5 5
6 Future 6 6 6 6 6 B 6 6
7 Host Serial 7 7 7 7 7 7 7
B Blank B B B BB B B
Power Connector and Ratings Label
The power connector supplied with the Master Station is an IEC 60320 C13 type with a locking mechanism. The red latch must be
pulled when connecting or disconnecting the power connector from the Master Station. Power rating information is shown on every
PSU module next to the power connection. The example below shows information for an AC PSU module.
Lower view of AC PSU module (P4740)
50/60Hz 50 VA
P4740
100 –240 V 2A T 250V
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6. Basic Commissioning
This section is intended to get the user started with a Master Station, for more detailed information about the Master Station and how to
fully commission field networks please refer to the Master Station Full Configuration Manual (PUB059-052). Red text refers to a setting or
menu within the Master Station interface.
Settings can only be changed on the primary side of a Hot Standby Master Station.
Administrator level access is required for commissioning.
Login Process
The user name and password for the Master Station can be found on the test certificate, delivered with the Master Station. Contact
your local Rotork representative to arrange a replacement if the test certificate is not present. Master Station is provided with only an
Administrator account from the factory.
The Administrator user name and password should be changed as soon as possible to improve security.
The Master Station on screen keyboard does not include a full set of characters. It is advisable to change the password on
screen instead of through a web browser to ensure the password is compatible. Refer to PUB059-052 for details of the on
screen keyboard.
Viewer permits read only access.
User permits limited editing access.
Administrator permits full editing access and creation of additional viewer, user and administrator accounts.
Fig. 6.1 Select menu Fig. 6.2 Select Login Fig. 6.3 Enter Administrator login credentials
Connecting to Ethernet Service Port
The Master Station can be directly connected to a Laptop/PC via the Ethernet Service port. In order to establish a connection to the Master
Station it is likely the laptop/PC internet connection settings will have to be adjusted to a fixed IP address arrangement. To set a static IP
address for your device, follow appropriate online instructions for the operating system of the Laptop/PC. To connect to a Master Station
with default settings, configure the static IP address to the values below.
Laptop/PC IP address = 10.201.1.3
Laptop/PC subnet mask = 255.255.255.0
It may be necessary to restart the Laptop/PC to apply the new internet settings.
The default IP address of the Master Station service port is 10.201.1.1. Enter this IP address into the web browser of the connected Laptop/
PC to open the home page of the Master Station.
If the IP address of the Master Station has been changed, this can be viewed via the touch screen interface in the Master Station settings.
The Laptop/PC must be configured within the same IP range and subnet mask to communicate.
The Master Station service port must be on a different Class C network to the Ethernet 1 and Ethernet 2 ports.
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Master Station Safe Use, Installation and Maintenance Manual
6. Basic Commissioning continued
Host Communication Settings
The Master Station includes Ethernet host communication as standard or Serial host communication with the optional Host Serial AIM.
Some communication settings are common to Ethernet and Serial.
Common settings:
These settings apply to Ethernet and Serial host communication.
Fig. 6.4 Select menu Fig. 6.5 Select Master Station Fig. 6.6 Select Master Station General Settings
Master Station General Settings tab: Hot Standby Module should be set to Disabled for a single or dual Master Station and Enabled for
a hot standby Master Station. Check this setting on both sides of a dual or hot standby Master Station.
CAUTION: The Hot Standby Module setting must be correctly configured to avoid potential damage to the Master
Station or connected FCUs on a Pakscan Classic field network loop. The hot standby Y loom must never be
used when Hot Standby Module is set to Disabled.
Fig. 6.7 Modbus Host Common Settings
Modbus Host Common Settings tab: Modbus Base Address Side A and Modbus Base Address Side B define the communication address
to side A and side B. These must be different for a dual Master Station. A hot standby Master Station is normally configured for the same
Modbus address on both sides but this is not mandatory.
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Fig. 6.8 Modbus Host Settings
Configure the Number of Additional Addresses for the number of FCUs supported by the Master Station or the range of FCU addresses in
use. The table below advises what value to set depending on the Master Station FCU count. FCU count is shown on the Master Station test
certificate.
Master Station total FCU count Setting for Number of Additional Addresses
60 0
120 1
180 2
240 3
Host Ethernet Database Format should be configured to match the database type in use. The database used for serial communication is
configured within the Host Serial interface settings.
Master Station Modbus Register Source should be set to All AIM if there are multiple field network AIMs installed. If a single field network
AIM is installed, select the appropriate AIM number. The test certificate will detail the location of the installed AIMs. AIM 1 refers to AIM
slot 1, AIM 2 refers to AIM slot 2, AIM 3 refers to AIM slot 3 and AIM 4 refers to AIM slot 4. Refer to section 2 for slot locations.
Modbus TCP Side A and Modbus TCP Side B should be enabled if using Modbus TCP.
6. Basic Commissioning continued
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6. Basic Commissioning continued
Ethernet Settings
Fig. 6.9 Common Host Ethernet Port Settings
Hot Standby Master Station only.
Standby Mode must be configured correctly for the Ethernet network topology. Passive standby mode means only the primary side will
communicate over Ethernet. Active standby mode means both primary and standby sides will communicate. Special consideration should
be given to the IP address of the primary and standby sides as duplicate active IP addresses are not permitted on the same physical
network.
Fig. 6.10 Host Port Settings for Side A
Side A Ethernet and Side B Ethernet settings allow the user to configure the IP address information for the Master Station. Each page
includes a tab for host port settings and a tab for service port settings.
Only the Host Port IP Address and Host Port Netmask need to be set.
A single Master Station requires only side A to be configured. A dual Master Station requires side A to be configured on side A and side B
to be configured on side B. Hot standby Master Station requires side A and side B to be configured.
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