SMAR TP302 User manual

Brand: SMAR

Model: TP302

Type: User manual

Introduction

III

INTRODUCTION

The TP302 is from the first generation of Fieldbus devices. It is a transmitter for position

measurements. It can measure displacement or movement of rotary or linear type. The TP302 reads

the position and makes it available to Fieldbus system. The digital technology and communication

provide an easy interface between the field and control room and several interesting features that

considerably reduce the installation, operation and maintenance costs.

The TP302 is part of Smar's complete 302 line of Foundation Fieldbus devices.

Fieldbus is not only a replacement for 4-20 mA or intelligent/smart transmitter protocols. It contains

much more. Fieldbus is a complete system enabling distribution of the control function to equipment

in the field.

Some of the advantages of bi-directional digital communications are known from existing smart

transmitter protocols: Higher accuracy, multi-variable access, remote configuration and diagnostics,

and multi-dropping of several devices on a single pair of wires.

Some of the disadvantages, in comparison to 4-20 mA technology, are communication speed too

low for closed loop control, poor inter-operability between devices of different type and

manufacturer. Others: not possible to pass data direct from one device to another (peer-to-peer

communication).

The main requirement for Fieldbus was to overcome these problems. Closed loop control with

performance like a 4-20 mA system requires higher speed. Since higher speed means higher power

consumption, this clashes with the need for intrinsic safety. Therefore, a moderately high

communication speed was selected, and the system was designed to have minimum

communication overhead. Using scheduling so as the system controls variable sampling, algorithm

execution and communication to optimize the usage of the network, not loosing time. Thus

achieving high closed loop performance is achieved.

Using Fieldbus technology, with its capability to interconnect several devices, very large control

schemes can be constructed. In order too be user friendly the function block concept was introduced

(users of Smar CD600 should be familiar with this, since it was implemented several years ago).

The user may now easily build and overview complex control strategies. Another advantage is

adding flexibility, the control system may be edited without having to rewire or change the hardware.

The need for implementation of Fieldbus in small as well as large systems was considered when

developing the entire 302 line of Fieldbus devices. They have the common features of being able to

act as a master on the network and be configured locally using a magnetic tool, eliminating the need

for a configurator or console in many applications.

The TP302, like the rest of the 302 family, has several Function Blocks built in, like PID controller,

Input Selector and Splitter/Output selector, eliminating the need for a separate device. This takes to

reduced communication and thereby less dead-time and tighter control, not to mention the reduction

in cost.

NOTE

Get the best results of the TP302 by carefully reading these instructions.

TP302 – Operation, Maintenance and Instructions Manual

NOTE

This manual is compatible with version 3.XX, where 3 denotes software version and XX software release.

The indication 3.XX means that this manual is compatible with any release of software version 3.

Waiver of responsibility

The contents of this manual abides by the hardware and software used on the current equipment

version. Eventually there may occur divergencies between this manual and the equipment. The

information from this document are periodically reviewed and the necessary or identified corrections

will be included in the following editions. Suggestions for their improvement are welcome.

Warning

For more objectivity and clarity, this manual does not contain all the detailed information on the

product and, in addition, it does not cover every possible mounting, operation or maintenance

cases.

Before installing and utilizing the equipment, check if the model of the acquired equipment complies

with the technical requirements for the application. This checking is the user’s responsibility.

If the user needs more information, or on the event of specific problems not specified or treated in

this manual, the information should be sought from Smar. Furthermore, the user recognizes that the

contents of this manual by no means modify past or present agreements, confirmation or judicial

relationship, in whole or in part.

All of Smar’s obligation result from the purchasing agreement signed between the parties, which

includes the complete and sole valid warranty term. Contractual clauses related to the warranty are

not limited nor extended by virtue of the technical information contained in this manual.

Only qualified personnel are allowed to participate in the activities of mounting, electrical connection,

startup and maintenance of the equipment. Qualified personnel are understood to be the persons

familiar with the mounting, electrical connection, startup and operation of the equipment or other

similar apparatus that are technically fit for their work. Smar provides specific training to instruct and

qualify such professionals. However, each country must comply with the local safety procedures,

legal provisions and regulations for the mounting and operation of electrical installations, as well as

with the laws and regulations on classified areas, such as intrinsic safety, explosion proof, increased

safety and instrumented safety systems, among others.

The user is responsible for the incorrect or inadequate handling of equipments run with pneumatic

or hydraulic pressure or, still, subject to corrosive, aggressive or combustible products, since their

utilization may cause severe bodily harm and/or material damages.

The field equipment referred to in this manual, when acquired for classified or hazardous areas, has

its certification void when having its parts replaced or interchanged without functional and approval

tests by Smar or any of Smar authorized dealers, which are the competent companies for certifying

that the equipment in its entirety meets the applicable standards and regulations. The same is true

when converting the equipment of a communication protocol to another. In this case, it is necessary

sending the equipment to Smar or any of its authorized dealer. Moreover, the certificates are

different and the user is responsible for their correct use.

Always respect the instructions provided in the Manual. Smar is not responsible for any losses

and/or damages resulting from the inadequate use of its equipments. It is the user’s responsibility to

know and apply the safety practices in his country.

Table of Contents

TABLE OF CONTENTS

SECTION 1 - INSTALLATION .......................................................................................................................................................... 1.1

GENERAL ...................................................................................................................................................................................... 1.1

MOUNTING .................................................................................................................................................................................... 1.1

ELECTRONIC HOUSING ROTATION ........................................................................................................................................... 1.7

ELECTRIC WIRING ....................................................................................................................................................................... 1.7

BUS TOPOLOGY AND NETWORK CONFIGURATION ................................................................................................................ 1.8

JUMPER CONFIGURATION ....................................................................................................................................................... 1.10

POWER SUPPLY ........................................................................................................................................................................ 1.10

RECOMMENDATIONS FOR MOUNTING APPROVED EQUIPMENTS WITH THE IP66/68 W CERTIFICATIONS (“W"

INDICATES CERTIFICATION FOR USE IN SALINE ATMOSPHERES) ..................................................................................... 1.10

ROTARY AND LINEAR MAGNET ............................................................................................................................................... 1.10

REMOTE POSITION SENSOR .................................................................................................................................................... 1.11

INSTALLATION IN HAZARDOUS AREAS ................................................................................................................................... 1.12

SECTION 2 - OPERATION ............................................................................................................................................................... 2.1

FUNCTIONAL DESCRIPTION – HALL SENSOR .......................................................................................................................... 2.1

FUNCTIONAL DESCRIPTION – ELECTRONICS ......................................................................................................................... 2.1

SECTION 3 - CONFIGURATION ...................................................................................................................................................... 3.1

TRANSDUCER BLOCK ................................................................................................................................................................. 3.1

HOW TO CONFIGURE THE TRANSDUCER BLOCK ................................................................................................................... 3.1

POSITION FIELDBUS TRANSDUCER .......................................................................................................................................... 3.1

PARAMETERS TABLE .................................................................................................................................................................. 3.2

CALIBRATION ............................................................................................................................................................................... 3.3

POSITION TRIM ............................................................................................................................................................................ 3.4

VIA LOCAL ADJUSTMENT ............................................................................................................................................................ 3.5

DISPLAY TRANSDUCER BLOCK ................................................................................................................................................. 3.6

DEFINITION OF PARAMETERS AND VALUES ............................................................................................................................ 3.6

PROGRAMMING USING LOCAL ADJUSTMENT ....................................................................................................................... 3.10

BLOCK TYPE AVAILABILITY AND INITIAL BLOCK SET............................................................................................................ 3.12

TABLE OF POINTS - LINEARIZATION ....................................................................................................................................... 3.13

SECTION 4 - MAINTENANCE PROCEDURES ................................................................................................................................ 4.1

GENERAL ...................................................................................................................................................................................... 4.1

RECOMMENDATIONS FOR MOUNTING APPROVED EQUIPMENT WITH THE IP66/68 W CERTIFICATIONS (“W" INDICATES

CERTIFICATION FOR USE IN SALINE ATMOSPHERES) ........................................................................................................... 4.1

DISASSEMBLY PROCEDURE ...................................................................................................................................................... 4.2

REASSEMBLY PROCEDURE ....................................................................................................................................................... 4.3

UPGRADING TP301 TO TP302 .................................................................................................................................................... 4.4

ACCESSORIES ............................................................................................................................................................................. 4.4

EXPLODED VIEW ......................................................................................................................................................................... 4.5

SPARE PARTS LIST...................................................................................................................................................................... 4.6

SECTION 5 - TECHNICAL CHARACTERISTICS ............................................................................................................................. 5.1

FUNCTIONAL SPECIFICATIONS ................................................................................................................................................. 5.1

PERFORMANCE SPECIFICATIONS............................................................................................................................................. 5.1

PHYSICAL SPECIFICATIONS ....................................................................................................................................................... 5.1

ORDERING CODE ........................................................................................................................................................................ 5.2

APPENDIX A - CERTIFICATIONS INFORMATION ........................................................................................................................ A.1

EUROPEAN DIRECTIVE INFORMATION ............................................................................................................................. A.1

HAZARDOUS LOCATIONS GENERAL INFORMATION .................................................................................................... A.1

HAZARDOUS LOCATIONS APPROVALS ............................................................................................................................ A.2

IDENTIFICATION PLATES ...................................................................................................................................................... A.5

CONTROL DRAWING .............................................................................................................................................................. A.7

APPENDIX B – SRF – SERVICE REQUEST FORM ....................................................................................................................... B.1

RETURNING MATERIALS ............................................................................................................................................................ B.2

TP302 – Operation, Maintenance and Instructions Manual

Installation Flowchart

Has the transmitter

been configured

in bench for the

application ?

Configure the transmitter

( Section 1 and Section 3).

Start

Field Installation.

Install the transmitter according

to the application.

Verify area classification and

its respective practices.

YES

Configure Fail Safe value

(Section 3).

Configure Damping (Section 3).

Configure the indication in

local Indicator (Section 3).

Configure the user unit in case

of specific measurements.

(Section 3)

Is the measurement

OK ?

YES

the

measuring ok

Using the GSD file, configure

the cyclic data in the system

configuration tool (Section 3)

YES

Consult the manual

Section 4 - Maintenance.

Consult the manual

Section 4 - Maintenance.

Dislocate the system to

upper position, execute the

upper position trim for 100%.

Dislocate the system to

lower position, execute the

lower position trim for 0%.

Power the transmitter.

Fix the transmitter magnet

in a position that allows to the

sensor to travel all magnet range.

Verify the most appropriate

position for local indicator.

Section 1

1.1

INSTALLATION

General

NOTE

The installation carried out in hazardous areas should follow the recommendations of Appendix

The overall accuracy of measurement and control depends on several variables. Although the

converter has an outstanding performance, proper installation is essential, in order to maximize its

performance.

Among all factors, which may affect converter accuracy environmental conditions are the most

difficult to control. There are, however, ways of reducing the effects of temperature, humidity, and

vibration.

In warm environments, the transmitter should be installed to avoid, as much as possible, direct

exposure to the sun. Installation close to lines and vessels subjected to high temperatures should

also be avoided.

Use of sunshades or heat shields to protect the transmitter from external heat sources should be

considered, if necessary.

Humidity is fatal to electronic circuits. In areas subjected to high relative humidity, the o-rings for the

electronics cover must be correctly placed. Removal of the electronics cover in the field should be

reduced to the minimum necessary, since each time it is re-moved; the circuits are exposed to the

humidity.

The electronic circuit is protected by a humidity proof coating, but frequent exposures to humidity

may affect the protection provided. It is also important to keep the covers tightened in place. Every

time they are removed, the threads are exposed to corrosion, since painting cannot protect these

parts. Code approved sealing methods on conduit entering the transmitter should be employed.

Although the transmitter is virtually insensitive to vibration, installation close pumps, turbines or

other vibrating equipment should be avoided.

Mounting

The TP302 mounting depends on the type of movement, linear or rotary. Two brackets are required

for mounting, one for the magnet and the other for the transmitter itself.

NOTE

Make sure that arrow engraved on the magnet coincides with the arrow engraved on the Position

Transmitter when the system is in mid travel. When mounting the Position Transmitter, consider

that:

1 . There is no friction between the internal magnet face and the position sensor salience all

over the travel (rotary or linear).

2. A minimum distance of 2 mm to 4 mm distance is recommended between the magnet

external face and the Position Transmitter face.

Should the transmitter installation change, or magnet change, or should any other modification, the

transmitter will require a re-calibration.

IMPORTANT

If the self-diagnostics detect a transmitter failure, for example the loss of the power, the analog

signal will go to 3.9 mA or to 21.0 mA to alert the user (High or low alarm signal is user

selectable).

TP302 – Operation, Maintenance, and Instructions Manual

1.2

The following Figures 1.1 and 1.3 show both linear and rotary typical mounting:

Rotary Movement

Install the magnet on the valve stem using the magnet mounting bracket.

ROTATY

MAGNET

BRACKET

VALVE

STEM

ROTARY

MAGNET POSITIONER

TRANSMITTER

POSITIONER

TRANSMITTER

BRACKET

Figure 1.1 – Transmitter on a Rotary Actuator

BRACKET FOR REMOTE

SENSOR

REMOTE SENSOR

REMOTE POSITION

TRANSMITTER

M6 x 1SCREWS

(2 PLACES)

“L” BRACKET WITH “U” CLAMP FOR

REMOTE POSITION TRANSMITTER.

Figure 1.2 – Position Transmitter on Rotary Actuator with Remote Position Sensor

Installation

1.3

Linear Movement

Install the magnet on the valve stem using the magnet mounting bracket.

The linear magnet movement must be orthogonal in relation to the main axis of the position

transmitter. For example, if the linear magnet movement is vertical, the transmitter main axis must

be horizontal, as show in Figure 1.3.

Magnet Bracket

Linear

Valve Yoke

Valve Stem

Linear Magnetic

Centralizer Gadget Linear

Position Transmitter

M6 x 25 Screw

Position Trasmitter Bracket

with Clamp “L”

“U”

Figure 1.3 - Transmitter on a Linear Actuator

TP302 – Operation, Maintenance, and Instructions Manual

1.4

CENTRALIZER

DEVICE

VALVE

STEM

VALVE YOKE

LINEAR

MAGNET

REMOTE

SENSOR

“L” BRACKET WITH “U” CLAMP

FOR REMOTE SENSOR

REMOTE POSITION

TRANSMITTER

LINEAR MAGNET

BRACKET

M6 x 1 SCREWS

(2 PLACES)

M6x1 SCREWS

(2 PLACES)

“L” BRACKET WITH “U”

CLAMP FOR REMOTE

POSITION TRANSMITTER

Figure 1.4 – Position Transmitter on Linear Actuator with Remote Position Sensor

Installation

1.5

See below the TP302 and magnets dimensional drawings.

Figure 1.5 – TP302 Dimensional Drawing / Magnets Dimensional Drawing

TP302 – Operation, Maintenance, and Instructions Manual

1.6

REMOTE SENSOR

(3.27)

Leave, at least, a 150 mm space, for

zero and span adjustment with the

magnetic tool.

PLUG

ELECTRICAL

CONNECTION

113

(4.45)

(0.35)

(2.16)

(6.89)

175

49.5

(2.17)

THREADS FOR SCREWS

M6 x 1 ( 2 PLACES )

127

107

(4.21)

FLEXIBLE SHIELD CABLE

AVAILABLE LENGHTS:

5 m, 10 m, 15 m, 20 m

(2.99)

(5)

(1.95)

(0.94)

Figure 1.5.a – Remote Sensor Dimensional Drawing

SPECIAL MOUNTING BRACKET – ROTARY VDI / VDE NAMUR

Mounting bracket of the position transmitter for rotary valves actuated via type actuators rack and

pinion, designed to comply with NAMUR VDI/VDE.

POSITON TRANSMITTER POSITON TRANSMITTER

ROTARY MAGNET ROTARY MAGNET

MAGNET BRACKET MAGNET BRACKET

MOUNTING BRACKET MOUNTING BRACKET

PNEUMATIC ACTUATOR

NAMUR VDI/VDER STANDARD PNEUMATIC ACTUATOR

NAMUR VDI/VDER STANDARD

Mounting 80 mm between centers, 20 mm stem

height.

Mounting 130 mm between centers, 30 mm

stem height.

Figure 1.5.b – Special Mounting Bracket Dimensional Drawing - Rotary VDI / VDE NAMUR

Installation

1.7

Electronic Housing Rotation

The electronic housing rotates for a better digital display reading. To rotate it, release the housing

rotation screw.

COVER

LOCKING

SCREW

HOUSING ROTARY

SCREW

Figure 1.6 – Cover Locking and Housing Rotation Set Screw

Figure 1.7 - Cover Locking Screw

Electric Wiring

Access the wiring block by removing the electrical connection cover.

Cable access to wiring connections is obtained by one of the two conduit outlets. Conduit threads

should be sealed by means of code-approved sealing methods.

The unused outlet connection should be plugged accordingly.

The wiring block has screws on which fork or ring-type terminals can be fastened. For convenience

there are two ground terminals: one inside the cover and one external, located close to the conduit

entries.

TP302 – Operation, Maintenance, and Instructions Manual

1.8

+GROUND

TERMINAL

POWER

SUPPLY

TERMINALS

COMUNICATION

TERMINALS

Figure 1.8 – Wiring Block

The TP302 uses the 31.25 kbit/s voltage mode option for the physical signaling. All other devices on

the same bus must use the same signaling. All devices are connected in parallel along the same

pair of wires.

Various types of Fieldbus devices may be connected on the same bus.

The TP302 is powered via the bus. The limit for such devices is 16 for one bus for non-intrinsically

safe requirement.

In hazardous area, the number of devices may be limited to 6 by intrinsically safe restrictions.

The TP302 is protected against reverse polarity and can withstand ±35 Vdc without damage.

WARNING

In hazardous areas with explosion proof requirements, the covers must be tightened with at least 8 turns. In

order to avoid the penetration moisture or corrosive gases, tighten the o-ring until feeling the o-ring touching the

housing. Then, tighten more 1/3 turn (120) to guarantee the sealing. Lock the covers using the locking screw.

In hazardous zones with intrinsically safe or non incendive requirements, the circuit entity parameters and

applicable installation procedures must be observed.

Cable access to wiring connections is obtained by the two conduit outlets. Conduit threads should be sealed by

means of code-approved sealing methods. The unused outlet connection should be plugged and sealed

accordingly.

Should other certifications be necessary, refer to the certification or specific standard for installation limitations.

Bus Topology and Network Configuration

Bus and tree topology are supported. Both types have a trunk cable with two terminations. The

devices are connected to the trunk via spurs. The spurs may be integrated in the device giving zero

spur length. A spur may connect more than one device, depending on the length. Active couplers

may be used to extend spur length.

Active repeaters may be used to extend the trunk length.

The total cable length, including spurs, between any two devices in the Fieldbus should not exceed

1900m.

Installation

1.9

Figure 1.9 - Bus Topology

Figure 1.10 - Tree Topology

TP302 – Operation, Maintenance, and Instructions Manual

1.10

Jumper Configuration

In order to work properly, the jumpers J1 and W1 located in the TP302 main board must be correctly

configured.

This jumper enables the simulation mode parameter in the AI block.

This jumper enables the local adjustment programming tree.

Table 1.1 - Description of the Jumpers

Power Supply

The TP302 receives power from the bus via the signal wiring. The power supply may come from a

separate unit or from another device such as a controller or DCS.

The voltage should be between 9 to 32 Vdc for non-intrinsic safe applications.

A special requirement applies to the power supply used in an intrinsically safe bus and depends on

the type of barrier used.

Use of PS302 is recommended as power supply.

Recommendations for mounting Approved Equipment with the IP66/68 W

certifications (“W" indicates certification for use in saline atmospheres)

NOTE

This TP302 certification is valid for stainless steel transmitter manufactured, approved with the

certification IP66/68 W. All transmitter external material, such as plugs, connections etc.,

should be made in stainless steel.

The electrical connection with 1/2” – 14NPT thread must use a sealant. A non-hardening

silicone sealant is recommended.

The instrument modification or replacement parts supplied by other than authorized

representative of Smar is prohibited and will void the certification.

Rotary and Linear Magnet

The Figure 1.12 shows typical shapes for both magnets. For better transmitter performance, the

linear magnet is presented with different lengths. Consult the ordering code table for the best

choice.

Rotary Magnet

Linear Magnet

Figure 1.12 – Linear and Rotary Magnet Models

Installation

1.11

Remote Position Sensor

The remote magnetic position sensor, based on hall effect, is recommended for high temperature or

extreme vibration applications. It prevents excessive wear of the equipment and, consequently,

increasing the transmitter lifetime..

Smart Position

Transmitter

Cable

Remote Position

Sensor

Figure 1.13 - Remote Position Sensor

The electric signals on the remote sensor’s cable and connections are of low intensity. Therefore,

when installing the cable inside the conduit (maximum limit 20 (meters) length), keep it away from

possible sources of induction and/or magnetic interference. The cable supplied by Smar is shielded

with excellent protection against electromagnetic interference, but despite of this protection, it is

recommended to avoid the cable sharing the same conduit with other cables.

The connector for Remote Position Sensor is easy to handle and simple to install.

See the installation procedure:

Figure 1.14 - Connecting the Cable to the Remote Position Sensor

Figure 1.15 - Connecting the Cable to the Position

Transmitter

TP302 – Operation, Maintenance, and Instructions Manual

1.12

Installation in Hazardous Areas

Consult the Appendix A for Hazardous Location Approvals.

Section 2

2.1

OPERATION

Functional Description – Hall Sensor

Sensor hall supplies an output voltage proportional to the applied magnetic field. This magnetic

sensor is ideal for use in system of sensor of linear or rotary position. The mechanical vibrations do

not affect sensor hall.

Functional Description – Electronics

Refer to the block diagram. The function of each block is described below.

Figure 2.1 - TP302 Block Diagram

Central Processing Unit (CPU), RAM, FLASH and EEPROM

The CPU is the intelligent portion of the transmitter, being responsible for the management and

operation of measurement, block execution, self-diagnostics and communication. The program is

stored in a FLASH memory for easy upgrade and saving data on power-down event occurrence. For

temporary storage of data there is a RAM. The data in the RAM is lost if the power is switched off,

however the main board has a nonvolatile EEPROM memory where the static data configured that

must be retained is stored. Examples of such data are the following: calibration, links and

identification data.

Controller Communication

Monitors line activity, modulate and demodulate communication signals; inserts and deletes start

and end delimiters, and check integrity of frame received.

Power Supply

Takes power of the loop-line to power the transmitter circuit.

Power Isolation

Isolates the signals to and from the input section, the power to the input section must be isolated.

A/D

The A/D converts the input signals to a digital format for the CPU.

TP302 – Operation and Maintenance Instruction Manual

2.2

Display Controller

Receives data from the CPU identifying which segments on the local indicator use to turn on. The

controller drives the backplane and the segment control signals.

Local Adjustment

There are two switches that are magnetically activated. The magnetic tool without mechanical or

electrical contact can activate them.

Local Indicator

Indicates the actual position to the CPU.

Figure 2.2 - Local Indicator

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SMAR TP302 User manual

SMAR TP302 User manual

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