Westlock ICoT PA Installation instructions

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 1 of 206
ICoT PA
INTELLIGENT VALVE POSITIONER
INSTALLATION & OPERATING
MANUAL
IOM: Tech-477 Revision:
Prepared By: Leiser
Marcos de Souza
Date:
4/1/2015
Drafting Work Order:
21424
ECN:
Reviewed By: Jason
Moorehead
Date: 6/2/15 Approved By: Adam Buga Date:6/17/15
This IOM contains confidential information and is issued in confidence on the condition that it be returned on demand and not be
copied, reproduced, disclosed to others or used in manufacture of the subject matter thereof without the written consent of Westlock

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 2 of 206
Revision History
Revision
4/1/15
Initial release
Westlock Controls Offices
USA
Westlock Controls Corp.
280 North Midland Ave, Suite 258, Saddle Brook, NJ 07663
Phone: [phone] •Fax: [phone]
Email: [email protected]
Internet http://www.westlockcontrols.com
Europe
Westlock Controls UK
22 Chapman Way, Tunbridge Wells
Kent, England TN23EF
Phone: [phone] •Fax: [phone]
Email: [email protected]
Internet: http://www.westlockuk.com
South America
Westlock Equipamentos de Controle Ltda.
Sales:
Al. Araguaia, 2044 – Sl. 1101, Bloco B
Edifício CEA – Alphaville
Barueri – São Paulo – Brazil
06455-000
Tel: + 55 11 2588-1400
Fax: + 55 11 2588-1410
Email: [email protected]
Internet: http://www.westlock.com.br
Operations:
Av. Antonio Bardella, 3000
Galpões 2A e 2B – Alto da Boa Vista
Sorocaba – São Paulo – Brazil
18085-852
Tel: + 55 15 2102-7400
Fax: + 55 15 2102-7400
Asia
Westlock Controls Singapore
Sales:
King's Centre #04-01
390 Havelock Road
Singapore
169662
Phone: [phone] •Fax: [phone]
Email: [email protected]
Internet: http://www.westlockuk.com

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 3 of 206
TableofContents
1Introduction ............................................................................................................ 8
1.1Product Certification........................................................................................... 8
1.2Warnings............................................................................................................ 8
1.3Description ......................................................................................................... 9
1.4Principles of Operation..................................................................................... 10
1.4.1Enclosures................................................................................................. 10
1.4.2Position Feedback ..................................................................................... 10
1.4.3Local Graphic LCD .................................................................................... 12
1.5Special Features .............................................................................................. 12
2Technical Specifications ...................................................................................... 13
3Order Guide ......................................................................................................... 14
4Definitions ............................................................................................................ 15
5Installation............................................................................................................ 19
5.1Mounting Positioner on a Rotary Actuator........................................................ 19
5.2Mounting Remote Positioner on a Rotary Actuator .......................................... 21
5.3Mounting Positioner on a Linear Actuator ........................................................ 23
5.4Mounting Remote Positioner on a Linear Actuator........................................... 25
5.5Pneumatic Connection ..................................................................................... 27
5.6SPECIAL NOTE Flow Capacity........................................................................ 28
5.7Setting of switches on a rotary ICoT ................................................................ 28
5.8Calibration ........................................................................................................ 29
5.8.1Enter Calibration (Menu Level) .................................................................. 29
5.8.2Automatic Calibration (ACAL).................................................................... 30
5.8.3Manual Calibration (MCAL) ....................................................................... 31
5.8.4Configure the Positioner’s Parameters (Cofg) ........................................... 32
5.8.5Manual Override of Input Signal via On-Board Keypad (Stro) ................... 34
5.8.6Node Address Assigning (Node Add) ........................................................ 34
5.9Description of Menus ....................................................................................... 35
5.9.1Description of Functions ............................................................................ 36
6Field Wiring.......................................................................................................... 40
7Maintenance and Repair...................................................................................... 41
7.1Preliminary Checks .......................................................................................... 41

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 4 of 206
7.1.1Voltage ...................................................................................................... 41
7.1.2Electrical Connection................................................................................. 41
7.1.3Pneumatic Connection............................................................................... 42
7.1.4Magnetic Position Feedback...................................................................... 42
7.1.5Supply Pressure ........................................................................................ 42
7.1.6Positioner Pressure Rating ........................................................................ 42
7.2FAQ’s ............................................................................................................... 43
7.3LCD Alert Codes and Error Messages ............................................................. 44
7.3.1LCD Alert codes ........................................................................................ 44
7.3.2LCD Error Messages ................................................................................. 44
8Fieldbus Network ................................................................................................. 52
8.1PROFIBUS Overview....................................................................................... 52
8.1.1About PROFIBUS PA ................................................................................ 52
8.2PROFIBUS PA – Profile................................................................................... 52
8.3The Function Blocks Application ...................................................................... 52
8.3.1Block Modes .............................................................................................. 53
8.3.2Common Parameters................................................................................. 55
8.3.3Quality and Status ..................................................................................... 55
8.3.4Read Back ................................................................................................. 55
8.3.5Fault State ................................................................................................. 55
8.3.6Slot ............................................................................................................ 56
8.3.7The Physical Block .................................................................................... 56
8.3.8Transducer Block....................................................................................... 57
8.3.9Analog Input Block..................................................................................... 77
8.3.10Analog Output Block............................................................................... 78
8.4Cyclic Data Exchange ...................................................................................... 79
9DTM ..................................................................................................................... 82
9.1Description ....................................................................................................... 82
9.2Initial Setup ...................................................................................................... 82
9.2.1ICoT PA DTM installation .......................................................................... 82
9.2.2Creating a PACTware project .................................................................... 84
9.2.3Writing Data to Device............................................................................... 87
9.2.4Reading Cyclic........................................................................................... 88

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 5 of 206
9.2.5Manipulating graphs .................................................................................. 88
9.3Calibration and Configuration........................................................................... 90
9.3.1Identification .............................................................................................. 90
9.3.2Transducer ................................................................................................ 91
9.4Variables .......................................................................................................... 99
9.4.1Trend Curve display .................................................................................. 99
9.4.2Process Variables.................................................................................... 100
9.5Diagnostics..................................................................................................... 100
9.5.1Simulation Analog Output ........................................................................ 100
9.5.2Simulation Analog Input........................................................................... 101
9.5.3Alert ......................................................................................................... 101
9.5.4Full Stroke Test ....................................................................................... 104
9.6Diagnosis ....................................................................................................... 105
9.6.1Device Diagnosis..................................................................................... 105
9.6.2Alarm AO ................................................................................................. 107
9.6.3Alarm AI................................................................................................... 108
9.7Adjust Value ................................................................................................... 110
9.7.1Servo PID Manual Tuning........................................................................ 110
9.7.2Servo PID Step response ........................................................................ 111
9.7.3Analog Output.......................................................................................... 112
9.7.4Analog Input ............................................................................................ 113
9.8Characterization Curve .................................................................................. 114
9.9PA Profile ....................................................................................................... 115
9.9.1Physical Block ......................................................................................... 115
9.9.2Transducer Block..................................................................................... 120
9.9.3Function Analog Output Block ................................................................. 128
9.9.4Function Analog Input Block .................................................................... 132
10EDD ................................................................................................................... 138
10.1Description.................................................................................................. 138
10.2Initial Setup ................................................................................................. 138
10.3Calibration and Configuration ..................................................................... 139
10.3.1Identification ......................................................................................... 139
10.3.2Basic Setup .......................................................................................... 140

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 6 of 206
10.3.3Advanced Setup ................................................................................... 141
10.3.4Feedback Configuration ....................................................................... 141
10.3.5Units ..................................................................................................... 142
10.3.6Valve and Actuator Info ........................................................................ 143
10.3.7Calibration ............................................................................................ 143
10.3.8Slew Rate Setup................................................................................... 145
10.3.9Clock .................................................................................................... 146
10.3.10LCD Contrast, Serial Number, Revision ............................................... 148
10.3.11Servo PID Tuning ................................................................................. 150
10.3.12Characterization Curve......................................................................... 154
10.4Process Variables & Trend Curves............................................................. 157
10.4.1Process Variables ................................................................................ 158
10.4.2Trend Curve display ............................................................................. 159
10.4.3Readback & Setpoint (AO) ................................................................... 160
10.4.4Output (AO).......................................................................................... 161
10.5Diagnostics ................................................................................................. 162
10.5.1Update diagnostics............................................................................... 162
10.5.2Device Status ....................................................................................... 162
10.5.3Alert...................................................................................................... 164
10.5.4Full Stroke Test .................................................................................... 167
10.6PA Profile – Block View .............................................................................. 168
10.6.1Physical Block ...................................................................................... 169
10.6.2Function Analog Output Block .............................................................. 173
10.6.3Transducer Block ................................................................................. 178
10.6.4Function Analog Input Block................................................................. 186
11References ........................................................................................................ 191
12Appendix A – Procedure to Adjust the Low Pressure Setting ............................ 192
13Appendix B – Procedure to Remove Electronics Cover and Electronic
Canister ............................................................................................................. 193
14Appendix C – Procedure to Check Transducer Operation ................................. 194
15Appendix D – General Maintenance Standard Flow .......................................... 195
16Appendix E - Grounding Schematic ................................................................... 198
Appendix F – Controlled Drawing ...................................................................... 199

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 7 of 206
17Appendix G – Procedure to Reset the Non-Volatile Memory to Factory
Settings.............................................................................................................. 201
18Appendix H - Controlling the ICoT PA Position using the Proficore Ultra
Interface, ProfiCaptain software......................................................................... 202

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 8 of 206
1 Introduction
1.1 Product Certification
IEC Ex FMG 06.0002x
Ex ia IIC T4
(Tamb = -40°C to +80°C)
II 1 G
Ex ia IIC T4
II 1 G
(Ta = -40°C to +80°C)
FM09 ATEX 0028
IS / I,II,III / 1 / ABCDEFG / T4 Ta = 85°C
WD-11704; Entity; Type 4,
10/AEx ia/Ex ia/IIC/T4 Ta= 80°C
WD-11704; Entity; Type 4X
NI/I /2 /ABCD;S/II, III/2/FG/ Ta= 85°C Type 4
This product is designed for use in intrinsically safe systems when
connected through the correct barriers.
1.2 Warnings
Never remove enclosure cover or make/break electrical connections
with power connected to the unit.
Perform all wiring in accordance with site and local codes and the
National Electric Code ANSI-NFPA-70 (US) or the Canadian Electric
Code Part I (Canada) for the appropriate area classifications.
Confirm that the ICoT POSITIONER model being installed is approved
for the hazardous area (consult unit identification label).
Ensure that approved and properly sized IS barriers are used in
installations with IS approved ICoT POSITIONERS (confirm entity
parameters from product ID label).
Confirm that power supplied to unit is within rated specifications listed
on the unit identification label.
Protect the unit from exposure to aggressive substances or
atmospheres to ensure that hazard rating is not compromised.
Disconnect power to and the inlet air supply before conducting any
service or maintenance. Avoid the introduction of any contaminants
into the manifold/valve assembly.

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 9 of 206
1.3 Description
The ICoT 5500 (ICoT PA) provides intelligence for the
control valve through a microprocessor-based system
utilizing the PROFIBUS PA protocol. Accurate
measurement of valve stem position, input signal,
actuator pressure, cycle time and cycle count data can
be recorded during normal operation.
The positioner has a local LCD display, which indicates
valve position, set-point in percentage open, calibration
status, alarms status and whether the ICoT is in local or
fieldbus control. If a failure condition occurs, an error
message is displayed on the local LCD display and
communicated to the Host system via fieldbus.
The ICoT PA is an electro-pneumatic servo system that
continuously controls the position of a valve based on
the fieldbus input signal. The ICoT senses valve position
via a non-contact Hall Effect sensor and controls valve
position through a current to pressure transducer
The ICoT PA is a two wire, polarity insensitive
instrument that receives both signal and power from the bus. Current consumption of the
ICoT is 12.5mA with an operating voltage of 9 – 32 Vdc.
The ICoT PA version allows calibration and access to on-line diagnostic information via
hand-held terminal or through software.
A set of hermetically sealed non-contact limit switches is an option that can be integrally
supplied with the ICoT PA.

WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
10/5/2013 TECH-477/D.W.O. 21424 Page 10 of 206
1.4 Principles of Operation
1.4.1 Enclosures
The ICoT PA Positioner can be built in three different enclosure materials: engineered
resin, 316 stainless steel and aluminum.
1.4.2 Position Feedback
Non-Contact Position Feedback
To provide consistently accurate performance information, all linkages, levers and
connecting rods, from the positioner to the control valve have been eliminated from
the design. Valve position sensing is performed totally by non-contacting means
based upon characterization of magnetic flux strength as a function of position.
Housing
Material:
Housing
Material:
316 Stainless