Westlock FPAC2 User manual

Page 1 of 14
FPAC2 UPGRADE
InstallatIon and operatIon manual
Copyright © Westlock. All rights reserved.
www.westlockcontrols.com VCIOM-05124-EN 17/06
TABLE OF CONTENTS
1. Introduction.................................................... 3
2 Replacing the electronic module ................. 6
3 Installing the new DD/CF revision 0501....... 7
4 Decommissioning the old device and
commissioning the new one......................... 9
5 Configuring the new standard
transducer block ......................................... 12
6 Reassigning the function blocks in the
existent control module(s) to the new
device ........................................................... 14
7 Downloading and testing the new
configuration................................................ 16
8 Appendix A - Some differences between
FPAC1 rev 2, 3, 4 and FPAC2 rev 5 ............. 18
8.1 Transducer basic parameters
mapping ................................................ 18
8.2 Discrete Input (DI) Channels ............... 19
8.3 Discrete Output (DO) Channels ........... 20
1 INTRODUCTION
This document is a quick guide on how to
replace an previous Intellis FPAC electronic
module device revisions 2, 3 or 4 with the new
FPAC2 electronic module device revision 5. This
document does not replace the installation and
operation manuals VCIOM-05123 and TECH-
502 that should be consulted for complete
information about the product. The replacement
process usually involves these steps:
1. Replace the electronic module or the
complete Intellis FF unit.
2. Install the new DD/CF (0501) in the FF Host
System database.
3. Decommission the old device and
commission the new one.
4. Reconfigure the new standard transducer
block to match the Intellis application.
5. Reassign the existent function blocks
configuration in the FF Host System’s
control module(s) to the new device.
6. Download the control module configuration
and test the new device.
This document shows an example where
the FPAC is controlling 1 (one) rotary valve
using the internal Hall Effect sensors as limit
switches. The application controls the valve
position through 1 (one) DO block and gets the
position feedback from 1 (one) DI block. Other
configurations can be adapted based on this
example. See IOMs VCIOM-05123 and TECH-
485 for more information on the Intellis and the
FPAC module.
The example below assumes you are using
DeltaV[1] revision 11.3 or greater (this is one
of the FF host system mentioned above). The
steps and windows may differ depending on
the FF Host System and versions. Also, even if
you are using the system mentioned above, it
may be possible to replace a device following
different methods and procedures. Then, keep
in mind that the example described in this
document serves as a general guideline.
Before starting to follow the steps mentioned
in the rest of the documents it is a good idea to
have available:
• The IOMs (old FPAC and the new FPAC - see
Figure 1 & 2 on next page)
• Screw drivers. The size and type of the screws
may vary depending on the Intellis model.
• Small wire cutters and wire tip finishing tools
according to your application’s installation
rules and procedures.
• Proper access rights to the FF host system
you are using. Some steps are not allowed to
be performed by all the system users.
• PPI and safety permits. All that may be
applicable not only to handle the Intellis
device but the ones applicable to the process,
area and or the plant where the Intellis device
is installed
• Make sure that any action or procedure
suggested below will not void the applicable
guarantee agreements.
IMPORTANT
Before replacing the module make
sure to follow all the necessary safety
procedures. Notice the valve and
actuator can move while replacing the
module and changing the configuration,
therefore make sure all safety measures
have been taken.

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FPAC2 UPGRADE
InstallatIon and operatIon manual
Fieldbus
input (polarity
insensitive)
Fieldbus input J2 J5 analog
pos pot
Earth
ground
Embedded
hall effect
sensors
Top / opened
limit SW
Bottom / closed
limit SW
Top
view
Side
view
FIGURE 1
FPAC revisions 2, 3 and 4
FIGURE 2
FPAC revision 5

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FPAC2 UPGRADE
InstallatIon and operatIon manual
2 REPLACING THE ELECTRONIC MODULE
Step 1: Turn off the bus power and remove
the fieldbus connector and I/O connectors.
Remove the old electronic module from the
housing. Put aside screws, washers and other
accessories. See Figure 3.
Step 2: Replace the 2-pin fieldbus connector
with the new 3-pin connector. Make sure to
connect the grounding (J2 BUS pin #2) to
the grounding point inside the housing. The
grounding pin (J2 BUS pin #2) should not be
connected to the cable shield. The cable’s
shield should be cut short and taped to avoid
strains, contact with any metallic surface or
other wires. See Figure 4.
Step 3: Install the new electronic module in
the housing. Make sure to put back washers,
tighten all screws and reconnect I/O and
fieldbus connectors. See Figure 5.
Step 4: Energize the fieldbus (9-32 VDC) and
verify that all LEDs blink once. If there is
communication on the fieldbus the BUS LED
will start blinking at a rate around 1 Hz. If the
magnets as properly aligned OPEN or CLSD
LED should light on indicating the current
valve position.
FIGURE 3
Remove the old FPAC from the housing
FIGURE 4
Replace the old 2-pin fieldbus connector with new 3-pin connector
FIGURE 5
New electronic module installed with I/O connectors on

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FPAC2 UPGRADE
InstallatIon and operatIon manual
3 INSTALLING THE NEW DD/CF
REVISION 0501
Step 5: Check if the FF Host System has the
support files for the FPAC device revision 5
(DD 0501 or higher). Open DeltaV Explorer,
click on Library\Device Definitions\Fieldbus
Devices\Westlock\FPAC VALVE CONTROLLER,
and check if the latest DD (REV 5) is installed.
See Figure 6.
Step 6: If it is not listed, contact Westlock
to receive the latest DD/CF files (0501)
or download it directly from the Fieldbus
Foundation registered products website, link
below[2]. See Figure 7.
NOTE
2. This URL is maintained by FieldComm
Group - Fieldbus Foundation division. In
case the link is not valid anymore contact
Westlock or browse the FieldComm
Group - Fieldbus Foundation web site
to find the FPAC registration web page
shown before.
FIGURE 6
FIGURE 7
http://www.fieldbus.org/index.php?option=com_
mtree&task=viewlink&link_id=1836&ffbstatus=
Registered&Itemid=324
Step 7: Install the new DD/CF 0501 into the
Fieldbus Host System following the system
instructions.

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FPAC2 UPGRADE
InstallatIon and operatIon manual
4 DECOMMISSIONING THE OLD DEVICE AND
COMMISSIONING THE NEW ONE
Step 8: Once the new device appears in the
Decommissioned Fieldbus Devices list check if
it is available for commissioning. If not, right-
click on it and select Place in Standby. Wait until
this process is finished and the window closes.
See Figure 8.
Step 9: Right-click on the old device’ and
select Decommission. In the window that
opens, choose the option Make Spare. On the
next window, click on Do Not Wait to close it.
See Figure 9.
FIGURE 8
FIGURE 9

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FPAC2 UPGRADE
InstallatIon and operatIon manual
Step 10: When decommissioning the old
device is finished, right-click on it and select
Properties, change device revision to “5” and
click on OK. See Figure 10.
Step 11: If a warning message appears
indicating some incompatibilities, click OK.
Right-click on the old device again and select
Commission. If a warning message appears,
click OK. A window to select the new device
will open. See Figure 11.
FIGURE 10
FIGURE 11

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FPAC2 UPGRADE
InstallatIon and operatIon manual
Step 12: Selected the new device from the list
and click OK. If a warning message appears,
click OK. In the window that will appear DO
NOT click Reconcile Device, just click Next.
See Figure 12.
Step 13: Click Next and finally click on Finish,
then wait until the device is commissioned.
See Figure 13.
FIGURE 12
FIGURE 13

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FPAC2 UPGRADE
InstallatIon and operatIon manual
5 CONFIGURING THE NEW STANDARD
TRANSDUCER BLOCK
Step 14: Once the new device is commissioned
it is necessary to reconfigure the new standard
transducer block(s) to match the old transducer
block configuration. There are just a few
parameters that have to be reconfigured for
the basic functionality of control and monitor
the valve position. Right-click on the device and
select Configure/Setup. The AMS window will
open. See Figure 14.
FIGURE 14
FIGURE 15 FIGURE 16
Step 15: In the menu tree, select Transducer
Basic Setup. Reconfigure the new standard
transducer block(s) Std Transducer 1 for the
equivalent application, according to Appendix
A, table 1. In this example, it is necessary to
reconfigure ACTION_ELEMENT parameter to
Single Action. It is not necessary to reconfigure
Transducer 2, leave it as it is. See Figure 15.
Step 16: On the menu tree, select Function
Block Utils, then Block Mode - Trd and
Resource. Make sure Resource target and
actual block modes are in Automatic (AUTO).
See Figure 16.

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FPAC2 UPGRADE
InstallatIon and operatIon manual
Step 17: Make sure transducer block(s) mode
is(are) also in Automatic (AUTO). See Figure 17.
Step 18: As soon as you finished reconfiguring
the transducer block(s) close the AMS window.
For more information and the complete
standard transducer block functionality refer
to VCIOM-05123.
NOTE
Although possible, it is not recommended to
use AMS for function block (DI, DO) channel
configuration once this configuration is not
saved in the persistent database. Use DeltaV
explorer or Control Studio for function
blocks configuration as illustrated in the
next section.
FIGURE 17
FIGURE 18
6 REASSIGNING THE FUNCTION BLOCKS IN
THE EXISTENT CONTROL MODULE(S) TO THE
NEW DEVICE
Step 19: Since the device VFD is not compatible
between device revision 5 and previous
revisions it is necessary to manually reassign
the function blocks in the control module(s).
See below a comparison between the old FPAC
and the new FPAC. Notice the new FPAC has
more transducer blocks. This characteristic
shifts the function block indexes, causing an
actual configuration mismatch. This difference
prevents the control module from working
without reassigning the function blocks.
See Figure 18.

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FPAC2 UPGRADE
InstallatIon and operatIon manual
Step 20: Open the control module(s) using
Control Studio to reassign the function blocks
in the application to the new device. In this
example there is 1 (one) DI block instantiated
in the FF Host. In the FPAC there are 1 (one)
DO and 1 (one) DI blocks. See Figure 19.
Step 21: Right-click on the block(s), and select
Assign I/O, then Unassign From Fieldbus
to remove the assignment from the old
FPAC. Repeat this for the DO and DI blocks.
Sometimes this step is automatically done
by the system, depending on the system’s
configuration. See Figure 20.
FIGURE 19
FIGURE 20 FIGURE 21
Step 22: After unassigning all function blocks,
save the configuration and reassign the function
blocks to the new FPAC. See Figure 21.
Step 23: Save the configuration again.
Usually it is not necessary to change any
parameterization in the function blocks.
However, depending on the application,
there are a few differences between the new
FPAC and the old one, especially concerning
CHANNELS. Refer to Appendix A tables 2 and
3 to confirm if you need to change any function
block channel.
Step 24: After the control module is
reconfigured, save the configuration.

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FPAC2 UPGRADE
InstallatIon and operatIon manual
7 DOWNLOADING AND TESTING THE NEW
CONFIGURATION
Step 25: On the Control Studio menu, click
Download. A message will appear, DO NOT
click Upload Them Now, just click on Download
Now. See Figure 22.
Step 26: If a message appears, click Yes/
OK and wait until the download is finished
successfully. See Figure 23.
FIGURE 22
FIGURE 24
FIGURE 23
Step 27: Close the download window and
open the Control Studio in online mode (or
the operator window). Command the valve to
move to the opened and closed positions and
check whether the new device is reporting
the valve position correctly. If necessary make
adjustments to the cams or limit switches.
See below screenshot after the replacement
showing the valve closed and opened.
See Figure 24.

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FPAC2 UPGRADE
InstallatIon and operatIon manual
8 APPENDIX A  SOME DIFFERENCES BETWEEN FPAC1 REV 2, 3, 4 AND FPAC2 REV 5
For the complete set of features for each device revision refer to IOMs VCIOM-05123 and
TECH-485.
8.1 Transducer basic parameters mapping
Look up at the old FPAC transducer block configuration and take note of the value in the ACTION_
ELEMENT parameter. This parameter has to be mapped into 3 (three) other parameters in the
new FPAC2 standard transducer block, as indicated in the table below:
TABLE 1  TRANSDUCER PARAMETERS BASIC CONFIGURATION MAPPING
FPAC1 rev 2,3,4 Transducer FPAC1 rev 2,3,4 Transducer FPAC2 rev 5 Standard Transducer blocks
Transducer Transducer 1 (Valve 1) Transducer 2 (Valve 2)
0 ACTION_ELEMENT = No Selection ACTION_ELEMENT = 0: No Selection
IO_ASSIGNMENT = 0: No Selection
ACTION_ELEMENT = 0: No Selection
IO_ASSIGNMENT = 0: No Selection
1 ACTION_ELEMENT = Single Action ACTION_ELEMENT = 1: Single Action
IO_ASSIGNMENT = 1: Top,Bot,Out0
SIGNAL_ACTION = 0: Increase to Open
ACTION_ELEMENT = 0: No Selection
IO_ASSIGNMENT = 0: No Selection
3 ACTION_ELEMENT = Double Action ACTION_ELEMENT = 1: Double Action
IO_ASSIGNMENT = 1: Top,Bot,Out0
SIGNAL_ACTION = 0: Increase to Open
ACTION_ELEMENT = 0: No Selection
IO_ASSIGNMENT = 0: No Selection
4 ACTION_ELEMENT = Single Action,
Reverse Acting
ACTION_ELEMENT = 1: Single Action
IO_ASSIGNMENT = 1: Top,Bot,Out0
SIGNAL_ACTION = 1: Increase to Close
ACTION_ELEMENT = 0: No Selection
IO_ASSIGNMENT = 0: No Selection
6 ACTION_ELEMENT = Double Action,
Reverse Acting
ACTION_ELEMENT = 1: Double Action
IO_ASSIGNMENT = 1: Top,Bot,Out0
SIGNAL_ACTION = 1: Increase to Close
ACTION_ELEMENT = 0: No Selection
IO_ASSIGNMENT = 0: No Selection
8 ACTION_ELEMENT = Independent,
both Normal Acting
ACTION_ELEMENT = 1: Single Action
IO_ASSIGNMENT = 1: Top,Bot,Out0
SIGNAL_ACTION = 0: Increase to Open
ACTION_ELEMENT = 1: Single Action
IO_ASSIGNMENT = 6: Aux1,Aux2,Out1
SIGNAL_ACTION = 0: Increase to Open
9 ACTION_ELEMENT = Independent,
1Reverse Acting 2Normal Acting
ACTION_ELEMENT = 1: Single Action
IO_ASSIGNMENT = 1: Top,Bot,Out0
SIGNAL_ACTION = 1: Increase to Close
ACTION_ELEMENT = 1: Single Action
IO_ASSIGNMENT = 6: Aux1,Aux2,Out1
SIGNAL_ACTION = 0: Increase to Open
10 ACTION_ELEMENT = Independent,
1Normal Acting 2Reverse Acting
ACTION_ELEMENT = 1 = Single Action
IO_ASSIGNMENT = Top,Bot,Out0
SIGNAL_ACTION = 0: Increase to Open
ACTION_ELEMENT = 1: Single Action
IO_ASSIGNMENT = 6: Aux1,Aux2,Out1
SIGNAL_ACTION = 1: Increase to Close
11 ACTION_ELEMENT = both Reverse ACTION_ELEMENT = 1 = Single Action
IO_ASSIGNMENT = Top,Bot,Out0
SIGNAL_ACTION = 1: Increase to Close
ACTION_ELEMENT = 1: Single Action
IO_ASSIGNMENT = 6: Aux1,Aux2,Out1
SIGNAL_ACTION = 1: Increase to Close
TABLE 2  DIFFERENCES BETWEEN DI BLOCK CHANNELS
DI.CHANNEL block - Discrete Input Channels
FPAC1 rev 2,3,4 FPAC2 rev 5 Notes
0 No Transducer Connection 0 No Transducer Connection No change
9 Open/Close 9 TRD1: 0-Closed / 1-Opened Same channel number and same functionality for valve 1
10 Open 10 TRD1: 0-Not Opened / 1-Opened Same channel number and same functionality for valve 1
11 Close 11 TRD1: 0-Not Closed / 1-Closed Same channel number and same functionality for valve 1
12 Open/Close/Stop 12 TRD1: 0-Closed / 1-Opened / 2-Stopped Same channel number and same functionality for valve 1
13 Maskable Signal 13 TRD1: Maskable Signal Same channel number and same functionality for transducer 1
14 Auxiliary Input 14 Auxiliary Input 1 Same channel number and same functionality for AUX1 input
15 Auxiliary Input 2 15 Auxiliary Input 2 Same channel number and same functionality for AUX2 input
16 Open/Close for second valve (when available) 29 TRD2: 0-Closed / 1-Opened Channel number has changed. Same functionality for valve 2
17 Open for second valve (when available) 210 TRD2: 0-Not Opened / 1-Opened Channel number has changed. Same functionality for valve 2
18 Close for second valve 211 TRD2: 0-Not Closed / 1-Closed Channel number has changed. Same functionality for valve 2
- - 212 TRD2: 0-Closed / 1-Opened / 2-Stopped New channel functionality for valve 2
- - 213 TRD2: Maskable Signal New channel functionality for transducer 2
8.2 Discrete Input (DI) Channels
For a complete description of the channels refer to IOMs VCIOM-05123 and TECH-485.

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FPAC2 UPGRADE
InstallatIon and operatIon manual
TABLE 3  DIFFERENCES BETWEEN DO BLOCK CHANNELS
DO.CHANNEL - Discrete Output Channels correspondence
FPAC1 rev 2,3,4 FPAC2 rev 5 Notes
0 No Transducer Connection 0 No Transducer Connection No change
1 Open/Close 1 TRD1: 0-Close / 1-Open Same channel number and same functionality for valve 1
2 Open 2 TRD1: 0-Not Open / 1-Open Same channel number and same functionality for valve 1
3 Close 3 TRD1: 0-Not Close / 1-Close Same channel number and same functionality for valve 1
4 Stop 4 TRD1: 0-Not Stop / 1-Stop Same channel number and same functionality for valve 1
5 Open/Close/Stop 5 TRD1: 0-Close / 1-Open / 2-Stop Same channel number and same functionality for valve 1
6 Open/Close for second valve (when available) 21 TRD2: 0-Close / 1-Open Channel number has changed. Same functionality for valve 2
7 Open for second valve (when available) 22 TRD2: 0-Not Open / 1-Open Channel number has changed. Same functionality for valve 2
8 Close for second valve 23 TRD2: 0-Not Close / 1-Close Channel number has changed. Same functionality for valve 2
- - 24 TRD2: 0-Not Stop / 1-Stop New channel functionality for valve 2
- - 25 TRD2: 0-Close / 1-Open / 2-Stop New channel functionality for valve 2
- - 91 FSTATE - TRD 1 (Valve 1) New channel to force fault state on transducer 1
- - 92 FSTATE - TRD2 (Valve 2) New channel to force fault state on transducer 2
8.3 Discrete Output (DO) Channels
For a complete description of the channels refer to IOMs TECH-485 and VCIOM-05123
FF, Fieldbus Foundation, Foundation Fieldbus, FieldComm Group and the related trademarks and
logos are property of the FieldComm Group ©2017 FieldComm Group
Delta V, Emerson and the related trademarks and logos are property of Emerson Electric Co.
©2017
The Westlock and related trademarks are owned by Crane Co. All other marks are the property of
their respective owners.
The contents of this publication are presented for informational purposes only, and while every
effort has been made to ensure their accuracy, they are not to be construed as warranties or
guarantees, express or implied, regarding the products or services described herein or their use
or applicability. Westlock reserves the right to modify or improve the designs or specifications of
such products at any time without notice.
Westlock does not assume responsibility for the selection, use and maintenance of any product.
Responsibility for the selection, use and maintenance of any product remains with the purchaser
and end-user.

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FPAC2 UPGRADE
InstallatIon and operatIon manual
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Westlock. We reserve the right to change designs and specifications without notice.
Engineering document reference
These installation and operating instructions are based on the latest engineering update, and form
part of the certification for the FPAC2 series. To ensure you have the most recent version of this
document, please check the library on our website (westlockcontrols.com).
Translations
Where translated the copy is taken from the original English document VCIOM-05124-EN as
checked by the relevant notified certification body and therefore the original English document
will prevail. No rights or liability can be derived from any translation.
Previous documents
VCIOM-05124-EN replaces all previous installation and operating instructions for the FPAC2 series
including TECH-508.
WARNING
This symbol warns the user of possible
danger. Failure to observe this warning
may lead to personal injury or death
and/or severe damage to equipment.
ATTENTION
This symbol identifies information about
operating the equipment in a particular
manner that may damage it or result
in a system failure. Failure to observe
this warning can lead to total failure of
the equipment or any other connected
equipment.
NOTE
This symbol draws attention to information
that is essential for understanding the
operation and/or features of the equipment.