PRM Integration Guide with Pepperl+Fuchs HiDMUX2700 HART Multiplexer

Transcription

1 PRM Integration Guide with Pepperl+Fuchs HiDMUX2700 HART Multiplexer This manual explains how to connect the HiDMUX2700 HART Multiplexer and configure Yokogawa s Plant Resource Manager (PRM) software. Notes (Yokogawa): This manual simply explains certain functional details of PRM and makes no claims as to its suitability for a particular purpose. No part of this manual may be transferred or reproduced without prior written consent from Yokogawa. Yokogawa assumes no responsibility for any direct or indirect loss or damage that arises from the use of this manual due to circumstances that cannot be predicted in advance. Notes (Pepperl+Fuchs): This manual has been prepared for informational purposes only. While Pepperl+Fuchs has made every effort to ensure the correctness and accuracy of this document s contents, it provides neither warranties nor guarantees, express or implied, regarding the Pepperl+Fuchs products described herein or their use. Pepperl+Fuchs reserves the right to make modifications to the designs and specifications of the products described herein at any time and without advance notice. 1

2 Contents 1 Introduction Field Connections Control Connections HART Communicator Grounding Operation Initial Setup HiDMUX2700 Settings RS-232/RS-485 Converter Start-up Sequence Controls Indicators Modes of Operation Principles of Operation HART Filters Multiple Multiplexers Troubleshooting HiDMUX Maintenance P+F HART Multiplexer Support on PRM Parts List Glossary

3 1 Introduction This manual outlines the requirements for connecting the analog outputs to the HISHPSM/32/TB-02 HART termination board. Please note that this board is available in many different configurations, including with or without HART filters, fuses, and 200 ohm resistors. The following text and connection diagrams refer to a connection with a DVC6000 Smart Valve, when partial stroke testing is requested or required. Partial stroke testing is as an alternative to periodic full stroke tests of critical ESD valves, which typically means a disruptive process shutdown. As part of its HART diagnostic data, the DVC6000 sends digital information on the HART loop when a partial valve stroke test is in progress, and when the ESD valve is stuck. This partial stroke test may be accomplished using the Pepperl+Fuchs HART termination board (HISHPSM/32/TB-02) shown in Figure 1. Figure 1 This HISHPSM/32/TB-02 termination board must be connected in a series between your field devices and the control system, as shown in Figure 2. 3

4 Figure 2 The system in Figure 2 consists of the following: 1) One of the following HPSM/32/TB R 32 channel termination boards: HPSM/32/TB-02, 32 channels without HART filters HPSM/32/TB-02/FUSE, 32 channels, with fuses HPSM/32/TB-02/HF16, 16 channels with HART filters / 16 without HPSM/32/TB-02/HF16/FUSE, 16 channels with HART filters & fuses HPSM/32/TB-02/HF32, 32 channels with HART filters HPSM/32/TB R, 32 channels with 200 ohm resistor in line 2) HiDMUX2700 3) RS-485/RS-232 Converter 4) Software (PRM) In order to perform this partial stroke test, the analog output must be connected correctly to the 4

5 RS2 RS1 RS2 RS1 RS2 RS R R R Yokogawa Electric Corporation SBDB HISHPSM/32/TB-02 termination board. Please refer to Figure 3 for the proper connection of the HART analog output. Figure 3 This connection will allow proper HART communication to the digital output and makes it possible to perform the requested partial stroke test. The following pages provide brief instructions on how to set up the HiDMUX2700, RS-232/RS- 485, and diagnostics. These pages are excerpted from the manual for the HPSM/32/TB-02 termination board. TB2 SHD + - SHD MUX SHIELD B A G B A G TB2 SHD RS SHIELD SHD RS V Input A 24V Input B SHD MUX SHIELD B A G B A G TB2 SHD RS SHIELD SHD RS V Input A 24V Input B SHD MUX SHIELD B A G B A G RS SHIELD SHD RS V Input A 24V Input B Keithley M1000 RS-232 / RS-485 Converter RS-485 OUT G A B G A B G A B G A B G A B G A B DATA + DATA Vdc GND G G 100 ohm termination G Y G R B resistor on the last MUX Figure 4 RS-485 Wiring 5

6 1.1 Field Connections Field wiring can have many variations, depending on the type of field device. The wiring will either be in parallel or series. 1.2 Control Connections If your unit is wired in parallel, no connections should be made to the control side terminals. 1.3 HART Communicator In HART communications without multi-drop mode, there is one slave (field device) and up to two masters (e.g. multiplexer, HART Communicator, I/O module). The HART Communicator can be connected to the field side terminals as a secondary master. In your software settings, the HiDMUX2700 must be the primary master in order to use the HART Communicator. There cannot be more than two masters. If three or more masters are connected, a primary/ secondary conflict will occur and communications will cease with all devices on that loop. When the HiDMUX2700 is used with a HART compatible I/O system, the HiDMUX2700 must be configured as the secondary master. Otherwise, configure the HiDMUX2700 as the primary master. The handheld terminal (HHT) is a secondary master by default, and can be connected to the loop when no other device on that loop is configured as a secondary master. WARNING! Do not connect the HART Communicator to any intrinsically safe (IS) field wiring unless the terminal is approved as intrinsically safe and suitable for the actual hazardous location classification of the specific hazardous location. Also consider the HART Communicator safety parameters and equivalent capacitance and inductance before concluding that you can safely connect it to the IS side of the circuit. 6

7 1.4 Grounding The HPSM is divided into two galvanically isolated sections, each with its own shield terminal: SHD1 and SHD2. The field side terminals are connected to SHD1, which provides a single point for the proper grounding of the field wiring shields. The control side shield terminals and the power supply shield terminals are connected to SHD2. SHD2 is only used for certain applications. 7

8 2 Operation 2.1 Initial Setup The default settings for each HiDMUX2700 are as follows: Address = 1 Baud rate = HiDMUX2700 Settings The User Switches buffer has eight inputs from a low profile DIP switch that can be accessed under the transparent plastic cover. The functions of the switches are as follows: Switch 8 (T) Reserved for TEST purposes Switch 7 (R1) BAUD RATE 1 Switch 6 (R0) BAUD RATE 0 Switch 5 (B4) ADDRESS 4 Switch 4 (B3) ADDRESS 3 Switch 3 (B2) ADDRESS 2 Switch 2 (B1) ADDRESS 1 Switch 1 (B0) ADDRESS 0 Further information is given on the front and side labels (Figure 5). The side label gives the correct setting for each DIP switch combination Address The address of the HiDMUX2700 is determined by the DIP switches as noted below (Figure 5). Each MUX on the same RS-485 network must have a different address, but they do not have to be sequential and do not necessarily need to start at address 1. Possible addresses are Address 0 is invalid and cannot be used. Note that the network properties of the software setup are for multi-dropping. This is when multiple HiDMUX2700 multiplexers are on the same 8

9 network, not the same I/O loop (also referred to as multi-dropping ). Multi-dropping should be enabled in the network setup Baud Rate Table 1 RS-485 Baud Rate SW 6 SW ON OFF OFF OFF The baud rate of the HiDMUX2700 must match the baud rate of the PC s COM port and the RS- 232/RS-485 converter. All three units must use the same baud rate to function properly. The baud rate can be either 9600 or and is selected as shown in Table 1. Figure RS-232/RS-485 Converter An RS-232 to RS-485 converter must be placed between the HIS and the computer s RS-232 port. Pepperl+Fuchs recommends the Phoenix Contact PSM-ME-232/485 for non-ce applications. If the system is set up with only one RS-232 to RS-485 converter, then the RS-485 network 9

10 components must be less than 1,200 meters (4,000 feet) apart. For distances over 1,200 meters, an RS-232 to RS-485 repeater can be used. The repeater amplifies the original RS-485 signal when it is transmitted over long distances. 2.2 Start-up Sequence The proper start-up sequence for the HiDMUX2700 is as follows: 1. Make all signal connections to the HPSM. 2. Connect RS-485 wires and adjust network settings. 3. Apply field power or source 4-20 ma. 4. Turn on power to or plug in the HiDMUX After the HiDMUX2700 has completed the start-up sequence, then start the AMS. 2.3 Controls The only controls on the Pepperl+Fuchs equipment are the DIP switches noted above. All other settings are a function of the software. Please refer to your software instruction manual for further details. 2.4 Indicators Three LEDs on the front of the HiDMUX2700 indicate the status. Normal operation is as follows: PWR ON: This green LED is lit when power is applied to the HiDMUX2700. Power is automatically applied when the HiDMUX2700 is plugged into the HPSM. HART TX: Indicates that the HiDMUX2700 has established a communications link with field devices. FAULT: Should not be lit during normal operation. A single LED on the termination board lights when 24 V DC power is applied. 10

11 2.5 Modes of Operation SCAN MODE: Command to the HiDMUX2700 from the software telling the HiDMUX2700 to periodically scan each device automatically. Otherwise, the HiDMUX2700 will only communicate with a device when told to do so by the software. BURST MODE: When a field device is in burst mode, it automatically sends information without being commanded to do so. This is a break from the master-slave nature of HART communication, but the HiDMUX2700 will support it when burst mode is selected in the software. 11

12 3 Principles of Operation Referring to Figure 6, the heart of the HiDMUX2700 is the microprocessor. One serial port together with the HART modem generates the physical layer of the HART protocol, while the channel select circuit together with the channel multiplexer links one specific channel (device) at a time. An RS-485 circuit completes the gateway between the maintenance workstation and the devices. The user switches circuit provides information required by the HiDMUX2700 for initialization and configuration. Specifically, the baud rate for communications to the maintenance workstation and the HiDMUX2700 address are selected MUX Block Diagram RS-485 Interface RS-485 Line +24V + Power Supply Section Opto Isol. MUX A + - HART Channel 1 GND CPU HART Modem + - HART Channel 32 Figure HART Filters HART filters may be necessary with certain systems for the following reasons: To increase low output impedance of DCS so the HART signals have sufficient amplitude To remove fast transients from step changes in DCS output To prevent disruption of DCS circuitry by HART signals Note that when a HART filter is used, the HART signal will not be available to any monitoring equipment on the control side of the HPSM, including the DCS or HHT. Pepperl+Fuchs 12

13 recommends HART filters for any HART output signal (valves). DCS systems from Bailey, Fischer and Porter, Honeywell, Foxboro, and Fisher-Rosemount may require HART filters. Consult with the valve or I/P supplier to know if filters are required for a specific control system or field device. HPSM/32/TB-02/HF16: Channels 1-16 have HART filters. Channels do not. HPSM/32/TB-02/HF32: Channels 1-32 have HART filters. CAUTION: HART filters are only for use with output signals. Transmitters will not function when connected to a channel with a HART filter 3.2 Multiple Multiplexers Up to 31 HiDMUX2700 multiplexers can be connected on a single RS-485 network to support 992 devices. Multiple HiDMUX2700 units are connected in daisy-chain form, and redundant terminals are provided for this on each board. 13

14 4 Troubleshooting Due to the modular nature of the HIS system, a communication failure may occur anywhere in the data transfer link from the software to the field device. In order to identify where the loss of communication has occurred, it is important to understand which components are working correctly. Often, some simple checks will save hours of troubleshooting. Some of the most common mistakes are: improper wiring connections, baud rate mismatches, improper network settings, and improper addressing of the HiDMUX HiDMUX2700 The LEDs at the front of the HiDMUX2700 provide a convenient indication to the user that the HiDMUX2700 is operational. During normal operation, the PWR ON LED should be lit. The FAULT LED should be off. The HART TX LED may either be off or flashing steadily. When power to the HiDMUX2700 is cycled or a Reset command is issued, all the LEDs will flash once. Then, the PWR ON LED will come on, and for the next 60 to 120 seconds the HART TX LED will repeat a sequence of three flashes and a pause. During this period, the HiDMUX2700 is scanning each of the 32 channels. When it is finished, the HART TX LED will either flash steadily or turn off altogether. If all of the above occur, the HiDMUX2700 is operating properly. In addition, the TEST setting on the option switches can be used to verify that the module is functioning normally. Follow the procedure below to use this feature: 1. With the power off, disconnect the module from the RS-485 network and set switch 8 to the TEST position (ON). 2. Switch the power on. The LEDs should light for about 1 second each in sequence (red, yellow, green). 3. If the LEDs do not flash, there is a fault with the module and it should be returned for replacement. 4. To return to normal operation, switch off power to the HiDMUX2700 and set the TEST switch to the OFF position. Ensure that the correct baud rate is selected and that an RS-485 address is set. Then, re-apply power. 14

15 If you suspect the HiDMUX2700 is not functioning properly, refer to Table 2 below. Table 2 HiDMUX2700 LED Indications Symptom Cause Solution Lights flash sequentially TEST switch is ON Switch off the power Set TEST switch to OFF Restart the system No LEDs lit Power fail or fuse open Check the 24 V DC LED and Only yellow LED lit Scanning is disabled. If scanning is enabled, then no HART devices were detected by the HiDMUX2700 fuse Check wiring continuity Red LED lit Self-test fault Contact Pepperl+Fuchs for further instructions 15

16 5 Maintenance Under normal operating conditions, the Pepperl+Fuchs apparatus does not require maintenance. It is designed to operate trouble-free and with high stability for long periods. WARNING! Any repair made by unauthorized personnel may completely invalidate the safety characteristics of the unit and could void all warranties. Repair not made by Pepperl+Fuchs is fully at user's risk and responsibility. In addition, the warranty terms of the unit will be null and void to all effect. 16

17 6 P+F HART Multiplexer Support on PRM The P+F HART Multiplexer uses an RS-485 serial communications link. As the PRM Field Communication Server has an RS-232 COM port, an RS-232/RS-485 converter is used. Figure 7 The baud rate for serial communications between the PRM Field Communication Server and the HART Multiplexer is The baud rate setting for both the computer COM port and the multiplexer should be

18 Figure 8 After making the settings for the PRM Field Communication Server COM port, configure the device path for PRM. As shown in the following two illustrations, create a project under LOCAL and select ELCON2700 for the IOM type. Figure 9 18

19 Figure 10 Also configure the HiDMUX2700 for master configuration as per the DIP switch setting and select the COM port that is connected to the RS pin cable. Select Preamble 10 for HART device communication. Figure 11 19

20 Figure 12 Click Apply in the Device Path Configuration Tool and then click Restart Field Comm. Service to restart the PRM Field Communication Server. Log on to the PRM client and go to network view. Select the HART network and go to Register Read Device Path. Click Yes if a message window pops up to inform that this operation could take a long time. 20

21 Figure 13 After registering the device path for the project and the HART Multiplexer in the HART network view, open Windows Explorer and select PrmHartMuxMaintTool.exe in the PRM/Tool folder. 21

22 Figure 14 Enter the name of the PRM Field Communication Server and select Get Multiplexer Info. to display the COM port, Master Multiplexer, and Slave Multiplexer data. When a communications link is established between the PRM Field Communication Server and the HART Multiplexer, the lights on the multiplexer will start flashing. Click Get Device List to display all the HART devices that are connected to the Slave Multiplexer. This test will confirm that the PRM Field Communication Server is communicating with the HART Multiplexer system and the HART devices. 22

23 7 Parts List Table 3 lists the replacement parts for the HPSM. No HiDMUX2700 parts can be replaced in the field. Part Number Table 3 Replaceable Parts Description Supply ID label Terminal blocks MVSTBW 2.5/3-ST Fuse 5x20 time-lag, 125 ma FS1, FS Vertical fuse holder for 125 ma FS1, FS ma TR5 Microfuse L

24 8 Glossary DCS: FSK: HART : HHT: IS: MW: PC: PLC: TB: Distributed control system Frequency shift keying Highway addressable remote transducer Hand held terminal Intrinsic safety Maintenance workstation Personal computer Programmable logic controller Termination board 24