text
stringclasses 4
values |
|---|
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 1
smartPOZ+ Positioner
User’s Manual
Version V1.2 – Oct. 2023
Forbes Marshall Pvt. Ltd.
Plot # B-85, Chakan, MIDC Phase-II
Sawardari, Tal Khed, Dist. Pune 410501. INDIA
smartPOZ+
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 2
Contents
Purpose of this Document ............................................................................................................................................................. 4
Intended use ....................................................................................................................................................................................... 4
Qualified Personnel .......................................................................................................................................................................... 4
General Safety & Security .............................................................................................................................................................. 4
Limitation of Liability and Optimum performance ............................................................................................................. 5
Compliance with Laws & Directives.......................................................................................................................................... 5
Product Disposal ............................................................................................................................................................................... 5
General Notes ..................................................................................................................................................................................... 8
1. INTRODUCTION ........................................................................................................................................................................ 9
2. MECHANICAL DIMENSIONS ............................................................................................................................................. 10
2.1 Rear mounting with pneumatic connections .............................................................................................................. 11
2.2 Exploded view: ........................................................................................................................................................................ 12
3. DON’Ts and DO’s .................................................................................................................................................................... 13
4. INSTALLATION ...................................................................................................................................................................... 13
4.1
Tools required ................................................................................................................................................................... 13
4.2
Mounting .............................................................................................................................................................................. 13
4.2.1 Feedback link & threaded pin assembly: .................................................................................................................. 14
4.2.2 Positioner mounting on valve actuator: .................................................................................................................... 15
4.2.3 Pin engagement in C-link: ............................................................................................................................................... 16
4.2.4 Positioner mounting with reference of stopper: ................................................................................................... 16
4.3
Feedback Lever Types, Dimensions and Effective rotation angle range ................................................... 18
4.4
Electrical connections..................................................................................................................................................... 19
4.5
Pneumatic Connections ................................................................................................................................................. 21
4.6
Pre-Power ON Checks ..................................................................................................................................................... 22
5
QUICK START GUIDE ........................................................................................................................................................... 22
6
SPECIFICATIONS ................................................................................................................................................................... 24
6.1 Positioner variants and nomenclature guide: ............................................................................................................ 25
7. KEY OPERATION ................................................................................................................................................................... 26
7.1
Plunger Operated Tactile Keys ................................................................................................................................... 26
8. DISPLAY& MODES ................................................................................................................................................................. 26
8.1
Display Fields ..................................................................................................................................................................... 26
8.2
Run Mode ............................................................................................................................................................................. 26
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 3
8.3
Configuration Mode ......................................................................................................................................................... 27
9. SOFTWARE FEATURES ....................................................................................................................................................... 28
9.1
Menu ...................................................................................................................................................................................... 28
9.2 Quick Menu ............................................................................................................................................................................... 31
10.
PUTTING INTO OPERATION ........................................................................................................................................ 31
10.1
Configuration................................................................................................................................................................. 31
10.2
Powerup and Run ........................................................................................................................................................ 31
10.3
Self-Calibration – Air to Open ................................................................................................................................. 32
10.3.1 Manual 3 Point Calibration .......................................................................................................................................... 33
10.3.2 Manual 5 Point Calibration .......................................................................................................................................... 36
10.3.3 Auto 2 Point Calibration ................................................................................................................................................ 39
10.3.4 Aborting self-calibration with a key press............................................................................................................. 40
10.4 Self-Calibration – Air to Close ......................................................................................................................................... 41
10.4.1 Manual 3 Point Calibration .......................................................................................................................................... 41
10.4.2 Manual 5 Point Calibration .......................................................................................................................................... 44
10.4.3 Auto 2 Point Calibration ................................................................................................................................................ 47
10.4.4 Aborting self-calibration with a key press............................................................................................................. 49
11.
MAINTENANCE SCHEDULE ......................................................................................................................................... 50
12.
TROUBLE SHOOTING ...................................................................................................................................................... 51
12.1 Error codes: ............................................................................................................................................................................ 54
12.2 Warnings: ................................................................................................................................................................................ 55
13.
HART® Communication ................................................................................................................................................ 56
13.1 Downloading EDD and FDI files ..................................................................................................................................... 56
13.2 Operating Mode .................................................................................................................................................................... 56
13.3 Configuration Mode ............................................................................................................................................................ 56
13.4 Calibration Mode .................................................................................................................................................................. 57
13.5 Diagnosis Mode..................................................................................................................................................................... 57
14.
External Communication ............................................................................................................................................... 58
Copyright Notice ............................................................................................................................................................................ 68
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 4
Purpose of this Document
The purpose of this document is to equip the reader with the necessary information required for the
safe installation, operation and maintenance of this device, prior to its commissioning. The information
within this document is aimed towards those individuals who are technically qualified and experienced
in the assembly, installation and operation/ maintenance of the device.
To avoid personal injury or property damage it is important to carefully read, understand, and follow all
of the contents of this manual, including all safety cautions and warnings. If you have any questions
about these instructions, contact the customer support division of the Manufacturer before proceeding.
Whilst the information in this document aims to be as accurate as possible, the Manufacturer makes no
warranty or representations with respect to the information herein. The proper utilization of this
information is ultimately the responsibility of the Customer.
Intended use
In order to ensure optimum functionality, the device needs to be utilized solely for those purposes and
in those manners as prescribed herein. The Customer is responsible for making certain that the
operating conditions for the device correspond to the technical specifications defined. Furthermore, the
Customer is also responsible for ensuring that any personnel that operate or maintain the device are
made aware of the implications of using or operating the device in unsuitable conditions.
The Manufacturer does not assume any liability for damages resulting from the failure to use the
device for its intended purpose or for damage caused by external forces or any other external
factors.
Qualified Personnel
The product described in this documentation may be installed, operated and maintained only by
personnel qualified for the specific task in accordance with the relevant documentation, in particular its
warning notices and safety instructions. Qualified personnel are those who, based on their training and
experience, are capable of identifying risks and avoiding potential hazards when working with these
products.
The Customer must ensure that operating personnel read and understand these instructions as well as
the specified hazard statements, warning and caution notes. Furthermore, the operating personnel
must be familiar with the applicable health, safety and accident prevention regulations and comply with
them.
General Safety & Security
The Customer must consider for the necessity of any protective clothing for its employees in the vicinity
in order to provide protection against hazards of temperature (high or low), chemicals, radiation,
dangers to eyes and face, noise and falling objects.
There is always a possibility of risk of injury if heavy products are handled manually. Customers are
requested to analyze the risk and use appropriate handling methods by taking into consideration the
task, the individual, the working environment and the load. Furthermore, it is the Customer’s
responsibility to ensure that general instructions for proper use of tools and safety of equipment, piping
and plant construction must also be complied with and “Warning Notices” need to be put up wherever
necessary.
The Customer is solely responsible to prevent unauthorized access to its plants, systems, machines and
networks, its information technology infrastructure, firewalls network, internet and appropriate
security measures.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 5
Incorrect installation, operation or maintenance of the device in potentially explosive
atmospheres may lead to ignition of the atmosphere and cause risk of fatal injury, death or
damage to personal property. Please note that the Customer is solely liable for any hazards,
damage or injury caused to its personnel or property due to the Customer’s failure to comply
with the safety instructions above and as established throughout the course of this manual.
Limitation of Liability and Optimum performance
For optimum performance, the Product should only be used in conjunction with components and
accessories supplied by the Manufacturer. If the product accessories and components from other
manufacturers are used, these must be recommended or approved by the Manufacturer.
The Manufacturer shall not be liable and the Warranty shall not apply, if the Product (i) is used in any
manner that is inconsistent with the intended purpose or design of the Product as described in user
manual, product literature and/or technical documentation provided by the Manufacturer of the
Product; (ii) is altered in any way; (iii) is used or maintained in any manner that is inconsistent with
Manufacturer's instructions or warnings (“User Instructions”) provided along with the Product; (iv)
subjected to any other misuse, lack of proper storage & handling, commissioning, maintenance, faulty
repair, neglect, or servicing by persons other than Manufacturer’s authorized person and/or failure to
operate in permissible ambient conditions.
Compliance with Laws & Directives
Observe the test certification, provisions and laws applicable in your country during connection,
assembly and operation.
Product Disposal
It is necessary to dispose this product only in accordance with local regulations at the authorized,
qualified collecting point specified for equipment and its parts. Kindly refer to the components
mentioned in this document. Please follow all waste disposal guidelines (Management & Handling) as
published by local governing authorities and local environmental laws.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 6
IMPORTANT
Read this User Manual thoroughly and understand its contents completely
before installing and powering-up the positioner.
Nomenclature and symbols
Product
Product refers to the smartPOZ+ Positioner control unit.
Nomenclature
This manual contains notes and instructions, which the user must observe to ensure the safety of all
user personnel and to protect the product and equipment connected to it. These are highlighted using
specific symbols and appear based on the severity levels as follows.
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
If used with the safety alert symbol indicates a potentially hazardous situation which if not avoided may
result in minor to moderate level injury.
CAUTION
If used without the safety alert symbol indicates a potentially hazardous situation which if not avoided
may result in damage to property.
NOTICE
If used without the safety alert symbol indicates a potentially hazardous situation which if not avoided
may result in undesirable state or result.
NOTE
This highlights important information about the product, using the product or part of the
documentation that will be beneficial to the user.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 7
smartPOZ+
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 8
General Notes
NOTE
Dear User,
This manual does not provide for every possible contingency situation that may arise during the
installation, operation and maintenance of the product.
For information or situations not covered by this manual, please contact your local Forbes Marshall
Service support.
The content herein is based, on the latest data available at the time of going to print and is subject to
change due to ongoing product improvements in the future.
WARNING
The successful operation of this product depends on its proper handling, installation, operation and
maintenance.
This product must be used for the sole purpose described in this manual.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 9
1. INTRODUCTION
The smartPOZ+ positioner is a two-wire device that uses a 4~20mA signal input as its setpoint, deriving its
power from the same. It compares the setpoint with the actual position of the Actuator stem and eliminates
the positioning error accurately using an internal PID control action.
The smartPOZ+ positioner is a Single Acting Linear Exi + HART® device.
It is the microprocessor based smartPOZ+ positioner that provides fast, sensitive and accurate positioning
for single acting linear pneumatic actuators.
The smartPOZ+ positioner series uses a link-coupled potentiometer feedback position sensing technique.
The position sensing is achieved by a combination of a shaft-mounted linkages and a potentiometer
mounted within the control unit.
At the heart of the smartPOZ+ positioner is a small piezo based transducer, which is a low power and low
air consumption device. The electrical signal from the micro-controller is converted to precise equivalent
pneumatic signals through the transducer, which operates a pilot valve, and in turn supplies the
proportional air to the valve actuator.
Main Features of the smartPOZ+ positioner:
Precise position control
Robust design
Auto/manual calibration for full stroke
Low air consumption
Can be used for Linear, Equal %, Inv Equal%, free adjustment irrespective of the plug characteristics
Split range feature for two valves
Alphanumeric LCD display
Local and remote monitoring over HART® protocol
Can be used for air- to-open, air–to-close applications
Potentiometric feedback passive output 4 ~ 20 mA
Basic programming front panel without configurator
Retro-fitting of existing positioner possible
NAMUR tubeless connection possible
Diagnostic Features ( also via HART®)
Spindle direction changes
Number of changes per day
Spindle stroke
Travel in mm / %
Spindle stroke limit
Setting of maximum stroke limit
Steady state deviation
Deviation in mm
Setpoint changes per day
Number of changes per day
Setpoint change
Total setpoint change
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 10
Setpoint change limit
Setting of maximum setpoint change
Average spindle velocity
mm/s
Total Valve operation time
hours/days/months
Total Calibrations done
Spindle up / down stroke time
Time taken from zero to full lift and full lift to zero
High friction limit
Partial stroke alert
Features available via PC based software / HART® :
Valve signature
Step response
Device variable logging :
Setpoint, Actual travel, Device temperature, Wear and tear, Pressure: Outlet 1, Outlet 2, Inlet
Actuator data – Spring range, Actuator type, Gland packing type
Actuator effective area
2. MECHANICAL DIMENSIONS
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 11
2.1 Rear mounting with pneumatic connections
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 12
2.2 Exploded view:
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 13
3. DON’Ts and DO’s
DON’Ts
•
Do not connect any voltages exceeding the specifications of the positioner.
•
Do not connect inlet air pressure exceeding the specifications of the positioner.
DOs
•
Confirm that the positioner is firmly mounted on the actuator support.
•
Ensure proper fitting of potentiometer linkages
•
Ensure that the air supply is free of water/ moisture, oil and dust conforming to the specifications of
air quality according to ISO8573-1: 2010 Class 3.3.3 or ISA S7.0.01. Confirm & set supply air
pressure as per valve datasheet/ name plate.
•
The control input signal of 4~20mA that powers the positioner must be able to drive a current ≥
3.4mA at:
-
Compliance voltage ≥ 9Vdc (load ≤ 450 Ω) for Exi with HART®
-
Compliance voltage ≥ 8Vdc (load ≤ 400 Ω) for Non-Exi with HART®
•
Ensure proper Earth is connected to the Earth tab of the Positioner Body.
•
Ensure correct external supply voltage of 18~30 VDC for Passive Current Output of 4~20mA.
4. INSTALLATION
4.1 Tools required
Flat tipped screw driver for M3, M5 screws
Phillips head screw driver for M3, M4 screws
4.2 Mounting
Ensure that valve-actuator coupling is fully tightened
Mount the smartPOZ+ positioner onto the support
Connect the pressure line to the pressure input port
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 14
4.2.1 Feedback link & threaded pin assembly:
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 15
4.2.2 Positioner mounting on valve actuator:
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 16
4.2.3 Pin engagement in C-link:
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 17
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 18
4.3 Feedback Lever Types, Dimensions and Effective rotation angle range
To achieve the best performance of feedback lever, effective rotation angle needs to be maintained.
The effective rotation angle of SmartPoz+ feedback lever is 25° upward and downward, with respect to
horizontal (0°) position.
For SmartPoz+ feedback lever details follow the table as below,
Lever Type
Valve Stroke
Lever Dimensions
Pot Count
1
10-60mm
When valve is 100%
close, minimum pot
count range should be
in between (100-900).
When valve is 100%
open, maximum pot
count range should be
≥ (minimum pot count
observed +2000)
2
10-120mm
NOTE
If the pot count difference between maximum pot count and minimum pot count is less than 2000 count
then performance may be degraded.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 19
4.4 Electrical connections
WARNING
•
Confirm that the cables are not live and do not carry any potential before attempting to make any
electrical connections.
•
Dismount the Cover of the control unit by carefully unscrewing the Phillips screws. Do not unscrew
the bolts to an extent that they become dislodged from the Cover.
•
Check that the cable is of the specified type and its open ends have been properly ferruled and
lugged.
•
Insert the Control Input Signal cable through the cable gland nut, rubber grommet of the
appropriate internal diameter and then run it through the upper leftward (as seen from front) cable
gland. Pull it gently outwards after it enters the terminal chamber.
WARNING
•
For Ex variant, ensure that the cable armour is properly clamped by the double compression gland.
•
For MAX variant, additionally insert the Position Tx Output cable through the cable gland nut,
rubber grommet of the appropriate internal diameter and then run it through the lower rightward
cable gland. Pull it gently outwards after it enters the terminal chamber.
(Vmin)
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 20
•
Terminate the 4~20mA Control Input Signal cable across terminals Iin+ and Iin- respectively, as
shown.
WARNING
•
For Ex variant, additionally terminate the third conductor to the internal EARTH stud.
•
To monitor data over HART®, connect the Hand Held HART® Communicator across the Iin+ and
Iin- lines respectively at the controller end as shown.
WARNING
•
For Ex variant, observe the proper installation of barriers as shown in the schematic below. Ensure
that the cable armour is properly clamped by the double compression gland.
•
Mount back the Terminal Cover by carefully fastening the screws.
WARNING
•
Tighten the respective cable gland nuts ensuring that the cable sheath is firmly gripped by the
rubber grommet and the cable armor is properly clamped between the cable gland ferrule and its
shell.
WARNING
•
Replace the Terminal Cover and mount the Cover of the control unit taking care that the gasket is in
place and not being damaged during cover closure. Fasten all the Allen headed bolts of the Cover.
WARNING
•
Ensure that all the bolts are completely fastened to maintain continued safety and ingress
protection during the use of the product.
smartPOZ+ / FMPoz
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 21
4.5 Pneumatic Connections
NOTE
The inlet instrument compressed air pressure must be regulated to a value as specified on the
actuator. This is usually in the range of 3 ~ 6 bar.
Inlet compressed air must be completely free of water/ moisture, oil and dust conforming to the
specifications of air quality according to ISO8573-1: 2010 Class 3:3:3 or ISA S7.0.01
The inlet and outlet pneumatic connection size is ¼” NPT. We strongly recommend the use of SS316
tubes with clear ferruling and Teflon-tape sealing for proper operation.
smartPOZ+
WARNING
Prevent damage to the gasket.
Before mounting the positioner cover, ensure that the gasketis correctly
located in its groove in the cover.
Not doing so will damage the gasket causing degradation of ingress
protection.
CAUTION
Always use clean, dry and oil-free instrument air.
The Positioner needs this to guarantee a fault-free operation.
Ensure that the air quality conforms to ISO8573-1: 2010 Class 3:3:3 or ISA
S7.0.01.
In case the air supply is part of a compressed air network, ensure that any
contaminants including oil, water, residues among others are completely
removed by blowing out
1.5…7.0 bar
air supply
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 22
4.6 Pre-Power ON Checks
Check that all the electrical and pneumatic connections have been done as described in this manual
Check that the smartPOZ+ positioner potentiometer linkages are installed as described in this
manual
5 QUICK START GUIDE
You will normally receive the smartPOZ+ positioner pre-mounted onto the support of the control valve
and factory-calibrated. The following is a list of steps that will have to be performed to set it into
operation. For details of any step, please refer to appropriate sections of this manual.
WARNING
Confirm that the cables are not live and do not carry any potential while the smartPOZ+ positioner
cover is open and you attempt to make electrical connections.
Install an AFR with moisture separator close to the valve
Connect clean air supply as specified on the actuator plate to the inlet port
Ensure that the supply air is free of water/ moisture, oil and dust conforming to the specifications of
air quality according to ISO8573-1: 2010 Class 3:3:3 or ISA S7.0.01
Open the smartPOZ+ positioner cover by unscrewing the 4 screws
Connect the control input 4~20mA signal cable
Connect the position transmitter output 4~20mA signal cable (if the option is included)
Close the smartPOZ+ positioner cover and fasten all the 4 screws
Feed the control input signal 4~20mA
smartPOZ
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 23
The smartPOZ+ positioner will start functioning; if it does not, read the section on
Troubleshooting.
(Vmin)
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 24
6 SPECIFICATIONS
Positioner type
smartPOZ+ Single Acting Linear Exi + HART®
Position sensing
Potentiometer sensor
Stroke length
10 ~ 120mm
Valve characteristics
Linear, Equal %, Inv Equal%, free adjustment
Actuator type
Single-acting, linear pneumatic actuator
1> MF series
2> U series
Control input (SP)
4~20mA, 2-wire with HART®
Linearity
± 1% of span
Hysteresis
1% of span
Display
Custom alphanumeric LCD with bar graph
User input
Via tactile keys; requires the cover to be open
Operating Power
(To maintain current ≥ 3.4mA)
Powered from the 4~20mA control input signal
Compliance voltage ≥ 9VDC (load ≤ 450 Ω) for Exi with HART
Compliance voltage ≥ 8VDC (load ≤ 400 Ω) for Non-Exi with HART
Ambient temperature Ta
[-] 25°C ~ [+] 80°C
Pneumatic input
1.5 ~ 7 bar pressure
Air consumption
0.023 m3/h at 6 bar inlet air pressure
Air capacity
>130 LPM (7.8 m3/h) @ 6 bar
Air quality
Filtered with a 5 micron filter
Dried according to ISO8573-1: 2010 Class 3.3.3 or ISA S7.0.01
Position Transmitter & Communication (optional)
Position transmitter
Passive 4~20mA output
External power supply
Vs = 18~30 VDC max, RL(Ω) (max) = [Vs - 10V]/20mA
Temperature stability
0.2% / 10°K of output current full scale
Accuracy (Iout)
± 0.25% of Span
Communication
HART® [1] over Control Input signal
Note: [1] Device Specific commands using communicator specified by Forbes Marshall Pvt. Ltd.
Enclosure
Housing
Aluminium pressure die cast
Weight
2.3 kg approximately
Dimensions
Refer Mechanical Dimensions
Connections
Weather proof
Terminations
Screw type, for 1mm2 conductor termination
Cable gland
M20 x 1.5mm
Single compression
Cable specs
Control input and Feedback: Shielded 2 core, 1mm2 each conductor,
7~12mm OD
Pneumatic connection
1/4" NPT
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 25
Approvals
Ingress protection
IP 66 Conforms to IEC60529
Certification EMI EMC
Conforms to IEC61326-1
Intrinsic Safe System Approval : Ex ia IIC T6 Gb (‐20°C ≤ Ta ≤ +50°C)
Standards referred
IS/IEC 60079-0:2014, IS/IEC 60079-11:2011
Vibration
Conforms to IEC60068-2-6
6.1 Positioner variants and nomenclature guide:
Product Name
smartPOZ+
Actuator Type
Linear
L
Rotary
R
Actuator Action
Single Acting
S
Double Acting
D
Fail Mode
Fail Safe
FS
Fail Freeze
FF
HART®
HART®
H
Non HART®
N
Output
Transmission
T
Non Transmission
N
Safety
Weather Proof
W
Exi
X
Exd
D
Housing
Aluminium
A
SS
S
Plastic
P
Example
Product
Name
Actuator
Type
Actuator
Action
Fail
Mode
HART® Output
Safety
Housing
smartPOZ+
L
S
FS
H
T
X
A
Model Name
smartPOZ+ L-S-FS-H-T-X-A
-
Linear actuator
-
Single Acting actuator
-
Fail Safe mode
-
HART® communication protocol
-
Transmission of output
-
EXi - Intrinsically safe
-
Aluminium housing
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 26
7. KEY OPERATION
7.1 Plunger Operated Tactile Keys
WARNING
Unscrew the Phillips screws to open the cover. Disconnect the cables and properly insulate the open ends.
Move the control unit to a designated Safe Area for further operations.
The three tactile keys are located on the main PCB, around the LCD display module. Operate the keys with
your fingers, taking care not to touch any other parts on the electronics PCB.
8. DISPLAY& MODES
CAUTION
Read the section ‘KEY OPERATION’, before proceeding with the reading of this section!
8.1 Display Fields
The LCD display has four fields, broadly referred to as Main, Index, Sub and Bar.
8.2 Run Mode
Use the key to move from a displayed parameter to the next.
Trvel – indicates the current travel of the spindle as a percentage of maximum stroke length
D Trv – indicates the desired travel or the input setpoint as a percentage of full scale
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 27
8.3 Configuration Mode
To access this mode, you have to enter the User Password by following a certain key sequence. Press
the
key until the display enters Config Menu. The smaller field at the bottom left shows the Menu
Number. The longer field at the bottom shows the Menu Title. The larger field on the top shows the Type of
menu you are in.
For details of the available configuration parameters please see sub-section Menu option under section
SOFTWARE FEATURES.
NOTE
This mode is accessible via Service Password only to Forbes Marshall Service Engineer. Unauthorized
persons should not attempt to access this mode.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 28
9. SOFTWARE FEATURES
9.1 Menu
The user interface enables following settings via the three tactile keys. Pressing the DN key for 5 sec
continuously triggers the User Menu
Menu
No.
Menu
Parameter
Specification /
Options /
Parameter Values
Function / Description
1
MltFn
Multifunction
Z ADJ
PoSn
Move the positioner UP slowly during installation
PoSn
Move the positioner DN slowly during installation
donE
Hold and fix the positioner using nuts
SwVEr
SoFt
Displays Software Version
xxxxx
EXIT
Exits from Configuration Menu
2
ScheK
Sensor check
PM-PV
xxxx
PM-PV
Piezo-Pilot valve testing with Pot ADC count (Ref. Page
18) . Use UP-DN key to move spindle up-down
InP P
xxxx
InP P
Inlet pressure sensor ADC count checking by providing
air pressure
OutP1
xxxx
OutP1
Outlet-1 pressure sensor ADC count checking by
providing air pressure
OutP2
xxxx
OutP2
Outlet-2 pressure sensor ADC count checking by
providing air pressure
I/P I
xxxx
I/P I
Input current ADC count check
Pfail
xxxx
Pfail
Power fail ADC count check
T SEN
xxxx
T SEN
Temperature sensor ADC count check
EXIT
EXIT
Exit from sensor check
3
SPL S
Spindle length
and valve friction
SPNDL
xxxx
SPNDL
Spindle length ( 10 ~ 120mm)
FRICT
LOW_F
Low friction
MID_F
Mid level friction
HII_F
High friction
VND V
YES
Will enable VND (Variable nozzle de-super heater)
no
Will disable VND (Variable nozzle de-super heater)
BS/EX
YES
Will enable Booster and/or Quick Exhaust
no
Will disable Booster and/or Quick Exhaust
EXIT
EXIT
Exit from spindle length and valve friction menu
4
CNT U
Control Input
Unit –Setpoint
unit selection
D Trv
Expected travel (%)
ma Ip
Input Current (mA DC)
5
TRV U
Travel Unit - Sets
mode of
displaying travel
Units
Trvel
Stem Travel (%)
ma Op
Output Current (mA DC)
mmPOS
Stem Travel (mm)
6
P/T D
Pressure and
temperature
P1bar
Inlet pressure
P2bar
Outlet pressure
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 29
display
Ipbar
Inlet pressure
DegC
Temperature
Dp ON
Enables display of parameters
Dp OFF
Disables display of parameters
7
SPDIR
Spindle Direction
RISE/FALL
Sets Stem Direction in relation to Set Point direction
RISE – Stem rises with rising Set Point
FALL – Stem falls with rising Set Point
8
VCHAr
Valve Control
characteristic
Linear, Equal %,
On-Off
Sets valve Control Characteristic
LnEAR
Equal Percentage
Options: EP 30, EP 40, EP 50
EPCst- Equal Percentage customized
Settable: within the range 20 to 55
IEP - Inverse Equal Percentage
Options: IEP30, IEP40, IEP50
InCst– Inverse Equal Percentage customized
Settable: within the range 20 to 55
F ADJ - Freely adjustable from 4~20mA
17 individual freely settable Control Input points over
range 4~20mA (0-100%) in 1mA step
9
VALVE
Control valve and
Pilot Valve
classification
Linear/ Rotary
Sets the classification of the valve
LnEAR – SAFS / SAFF / DAFS / DAFF
Rotry – SAFS / SAFF / DAFS / DAFF
10
IRSET
Input Range
Setting
Sets the Control Input current range. This function can
be used to achieve Split Range feature. For e.g. One
smartPOZ+ positioner can have a range of 4~12mA
and the cascaded second smartPOZ+ positioner can
have 12~20mA.
St mA - Sets lower end current value (mA)
St VL- Sets lower end of Travel (%) corresponding to St
mA
EndmA - Sets upper end current (mA)
EndVL - Sets upper end of Travel (%) corresponding to
End mA
11
P CAL
Control valve
calibration and
tuning
A 2Pt/ M 3Pnt/ M
5Pnt/ EXIT
Selects 1 of 3 types of Calibration or only Tuning.
A 2Pt – performs 2-point auto calibration
M 3Pt – performs 3-point manual calibration
M 5Pt – performs 5-point manual calibration
EXIT – Exit this Menu
12
PWord
User password
Yes/No
Enables or Disables the need to enter User Password
(any sequential combination pattern of 5 keys)
Yes – enables
No – disables
13
F CFG
Factory default
config data
FACd - Yes/No
Sets all configuration data to Factory Default value if
required under certain situations.
USE THIS OPTION WITH DUE CAUTION as it will
erase all configuration data.
FACd – Store factory default / reset data
Store/Reset
SurE
Yes – will set configuration values to Default
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 30
No – will retain the present configuration values
14
C DSP
Cyclic Display
Yes/No
Sets mode of display
Yes – sets to Cyclic mode
No – sets to static mode
15
E MSG
Message display
Yes/No
Enables or Disable the displaying of Messages [3]
Yes – enable
No – disables
16
CtyPE
Control response
type
OPTxx
Sets the Response Rate of the system
OPT-4 - Slowest
OPT-3- Slow level 3
OPT-2- Slow level 2
OPT-1- Slow level 1
OPT- Normal
OPT+1 – Fast level 1
OPT+2 – Fast level 2
OPT+3 – Fast level 3
OPT+4 – Fastest
In case of a slow response, select lower OPT levels of
OPT-1 to OPT-4.
In case of a fast response, select higher OPT levels
OPT+1 to OPT+4.
17
TCLOs
Tight Close
AEXIT/ AFILL/
NORML
Sets Normal or nature of Tight Close
AEXIT – Tight close by Air Exit
AFILL – Tight close by Air Fill
NORML – As per control
18
DSENS
Displayed sense
OPEN, CLOSE
Sets the sense of the displayed Travel
OPEN – shows the Travel (TrveL/ma Op/mm POS) in
terms of being open.
CLOSE - shows the Travel (TrveL/ma Op/mm POS) in
terms of amount of closure.
19
P ADR
HART® Polling
address
Sets the HART® Polling address for the device
Address range: 0 ~15
20
I RNG
Output current
alarm range
4_20I/ 22IEr/
3I5Er
4_20I – 4~20mA with no error indication
22IEr – 4~20mA, parked at 22mA in case of error
3I5Er – 4~20mA, parked at 3.5mA in case of error
21
DgPrm
Diagnostic
parameters
Number of
A count which is incremented once every 100 direction
changes of the spindle
SPL/D– Spindle direction changes per day
SPT/D – Setpoint direction changes per day
SSD/D – Daily setpoint reversals
OPH/D – Operational hours per day
UPV/S – Up velocity
DNV/S – Down velocity
WR/TR – Wear and tear of the valve in mm
FR/ST – Friction / Stiction
HUNTG – Hunting in percentage (%)
Ccntr – Number of calibrations done till date
Ctime – Time taken for last calibration
22
PSTRK
Partial stroke - %
stoke / time in
hrs
PtSt
No/Yes
ItHrs
Set the interval in hours
StrkP
Set the stroke position
23
PozLm
Software limit
Software limit
Displays the software limit switch position in %
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 31
switch
percentage
switch (%)
24
MODEL
Factory set - Not
editable
Displays the positioner model as configured at FM
factory
25
SPAdJ
Span Calibration
xxxx END2
Adjust the span value using UP-DN keys
26
DavFS
Double Acting
Valve fail safe
selection
Selects the type of failsafe for double acting valve
Dnrml – Normal as per control
ATCFS – Air- to - close failsafe
ATOFS – Air - to - open failsafe
9.2 Quick Menu
Quick Manual and Quick Auto modes [3]
We strongly recommend that the unit be configured to run in Auto mode. However, under emergency
situations that require quick switchover to Manual mode, the following option is available:
While in Auto mode, to switch to Quick Manual mode without going through the Menu, keep the ‘UP’ key
pressed until the unit switches over to the Manual mode. The setpoint will remain held at the last value as
captured while in the Auto mode. Using, RIGHT and UP keys the user can decrement or increment
respectively the setpoint.
While in Quick Manual mode, to switch back to Auto mode without going through the Menu, keep the
‘ENTER’ key pressed until the unit switches over to the Auto mode. The setpoint will hereafter follow the
control input. In case of a power cycle, the unit always returns to Auto mode after power resumption;
irrespective of whether it was in Quick Manual mode or Auto mode.
10.
PUTTING INTO OPERATION
10.1 Configuration
The smartPOZ+ positioner would come pre-configured with the settings meant for the type of actuator
on which it is mounted. Therefore, if a change is required, the user should modify settings after due care
and understanding.
10.2 Powerup and Run
After power up you will see information in the following sequence
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 32
Note that the third screen displays the current software version in the format *_*_*
The smartPOZ+ Positioner will then enter the dynamic run mode and start the control action as per
applied set point or desired position. The data to be displayed can be selected using the UP key.
D Trv: Desired position in percentage or the setpoint. This is displayed as –
Desired Travel
Actual Travel
NOTE
In this mode, the smaller digits at the bottom left corner indicate the Actual Travel, however
with a reduced resolution of 1 unit. The larger digits on the top indicate the Desired Travel.
Other run-time screens can be -
Trvl: Actual travel of stem in percentage
Actual Travel
The bar indicator shows the percentage opening
Pressing the
key forat least 4 seconds invokes the Config Mode. It should be noted that the device
does not respond to changes in setpoint in Config Mode. Therefore, the user is advised to put the
SmartPOZ+ Positioner in Run mode before checking the performance.
NOTE
No activity in the Config Mode for about 60 seconds, (except when it is in calibration) brings the
smartPOZ+ Positioner back to the Run Mode. Therefore, the user should save all data before leaving
the smartPOZ+ Positioner unattended in the Config Mode. This will ensure that no new
calibrated/programmed data is lost.
10.3 Self-Calibration – Air to Open
IMPORTANT NOTE
The various options of the Calibration procedure explained below are to be performed only in case the
Positioner is part of the individual stand-alone supply and not pre-mounted on the valve-actuator from
FMPL.
While calibrating the positioner, do not hold or place tools made of magnetic material, Walkie
Talky, Mobile Phones within 1m range of the positioner.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 33
Follow these steps for calibrating the device –
Confirm the presence of operating air supply as per specifications
Check the alignment of the potentiometer linkage assembly. Ensure that it is aligned to the
coordinates as per the installation.
Select the Sensor type, Stroke length and other parameters as required for the actuator/valve
application. Refer to the section Config Mode for details.
Via Menu 2, PiJO VOLT option, move the spindle 3-4 times across the complete stroke length. This
will help to free the spindle movement if the valve has not been used for a long time.
Return to the Run Mode.
Press
key until the unit enters configuration mode. Using key go to Menu 11.
Press
. Using key you will see 3 calibration options.
Followed by an Exit option
10.3.1 Manual 3 Point Calibration
Using select 3 Point calibration.
Press
.
The display will toggle between the following screens.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 34
Wait for the spindle to reach the zero position.
Reset the Dial gauge to zero.
Press
.
The display will progress through the following screens sequentially.
----------------------------------------
In case VND option has been set via Menu 3, the following additional screen will appear.
Set the extreme end-2 using
and
keys such that the pressure indicated on the Output Gauge
does not exceed the specified actuator pressure.
Then press
.`
----------------------------------------
As per the required stroke length set this value using and
keys. Each press of the key will cause
a rise or fall by 0.5% of spindle length. For example, for a nominal 30mm length of spindle set a
value of 31.6mm if that is the maximum possible physically as seen from the dial. Then press
.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 35
Next, set the value on the display equal to the set dial value using and
keys
Then press
.
Then press ENTER. Then -
Wait until the MAIN display value is almost equal to the bottom SUB value of 50.
On the Dial, adjust the position to 50% (15.8mm) of the required stroke length (31.6mm) using
and
keys. Each press of the key will cause rise or fall by 0.5% of spindle length.
Then press
.
The display will progress through the following screens sequentially.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 36
Display will momentarily show that the configuration is being updated and then return to Run
mode.
10.3.2 Manual 5 Point Calibration
Go to Menu 11
Using select 5 Point calibration.
Press
.
The display will toggle between the following screens.
Wait for the spindle to reach the zero position.
Reset the Dial gauge to zero.
Press
.
The display will progress through the following screens sequentially.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 37
----------------------------------------
In case VND option has been set via Menu 3, the following additional screen will appear.
Set the extreme end-2 using
and
keys such that the pressure indicated on the Output Gauge
does not exceed the specified actuator pressure.
Then press
.`
----------------------------------------
As per the required stroke length set this value using and
keys. Each press of the key will cause
rise or fall by 0.5% of spindle length. For example, for a nominal spindle length of 30mm set a value
of 31.6mm if that is the maximum possible physically as seen from the dial. Then press
.
Next, set the value on the display equal to the set dial value using and
keys
Then press
.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 38
Then press ENTER. Then -
Wait until the MAIN display value is almost equal to the bottom SUB value of 50.
On the Dial, adjust the position to 50% (15.8mm) of the required stroke length (31.6mm) using
and
keys. Each press of the key will cause rise or fall by 0.5% of spindle length.
Then press
.
The display will progress through the following screens sequentially.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 39
Display will momentarily show that the configuration is being updated and then return to Run
mode.
10.3.3 Auto 2 Point Calibration
Go to Menu 11
Using select Auto 2 Point calibration.
Press
.
The display will progress through the following screens sequentially.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 40
Display will momentarily show that the configuration is being updated and then return to Run
mode.
10.3.4 Aborting self-calibration with a key press
•
Self-calibration can be aborted at any point of time by pressing
key for more than 5 seconds.
•
Program shall terminate and exit to control action without saving any parameters. User will need to
enter user menu again to initiate self-calibration.
•
The program shall terminate and display Abort for 2 seconds and exit to control action.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 41
10.4 Self-Calibration – Air to Close
IMPORTANT NOTE
The various options of the Calibration procedure explained below are to be performed only in case the
Positioner is part of individual stand-alone supply and not pre-mounted on the valve-actuator from
FMPL.
While calibrating the Positioner, do not hold / use or place tools made of magnetic material, Walkie-
talky, mobile phones within 1m range of the Positioner.
Follow these steps for calibrating the device:
Confirm the presence of operating air supply as per specifications
Check the alignment of the potentiometer linkage assembly. Ensure that it is aligned to the
coordinates as per the installation.
Select the Sensor type, Stroke length and other parameters as required for the actuator/valve
application. Refer to the section Config Mode for details.
Via Menu 2,PiJO VOLT, move the spindle 3-4 times across the complete stroke length. This will help
to free the spindle movement if the valve has not been used for a long time.
Return to the Run mode.
Press
key until the unit enters configuration mode. Using key go to Menu 11.
Press
. Using key you will see 3 calibration options.
Followed by an Exit option
10.4.1 Manual 3 Point Calibration
Using select 3 Point calibration.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 42
Press
.
The display will toggle between the following screens.
Wait for the spindle to reach the zero position.
Reset the Dial gauge to zero.
Press
.
The display will progress through the following screens sequentially.
----------------------------------------
In case VND option has been set via Menu 3, the following additional screen will appear.
Set the extreme end-2 using
and
keys such that the pressure indicated on the Output Gauge
does not exceed the specified actuator pressure.
Then press
.
----------------------------------------
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 43
As per the required stroke length set this value using and
keys. Each press of the key will cause
rise or fall by 0.5% of spindle length. For example, for a nominal 30mm spindle length you may set a
value of 31.6mm if that is the maximum possible physically as seen from the dial. Then press
.
Next, set the value on the display equal to the set dial value using and
keys
Then press
.
Then press ENTER. Then -
Wait until the MAIN display value is almost equal to the bottom SUB value of 50.
On the Dial, adjust the position to 50% (15.8mm) of the required stroke length (31.6mm) using
and
keys. Each press of the key will cause rise or fall by 0.5% of spindle length.
Then press
.
The display will progress through the following screens sequentially.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 44
Display will momentarily show that the configuration is being updated and then return to Run
mode.
10.4.2 Manual 5 Point Calibration
Go to Menu 11
Using select 5 Point calibration.
Press
.
The display will toggle between the following screens.
Wait for the spindle to reach the zero position.
Reset the Dial gauge to zero.
Press
.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 45
The display will progress through the following screens sequentially.
----------------------------------------
In case VND option has been set via Menu 3, the following additional screen will appear.
Set the extreme end-2 using
and
keys such that the pressure indicated on the Output Gauge
does not exceed the specified actuator pressure.
Then press
.
----------------------------------------
As per the required stroke length set this value using and
keys. Each press of the key will cause
a rise or fall by 0.5% of spindle length. For example, for a nominal 30mm spindle length you may set
a value of 31.6mm if that is the maximum possible physically as seen from the dial. Then press
.
Next, set the value on the display equal to the set dial value using and
keys
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 46
Then press
.
Then press ENTER. Then -
Wait until the MAIN display value is almost equal to the bottom SUB value of 50.
On the Dial, adjust the position to 50% (15.8mm) of the required stroke length (31.6mm) using
and
keys. Each press of the key will cause rise or fall by 0.5% of spindle length.
Then press
.
The display will progress through the following screens sequentially.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 47
Display will momentarily show that the configuration is being updated and then return to Run
Mode.
10.4.3 Auto 2 Point Calibration
Go to Menu 11
Using select Auto 2 Point calibration.
Press
.
The display will progress through the following screens sequentially.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 48
Display will momentarily show that the configuration is being updated and then return to Run
Mode.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 49
10.4.4 Aborting self-calibration with a key press
•
Self-calibration can be aborted at any point of time by pressing
key for more than 5 seconds.
•
Program shall terminate and exit to control action without saving any parameters. User will need to
enter user menu again to initiate self-calibration.
•
The program shall terminate and display Abort for 2 seconds and exit to control action.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 50
11.
MAINTENANCE SCHEDULE
11.1
Regular maintenance
Regularly drain the condensate accumulated in the condensate separator of the compressed-air
pressure-regulator assembly.
Inspect the compressed air quality after any maintenance activity on the compressor/ line and
ensure it is oil and moisture free; see specifications.
Check for leakages and seal any leakages in the inlet and outlet pneumatic tubing and joints.
Once a year replace sintered bush exhaust.
11.2
Annual re-calibration
Once a year recalibrate the SmartPOZ+ positioner following the Manual 3-Point calibration
procedure explained under the sub-section Positioner Calibration.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 51
12.
TROUBLE SHOOTING
Before operating the Positioner perform the pre-power-up checks, maintenance checks and follow
all Warnings and Notes.
Listed here are some common observations with possible causes & steps to take corrective actions to
help rectify problem.
NOTE
Please read the contents of this table in conjunction with the following Chapters/Sections
- Specifications
- Software Features/ Menu
- Electrical connections
- Installation/ Mechanical installation
Sr.No. Observation/Symptom
Cause
Corrective Action
1
smartPOZ+ Positioner
is not Turning 'ON'
Compliance voltage is less than
specified
Check & provide Compliance voltage as
recommended (Vmin~24VDC) &
confirm.
Input wires I/P+ & I/P- are not
connected or are open
Check & connect wires with correct
polarity then confirm.
Input wires I/P+ & I/P- polarity (+/-)
reversed
Correct polarity & confirm.
High water & oil content in Supply Air
Instrument supply air should be free
from dust, water/ moisture & oil
conforming to the specifications of air
quality as according to ISO8573-1: 2010
Class 3:3:3 or ISA S7.0.01. Provide
specified quality Supply Air & confirm.
Input I/P+ & I/P- electrical loop
(4~20mA) not complete.
Perform loop test. If required correct it
& confirm.
2
Display ‘OFF’ or
frequently turning 'ON-
OFF-ON'
High water & oil content in Supply Air
Instrument Supply Air should be free
from Dust, Water/ moisture & Oil
conforming to the specifications of air
quality according to ISO8573-1: 2010
Class 3:3:3 or ISA S7.0.01. Provide
specified quality supply air & confirm.
Input wires I/P+ & I/P- are not
connected or are open.
Check & connect wires with correct
polarity then confirm.
Input wires I/P+ & I/P- polarity (+/-)
reversed.
Correct wires polarity & confirm.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 52
Sr.No. Observation/Symptom
Cause
Corrective Action
3
smartPOZ+ Positioner
does not respond to
Control Input signal (set
point)
High water & oil content and dust in
Supply Air
Instrument Supply Air should be free
from Dust, Water/ moisture & Oil
conforming to the specifications of air
quality according to ISO8573-1: 2010
Class 3:3:3 or ISA S7.0.01. Provide
specified quality supply air & confirm.
Input Supply Air pressure is not
available or less than specified on
Actuator Nameplate.
Provide Supply Air Pressure as
recommended on Actuator Nameplate
& confirm.
4
Valve does not achieve
full lift during normal
operation
Insufficient Supply Air Pressure
1] Provide Supply Air Pressure as
recommended on Actuator Nameplate
& confirm.
2] If problem persists, check for Valve /
Actuator problems as mentioned in
Valve User Manual.
Calibration not done properly.
Re-perform Manual 3 Point calibration
as described in the Manual.
Setpoint calibration (4 ~ 20mA) not
done properly
Command input current mismatch
Leakage in Pneumatic circuit.
Perform Soap-Bubble test and seal the
leak.
5
Valve movement too
Slow/Fast
Insufficient Supply Air Pressure
1] Provide Supply Air Pressure 1bar in
excess of that recommended on
Actuator Nameplate& confirm.
2] If problem persists, check for Valve /
Actuator problems as mentioned in
Valve User Manual.
Control Response setting is not set as
required.
Set control response-rate option via
Menu 16 as required & confirm.
(Select option (+/-) 1 to 4 as required to
make the movement Fast or Slow)
Control parameters are not tuned
correctly.
Via Menu 11 perform Auto 2 Point
Calibration.
Valve stem friction too high
Check stem alignment & corrosion
to valve stem.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 53
Sr.No. Observation/Symptom
Cause
Corrective Action
6
Calibration procedure not
possible
Check error number on display .
Confirm settings & correct if required.
Check if handwheel is locked/ low inlet
pressure/high friction of valve stem/
heavy leakage in actuator
diaphragm/bush/ incorrect installation
of positioner . Rectify and then perform
calibration. Menu numbers for
reference: Actuator Series -3, Set Point
Direction - 7, Control Valve
Characteristics - 8, Current Range
Setting- 10, Tight close setting - 17
Input Air pressure not as required by
the valve actuator as per Valve Data
sheet/ Actuator Nameplate.
1] Instrument Supply Air should be free
from Dust, Moisture & Oil as specified.
Provide specified quality Supply Air &
confirm.
2] Confirm & provide Supply Air
Pressure as recommended on Actuator
Nameplate & confirm.
7
Spindle hovering around
the set point / loss of
linearity
High friction and / or jerky movement
/ sticky valve stem
Rectify cause.
Backlash between positioner lever and
stem link due to incorrect installation
Install positioner correctly
Input Air pressure not as required by
the valve actuator as per Valve Data
sheet/ Actuator Nameplate.
1] Instrument Supply Air should be free
from Dust, Water/ moisture & Oil
conforming to the specifications of air
quality according to ISO8573-1: 2010
Class 3:3:3 or ISA S7.0.01. Provide
specified quality Supply Air & confirm.
2] Confirm & provide Supply Air
Pressure as recommended on Actuator
Nameplate & confirm.
8
Leakage observed even
when the valve is closed.
Tight-close setting disturbed.
Confirm settings via Menu 17 & correct
if required. Then confirm that there is
no leakage.
Calibration not done properly.
Re-perform Auto 2 Point calibration &
confirm.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 54
Sr.No. Observation/Symptom
Cause
Corrective Action
9
Re-transmission current
output not functioning.
External DC supply as specified not
connected or polarity of supply wires
reversed.
1] Provide Supply Voltage as specified &
confirm.
2] Correct polarity of wires & confirm.
3] Check Model via Menu-24 to confirm
that the Model supports Current Output
as indicated by the ‘T’ in
SmartPOZ+ L-S-FS-H-T-*-*
If problems persist in spite of taking
suggested corrective actions, call
FORBES MARSHALL SERVICE CENTER.
12.1 Error codes:
The Positioner indicates certain run-time conditions as error codes on the display. The description of
each error code follows.
ERROR 1 : Low compliance voltage
ERROR 2 : Piezo Voltage low
ERROR 3 : Feedback Potentiometer fail
ERROR 4 : Pilot Valve or related electronic section has problem
ERROR 5 : Atmosphere temperature out of range
ERROR 6 : Supply air pressure fail
ERROR 7 : Supply air pressure low
ERROR 8 : Outlet pressure to actuator-1 is low
ERROR 9 : Outlet pressure to actuator-2 is low
ERROR 10 : Potentiometer count below minimum limit
ERROR 11 : Potentiometer count above maximum limit
ERROR 12 : Potentiometer span below minimum limit
ERROR 13 : Stroke value out of range
ERROR 14 : Calibration time above maximum limit
ERROR 15 : Tuning time above maximum limit
ERROR 16 : Spindle stuck
ERROR 17 : Partial stroke event fail
ERROR 18 : Configuration data corrupt
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 55
12.2 Warnings:
Warning 1 : Input Current below minimum limit
Warning 2 : Input Current above maximum limit
Warning 3 : Output Current below minimum limit
Warning 4 : Output Current above maximum limit
Warning 5 : Supply pressure below minimum limit
Warning 6 : Supply pressure above maximum limit
Warning 7 : Outlet pressure to Actuator – 1 count is below minimum limit
Warning 8 : Outlet pressure to Actuator - 1 count is above maximum limit
Warning 9 : Outlet pressure to Actuator – 2 count is below minimum limit
Warning 10 : Outlet pressure to Actuator - 2 count is above maximum limit
Warning 11 : Air leak detected
Warning 12 : Friction / Stiction high
Warning 13 : Hunting range out of limit
Warning 11 : Valve seat wear/tear detected
Warning 15 : Self test running/ Calibration running
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 56
13.
HART® Communication
13.1 Downloading EDD and FDI files
The EDD and FDI files of the smartPOZ+positioner should be downloaded from HART® Registered
Products of the FieldComm Group: https://www.fieldcommgroup.org/ . There are two methods to
communicate with the smartPOZ+ on HART® :
-
Using a hand-held communicator - HART® 475 or later
-
Using a PC – based the software FDI package IDE - Release 1.5.0 or later
The smartPOZ+ positioner supports the following HART® commands:
13.2 Operating Mode
Command
Displayed parameter
Read unique identifier
Travel
Read primary variable
Setpoint
Read loop current and percent of range
Temperature
Read dynamic variable and PV current
Inlet pressure
Read loop configuration
Outlet pressure - 1
Read device variable classification
Outlet pressure - 2
Read device variable with status
Device status
Read unique ID associated with tag
Read PV Transducer/Sensor Information
Read Device Information
Read Unique Identifier associated with Long Tag
13.3 Configuration Mode
Command
Write Polling Address
Read Message
Read Tag, Descriptor, Date
Read Final Assembly Number
Write Message
Write Tag, Descriptor, Date
Write Final Assembly Number
Read Long Tag
Write Long Tag
Reset Configuration Changed Flag
Write PV Damping Value
Write PV Range Values
Read set point source and value
Write set point source and Value
Read sensor type and valve-actuator related data
Write sensor type and valve-actuator related data
Read Type of Pilot-valve
Write type of Pilot-valve
Read Basic Valve Configuration like valve direction and valve flow characteristics.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 57
Write Basic Valve Configuration like valve direction and valve flow characteristics.
Read software limit for actual displacement of valve
Write software limit for actual displacement of valve
Read unit and range of input mA source for split range
Write unit and range of input mA source
Read Partial stroke Data.
Write Partial stroke Data.
Read PID parameters.
Write PID parameters.
Read Configured Positioner features.
Write specific features of positioner to configure the valve performance as per requirement.
Read value of free adjustable characterization of valve
Write value of free adjustable characterization
Read Dynamic variable assignments
Write Device variable unit
Read Device variable information
Write Number of Response Preambles
13.4 Calibration Mode
Command
Auto valve Calibration
Input current calibration
Output current calibration
Pressure sensor calibration
Temperature sensor calibration
13.5 Diagnosis Mode
Command
Read Factory Data
Read Diagnosis features of smartPOZ+
Read Additional Device Status
Perform Device Reset
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 58
14.
External Communication
This section will guide you to understand smartPOZ+ additional value-added features like
diagnostics using HART Host Connectivity.
HART is a bi-directional communication protocol that provides data access between intelligent
field instruments and host system. A host can be software application from PC or laptop
connected to plants process control platform or system using any control platform or handheld
instrument.
Forbes Marshall smartPOZ+ works with different Host communication platforms as below,
•
EDD HART HOST (Ver 7.0 and above)
•
Handheld Communicator – TREX/475 Field Communicator
•
FM Valve Signature Application
•
FM RTU201- with EVERSENSE Application
We will go through each HART communication platform details in the next sections.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 59
14.1
EDD HART HOST (Ver 7.0 and above)
Basic requirements to work with EDD HART HOST are as follows
• HART Complied Device
• FDI EDD
• HART HOST Reference Run Time environment
• HART Modem
• PC/Laptop
HART HOST Connectivity Steps are as follows –
• FDI EDD - The EDD and FDI files of the smartPOZ+ positioner should be downloaded
from HART® Registered Products of the FieldComm Group link
: https://www.fieldcommgroup.org/ .
• Open HART HOST Reference Run Time environment. Select COM PORT (PC/Laptop)
and HART Device Address.
• Connect HART Complied device with PC/Laptop via HART Modem.
• Import EDD into HART HOST
• Run the Environments.
14.2
Handheld Communication by using TREX /475 Field Communicator
Basic requirements to work with Handheld TREX/ 475 Field communicator -
•
Download EDD file of TREX/475 Field Communicator from online data
download link https://www.fieldcommgroup.org/
• Upload into Handheld Communicator.
• Run the Environments.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 60
14.3
Valve Signature Application
smartPOZ+ Valve signature Application comes with advanced diagnostics features, which helps
user for predictive and preventive maintenance of the Positioner, Actuator and Valve.
Download Valve signature Application software file from the FM data download link and install
the software on your laptop or Desktop.
After Installation of software,
•
Connect smartPOZ+
•
Open the smartPOZ+Valve signature Application software and connect by adding
communication port short address.
smartPOZ+ Valve signature Application comes with different screens for configuration,
Calibration, observations and analysis of data.
Valve Signature Application having different menu options as below,
•
Parameter View
•
Trends
•
Partial Stroke
•
Valve Signature
•
Calibration
•
Diagnostics
Application Parameter View screen shot as shown below for user reference.
Parameter View –
As shown in the above screenshot smartPOZ+ Parameter View. It gives details of smartPOZ+
unit under test parameters like, Device Tag Name, Model Name and Actuator type, it will show
different 16 parameters available for view, as well as about 7 parameters (*) are available for
data logging. From same screen user can ‘Start Data Logging’ and can ‘View Logged Data’, as
well as can select other menu options as per requirements. It includes comm parameters (Comm
port, Short Address) and communication status (Connect, Disconnect) and software version
number also on same screen.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 61
Trends –
Total 7 different trends as below are available as per user requirements Time/Date vs %.
•
Actual Travel
•
Dezire Travel (Setpoint)
•
Supply Air Pressure
•
Outlet Pressure to Actuator
•
Device Temperature
•
Velocity Upward Direction
•
Velocity Download Direction
Configure –
Configuration screen for Device Configuration, Actuator Configuration, Setpoint Configuration as
below,
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 62
Partial Stroke –
Configuration screen for Partial Strok Disable or Enable Auto or Manual mode. Configured
parameters are observed like Time interval for Partial Strokes (Days) and Partial Strok Value
(%) as below,
Valve Signature –
For Control Valves, the Pattern, how it opens and close is unique to each type of control valves.
This pattern can be used for Valve Dignostics, which is called as ‘Valve Signature’.
For smartPOZ+ have this Valve signature is an additional Diagnostics feature.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 63
SmartPoz+ with Valve Signature software have Diagnostics feature available as below,
•
Facility to check factory set values vs current values
•
View Step Response
•
View Valve Signature
Check factory set values vs current values - example as below,
View Step Response option
To view Step response, user to select one of Plot of option and Test1 or Test 2 calendar option
as required.
User can view different plots as below,
•
Setpoint, Travel v/s Time
•
Pressure v/s Time
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 64
Setpoint v/s Time - example as below,
Pressure v/s Time - example as below,
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 65
View Valve Signature option
To view Valve Signature , user to select one of Plot of option and Test1 or Test 2 calendar option
as required.
User can view different plots as below,
•
Pressure v/s Travel
•
Pressure v/s Time
Pressure v/s Travel - example as below,
Pressure v/s Time - example as below,
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 66
Calibration –
Calibration screen will be as below – Here Calibrations values at Factory and current are
available for user’s ref. as well as user can perform Valve Calibration after clicking ‘Start Valve
Calibration’ button.
Diagnostics –
Diagnostics screen will be as below – Here for Positioner, Actuator and Valve - errors and
warnings are listed with the status indication LED. Here LED will be ON with RED colour means,
the particular error or warning condition observed.
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 67
14.4
RTrU301
HART® devices have the capability to operate in one of two network configurations: Point-to
point connection or Multi drop mode. Using the polling address structure of the HART®
protocol, the polling address of the field devices will vary in a range of 0 ~ 4.
The RTru301 IoT Gateway device Read 5 types of HART® variable: Primary Variable (PV),
Secondary Variable (SV), Third Variable (TV), and Fourth Variable (QV), unit of each variable
and Loop current and another of 4 variables s below,
PV – Desired Travel (Setpoint)
SV – Actual Travel
TV – Device Temperature
QV – Wear and Tear
Other Variables -
Outlet Pressure to Actuator -1
Outlet Pressure to Actuator -2
Supply Air Pressure
Valve in Operation (yy:mm:dd)
Error and Warnings for Diagnostics – Information will be available same as per listing 12.1,
12.2 and 13.5 above.
The RTru301 device sends a request to HART® slave device based on the Polling ID set. The
RTru301 device sends a HART® request to next slave based on the time(in seconds) set in
HART® Query Time parameter. The Query response time is used to set the RTru301 waiting
time for the response from the HART® slave device. The Query attempt is used to set the no.
of requests sent to the HART® slave device when no response is received.
The button ‘Get Device Data‘ is used to show information of connected devices. The RTru301
Device can change the Polling Address of the HART® slave device.
Follow the steps below to change the polling ID of any HART® slave device:
1. Write new Polling ID in ‘Polling ID’ input box that you want to change
2. Pressing the ‘Change’ button, the RTru301 device changes the Polling ID of HART® slave
device
________________________________________________________________________________________________________________________smartPOZ+ User’s Manual 68
Copyright Notice
© All rights reserved. Any reproduction or distribution in part or as a whole without written
permission of Forbes Marshall Pvt. Ltd., its associate companies or its subsidiaries (“FM Group”) is
prohibited.
Information, designs or specifications in this document are subject to change without notice.
Responsibility for suitability, selection, installation, use, operation or maintenance of the product(s)
rests solely with the Customer and/or user.
Forbes Marshall Pvt. Ltd.
B-85, Phase-II, Chakan Industrial Area
Sawardari, Chakan
Tal: Khed, District: Pune
Maharashtra, India – 410501
Tel: +91-21-35393400
Website: www.forbesmarshall.com
Email: support@forbesmarshall.com
End
V1.1 160923
|
1
RTru301
IoT Gateway
User’s Manual
Version 1.0
Forbes Marshall Pvt. Ltd.
Plot # B-85, Chakan, MIDC Phase-II
Sawardari, Tal Khed, Dist. Pune 410501. INDIA
2
CONTENTS
CONTENTS ............................................................................................................................................... 2
LIST OF TABLES..................................................................................................................................... 4
LIST OF FIGURES ................................................................................................................................... 5
Purpose of this document ................................................................................................................. 6
Intended use .......................................................................................................................................... 6
Qualified Personnel ............................................................................................................................. 6
General Safety & Security .................................................................................................................. 6
Limitation of Liability and Optimum performance .................................................................. 7
Compliance with Laws & Directives .............................................................................................. 7
Product Disposal .................................................................................................................................. 7
Nomenclature and symbols .............................................................................................................. 7
General Notes ........................................................................................................................................ 8
1. INTRODUCTION ................................................................................................................................ 9
1.1 Notice ............................................................................................................................................................................... 9
1.2 Trademarks ................................................................................................................................................................... 9
1.3 Checking the contents of the package ................................................................................................................. 9
1.4 List of Accessories ....................................................................................................................................................... 9
1.5 Product Ordering Code ............................................................................................................................................. 9
2. SPECIFICATIONS ............................................................................................................................. 10
2.1 Technical Specification Sheet .............................................................................................................................. 10
3. PRODUCT VIEW .............................................................................................................................. 12
3.1 Front View - RTru301 ............................................................................................................................................ 12
4. INSTALLATION & MOUNTING DETAIL .................................................................................... 13
4.1 Safety precautions during installation ............................................................................................................ 13
4.2 Mechanical Dimension ........................................................................................................................................... 13
4.3 DIN Rail Mount .......................................................................................................................................................... 14
5. TERMINAL CONNECTIONS .......................................................................................................... 15
5.1 Sticker of RTru301 IoT Gateway ........................................................................................................................ 15
5.2 Connecting the RTru301 ....................................................................................................................................... 16
6. CONFIGURATION GUIDELINES .................................................................................................. 17
6.1 Parameter Configuration ...................................................................................................................................... 17
6.1.1 Device Info ............................................................................................................................................................... 18
6.1.2 General ...................................................................................................................................................................... 19
6.1.3 Communication ..................................................................................................................................................... 20
6.1.4 MQTT ......................................................................................................................................................................... 23
6.1.5 Input – Output ........................................................................................................................................................ 26
6.1.6 HART® ...................................................................................................................................................................... 29
6.1.7 Modbus ..................................................................................................................................................................... 30
6.1.8 SMS ............................................................................................................................................................................. 31
6.1.9 Calibration ............................................................................................................................................................... 32
7. INPUT OUTPUT INTERFACE CHECK ........................................................................................ 33
7.1 Cellular Communication ........................................................................................................................................ 33
7.2 Modbus Communication ....................................................................................................................................... 34
7.3 HART® Communication ....................................................................................................................................... 35
7.4 Analog Input Interface ........................................................................................................................................... 40
7.5 Digital Input Interface ............................................................................................................................................ 42
3
7.6 Digital Output Interface ......................................................................................................................................... 44
7.7 Analog Output Interface ........................................................................................................................................ 45
8. CALIBRATION .................................................................................................................................. 47
8.1 Analog Input Channel 1 (4 ~ 20mA) ................................................................................................................ 47
8.2 Analog Input Channel 2 (Temperature) ......................................................................................................... 47
8.3 Analog Output Calibration .................................................................................................................................... 47
9. REPLACEMENT OF BATTERY ..................................................................................................... 48
9.1 Replacement of Battery from Battery Holder .............................................................................................. 48
10. TROUBLESHOOTING TIPS ........................................................................................................ 49
11. REVISION HISTORY ..................................................................................................................... 50
4
LIST OF TABLES
Table 1 List of Accessories ........................................................................................................ 9
Table 2 Product Ordering Code ................................................................................................. 9
Table 3 Terminal Connection Details ....................................................................................... 12
Table 4 RUN/ERROR LED Indication ...................................................................................... 17
Table 5 RTru301 Device Configuration Parameters ................................................................. 18
Table 6 General Configuration Parameters ............................................................................. 19
Table 7 Communication Parameters ....................................................................................... 21
Table 8 MQTT Parameters ...................................................................................................... 24
Table 9 Analog Input Parameters ............................................................................................ 26
Table 10 Digital Input Parameters ........................................................................................... 27
Table 11 Analog Output Parameters ....................................................................................... 28
Table 12 Digital Output Parameters......................................................................................... 28
Table 13 HART® Parameters .................................................................................................. 29
Table 14 Modbus Parameters ................................................................................................. 30
Table 15 SMS Parameters ...................................................................................................... 31
Table 16 Calibration Parameters ............................................................................................. 32
Table 17 RSSI (Receiving Signal Strength Indication) ............................................................. 33
Table 18 Network Status Indication ......................................................................................... 33
Table 19 Modbus Register Length Data Format ...................................................................... 34
Table 20 JSON Key Description for Payload of Modbus Topic ................................................ 35
Table 21 Start Delimiter ........................................................................................................... 38
Table 22 JSON Key Description for Payload of HART® Topic ................................................ 39
Table 23 SMS Format - Analog Input ...................................................................................... 41
Table 24 JSON Key Description for Payload of Periodic Data Topics for Analog Input ............ 41
Table 25 JSON Key Description for Payload of Alert Topics for Analog Input .......................... 42
Table 26 SMS Format - Digital Input ........................................................................................ 43
Table 27 JSON Key Description for Payload of Periodic Data Topics for Digital Input ............. 43
Table 28 JSON Key Description for Payload of Alert Topics for Digital Input ........................... 44
Table 29 SMS Format - Digital Output SET/RESET ................................................................ 44
Table 30 SMS Format - Digital Output Impulse ....................................................................... 44
Table 31 Format of Topic Published by MQTT Server- Digital Output SET/RESET ................. 44
Table 32 Format of Topic Published by MQTT Server - Digital Output Impulse ....................... 45
Table 33 JSON Key Description for Payload of Periodic Data Topics for Digital Output .......... 45
Table 34 SMS Format - Analog Output .................................................................................... 46
Table 35 Format of Topic Published by MQTT Server - Analog Output ................................... 46
Table 36 JSON Key Description for Payload of Periodic Data Topics for Analog Output ......... 46
5
LIST OF FIGURES
Figure 1 Front View - RTru301 IoT Gateway ........................................................................... 12
Figure 2 Front Sticker .............................................................................................................. 15
Figure 3 Serial No Sticker ........................................................................................................ 15
Figure 4 RS485 Port 1 (Modbus Master) Connection Details................................................... 16
Figure 5 Device Info Web Page ............................................................................................... 18
Figure 6 General Web Page .................................................................................................... 19
Figure 7 Communication Web Page ........................................................................................ 20
Figure 8 MQTT Web Page ...................................................................................................... 23
Figure 9 Input - Output Web Page ........................................................................................... 26
Figure 10 HART® Web Page .................................................................................................. 29
Figure 11 Modbus Web Page .................................................................................................. 30
Figure 12 SMS Web Page ....................................................................................................... 31
Figure 13 Calibration Web Page .............................................................................................. 32
Figure 14 HART® Packet Structure ......................................................................................... 37
Figure 15 HART® Web page ................................................................................................... 39
Figure 16 Analog Input Web page ........................................................................................... 41
Figure 17 Digital Input Filter Time ............................................................................................ 42
Figure 18 Digital Input Web page ............................................................................................ 43
Figure 19 Digital Output Web page ......................................................................................... 44
Figure 20 Analog Output Web page ........................................................................................ 46
Figure 21 Calibration - Analog Input ........................................................................................ 47
Figure 22 Calibration - Analog Output ..................................................................................... 47
Figure 23 Battery Replacement instructions ............................................................................ 48
6
Purpose of this document
The purpose of this document is to equip the reader with the necessary information required for the safe
installation, operation and maintenance of this device, prior to its commissioning. The information within
this document is aimed towards those individuals who are technically qualified and experienced in the
assembly, installation and operation/ maintenance of the device.
To avoid personal injury or property damage it is important to carefully read, understand, and follow all of
the contents of this manual, including all safety cautions and warnings. If you have any questions about these
instructions, contact the customer support division of the Manufacturer before proceeding.
Whilst the information in this document aims to be as accurate as possible, the Manufacturer makes no
warranty or representations with respect to the information herein. The proper utilization of this
information is ultimately the responsibility of the Customer.
IMPORTANT
Read this User Manual thoroughly and understand its contents completely
Before installing and powering-up the Positioner.
Intended use
In order to ensure optimum functionality, the device needs to be utilized solely for those purposes and in
those manners as prescribed herein. The Customer is responsible for making certain that the operating
conditions for the device correspond to the technical specifications defined. Furthermore, the Customer is
also responsible for ensuring that any personnel that operate or maintain the device are made aware of the
implications of using or operating the device in unsuitable conditions.
The Manufacturer does not assume any liability for damages resulting from the failure to use the
device for its intended purpose or for damage caused by external forces or any other external
factors.
Qualified Personnel
The product described in this documentation may be installed, operated and maintained only by personnel
qualified for the specific task in accordance with the relevant documentation, in particular its warning
notices and safety instructions. Qualified personnel are those who, based on their training and experience,
are capable of identifying risks and avoiding potential hazards when working with these products.
The Customer must ensure that operating personnel read and understand these instructions as well as the
specified hazard statements, warning and caution notes. Furthermore, the operating personnel must be
familiar with the applicable health, safety and accident prevention regulations and comply with them.
General Safety & Security
The Customer must consider the necessity of any protective clothing for its employees in the vicinity in
order to provide protection against hazards of temperature (high or low), chemicals, radiation, dangers to
eyes and face, noise and falling objects.
There is always a possibility of risk of injury if heavy products are handled manually. Customers are
requested to analyze the risk and use appropriate handling methods by taking into consideration the task,
7
the individual, the working environment and the load. Furthermore, it is the Customer’s responsibility to
ensure that general instructions for proper use of tools and safety of equipment, piping and plant
construction must also be complied with and “Warning Notices” need to be put up wherever necessary.
The Customer is solely responsible to prevent unauthorized access to its plants, systems, machines and
networks, its information technology infrastructure, firewalls network, internet and appropriate security
measures.
Incorrect installation, operation or maintenance of the device in potentially explosive atmospheres
may lead to ignition of the atmosphere and cause risk of fatal injury, death or damage to personal
property. Please note that the Customer is solely liable for any hazards, damage or injury caused to
its personnel or property due to the Customer’s failure to comply with the safety instructions above
and as established throughout the course of this manual.
Limitation of Liability and Optimum performance
For optimum performance, the Product should only be used in conjunction with components and accessories
supplied by the Manufacturer. If the product accessories and components from other manufacturers are
used, these must be recommended or approved by the Manufacturer.
The Manufacturer shall not be liable and the Warranty shall not apply, if the Product (i) is used in any
manner that is inconsistent with the intended purpose or design of the Product as described in user manual,
product literature and/or technical documentation provided by the Manufacturer of the Product; (ii) is
altered in any way; (iii) is used or maintained in any manner that is inconsistent with Manufacturer's
instructions or warnings (“User Instructions”) provided along with the Product; (iv) subjected to any other
misuse, lack of proper storage & handling, commissioning, maintenance, faulty repair, neglect, or servicing
by persons other than Manufacturer’s authorized person and/or failure to operate in permissible ambient
conditions.
Compliance with Laws & Directives
Observe the test certification, provisions and laws applicable in your country during connection, assembly
and operation.
Product Disposal
It is necessary to dispose of this product only in accordance with local regulations at the authorized,
qualified collecting point specified for equipment and its parts. Kindly refer to the components mentioned in
this document. Please follow all waste disposal guidelines (Management & Handling) as published by local
governing authorities and local environmental laws.
Nomenclature and symbols
Product
Product refers to the RTru 301 IOT gateway.
Nomenclature
This manual contains notes and instructions, which the user must observe to ensure the safety of all user
personnel and to protect the product and equipment connected to it. These are highlighted using specific
symbols and appear based on the severity levels as follows.
8
DANGER
Indicates an imminently hazardous situation which if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
If used with the safety alert symbol indicates a potentially hazardous situation which if not avoided may
result in minor to moderate level injury.
CAUTION
If used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may
result in damage to property.
NOTICE
If used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may
result in undesirable state or result.
NOTE
This highlights important information about the product, using the product or part of the documentation
that will be beneficial to the user.
General Notes
NOTE
Dear User,
This manual does not provide for every possible contingency situation that may arise during the installation,
operation and maintenance of the product.
For information or situations not covered by this manual, please contact your local Forbes Marshall Service
support.
The content herein is based on the latest data available at the time of going to print and is subject to change
due to ongoing product improvements in the future.
WARNING
The successful operation of this product depends on its proper handling, installation, operation and
maintenance.
This product must be used for the sole purpose described in this manual.
9
1. INTRODUCTION
The RTru301 IoT Gateway is used to monitor a device's interface data remotely and send it to a central
location over the internet using a cellular communication network. The RTru301 will read the data from the
inbuilt I/O channels such as inputs. Additionally, it will read data from any device over Modbus or HART®
protocols. The RTru301 Device has an inbuilt cellular modem which helps to get connected to the internet
over a GSM network. The RTru301 Device can change the status of digital output and generates the analog
output current (4 ~ 20mA) based on an SMS configuration.
1.1 Notice
The contents of this manual are subject to change without notice as a result of continuous improvements to
the instrument’s performance and functions.
Every effort has been made to ensure accuracy in the preparation of this manual. Should any errors or
omissions come to your attention, however, please inform FORBES MARSHALL Sales office or sales
representative. Under no circumstances may the contents of this manual, in part or in whole, be transcribed
or copied in any form without our written permission.
1.2 Trademarks
Our product names or brand names mentioned in this manual are the trademarks or registered trademarks
of Forbes Marshall (P) Ltd. (hereafter referred to as Forbes Marshall).
Adobe®, Acrobat®, and Postscript® are either registered trademarks or trademarks of Adobe Systems
Incorporated. All other product names mentioned in this user's manual are trademarks or registered
trademarks of their respective companies.
1.3 Checking the contents of the package
Unpack the box and check the contents before using the product. If the product is different from which you
have ordered, if any parts or accessories are missing, or if the product appears to be damaged, contact your
sales representative. The User Manual is supplied in the package.
1.4 List of Accessories
The product is provided with the following accessories according to the model and suffix codes (see the table
below). Check that none of them are missing or damaged.
Table 1 List of Accessories
No
Item name
Part number
Qty
Remarks
1
Cellular antenna
Part No: ET-LT3M-1L3-SMS
Manufacturer: ETEILY TECHNOLOGIES
1
External
1.5 Product Ordering Code
Table 2 Product Ordering Code
Ordering Code RTru301
Model
Mounting
Input Type 1
Input Type 2
Output Type 1
Output Type 2
RTru301
X
X
X
X
D
DIN Rail
N
None
N
None
N
None
N
None
1
AI
(4~20mA)
1
Digital
Input
1
AO
(4~20mA)
1
Digital
Output
10
2. SPECIFICATIONS
2.1 Technical Specification Sheet
RTru301 IoT Gateway
CPU
ARM Cortex - M4 Core, 192MHz
External Memory
4MByte (stores data when network fails)
RTC with battery backup
Yes
Battery
1 x CR2032
Internal Temperature Monitor
Yes
Expansion Connector
Yes (SPI & I2C)
LED Indication
Run/Error indication, Serial Transmit (TX), Serial
Receive (RX), Cellular Signal Strength (RSSI), Server
Connectivity (NET), Power Supply Indication (PWR)
Hardware Interface
1 x ETH 10/100BaseT/TX
2 x RS485 (1 Port : Standard, 1 Port : Optional)
2 x Digital Input : Optional
2 x Digital Output : Optional
1 x Analog Input with HART® Master (Isolated) : Optional
1 x Analog Output (4~20mA) : Optional
Protocol And Interface
Modbus RTU Master and firmware upgrade via RS485,
DHCP server, Web Server and Telnet via Ethernet Port,
MQTT and NTP via cellular
Serial Communication
Baudrate (kbps) : 9600/19200/38400/57600/115200
2 - pin plug in screw terminal
Ethernet
1 x RJ45(10 x 100Mbps)
Antenna Connector
1 x SMA Female
SIM Card Slots
2 x Micro SIM(3FF)
Cellular Communication
4G Module
Frequency Band: GSM 900/1800 MHz
LTE-TDD B34/B38/B39/B40/B41
LTE-FDD B1/B3/B5/B8
Analog Input (Optional)
Input type: Current (4~20mA)
Accuracy: 0.125% of full scale
Input Impedance: 250 Ω
HART® Master support: 4 Devices (max)
Analog Output (Optional)
Output type: Source(4~20mA)
Accuracy: 0.25% of full scale
Load capacity: 500 Ω @24 VDC max.
Digital Input
Input voltage range: 24 VDC (+/- 10%) External power
supply
Digital Output (Optional)
Output type: Open collector (sink type)
Max. Current: 50mA/output
Supply Voltage
9 to 36VDC, <10W, 3 - Pin plug - in screw terminal, reverse
polarity protected
Operating Temperature Range
0°C to 55°C
Relative Humidity
0 ~ 95% RH (Non-Condensing)
Enclosure
Dimensions (mm) : 107 (W) x 88 (H) x 63 (D)
Material : ABS plastic, DIN rail mount
Ingress Protection Rating
IP20
Weight (w/o antenna)
230g approx.
Certification (EMI / EMC)
EN/IEC 61326-1:2012 ( Industrial)
11
Isolation (Withstanding voltage)
Between power supply input terminals and output terminals*: 500 VAC for 1 minute
Between power supply input terminals and ground terminal: 500 VAC for 1 minute
Between grounding terminal and analog and digital output terminals: 500 VAC for 1 minute
Insulation resistance: > 200MΩ @500VDC between power supply input terminals and output terminals
* Output terminals indicate RS485/Analog, Output/Analog, Input/Digital, Input/Digital, Ethernet
12
3. PRODUCT VIEW
3.1 Front View - RTru301
Figure 1 Front View - RTru301 IoT Gateway
Table 3 Terminal Connection Details
No.
Terminal Type
Description
(Left to Right Direction)
1
MSTB Connector 3-pin for 24DC input power
Part No:-MSTB-2.5/3-ST-5.08 (1757022)
Manufacturer : Phoenix Contact
DCIN+
DCIN-
EARTH
2
MSTB Connector 4-pin for Digital Input Channel
Part No:-MSTB-2.5/4-ST-5.08 (1757035)
Manufacturer : Phoenix Contact
DI1+(Positive)
DI1-(Negative)
DI2+(Positive)
DI2-(Negative)
3
MSTB Connector 2-pin for RS485-1
Part No:-MSTB-2.5/2-ST-5.08 (1757019)
Manufacturer : Phoenix Contact
D+
D-
4
RJ45 Socket for Ethernet
Part No:-TCT-LPJK7002A98NL
Manufacturer : Link-PP
For
RJ45
based
ethernet
connection for web server
5
MSTB Connector 3-pin for Digital Output Channel
Part No:-MSTB-2.5/3-ST-5.08 (1757022)
Manufacturer : Phoenix Contact
DO1
DO2
COMM
6
MSTB Connector 3-pin for Analog Input(4 ~ 20mA)
Part No:-MSTB-2.5/3-ST-5.08 (1757022)
Manufacturer : Phoenix Contact
AI+(Positive)
AI- (Negative)
(24VDC)
7
MSTB Connector 2-pin for Analog Output(4 ~ 20mA)
Part No:-MSTB-2.5/2-ST-5.08 (1757019)
Manufacturer : Phoenix Contact
AO+(Positive)
AO- (Negative)
8
MSTB Connector 2-pin for RS485-2
Part No:-MSTB-2.5/2-ST-5.08 (1757019)
Manufacturer : Phoenix Contact
D+
D-
13
4. INSTALLATION & MOUNTING DETAIL
4.1 Safety precautions during installation
WARNING
- To minimize the possibility of fire or shock hazards, do not expose this instrument to rain or excessive
moisture.
- Do not use this instrument in areas under hazardous conditions such as excessive shock, vibration, dirt,
moisture, corrosive gases or oil. The ambient temperature of the areas should not exceed the maximum
rating specified.
WARNING
Earth the device to prevent an electric shock or fire. The protective conductor terminal is marked with a
label on the product terminals with the following symbol:
CAUTION
- Be sure all personnel involved in installation, servicing, and programming are qualified and familiar with
electrical equipment and their ratings
- Do not install, store, or use it in the place with a lot of dust, corrosive and flammable gases, vibrations and
shocks exceeding the allowed values, place low or high temperature outside of the installation condition,
direct sunlight and near equipment generating strong radio waves or magnetic fields, It may cause accidents.
- This equipment can be damaged if incorrect power source voltage is applied. This equipment can be
damaged if the power source is applied with incorrect polarity on its respective terminal. Never plug unit
power supply connectors or power supply cables in the terminal while the main power source is ON.
4.2 Mechanical Dimension
Dimension without plug-in connector (mm): 107(W) x 88(H) x 63(D)
Dimension with connector (mm): 107(W) x 113(H) x 80(D)
14
4.3 DIN Rail Mount
Installing the RTru301 module on a DIN rail
NOTE
Before mounting RTru301 device on a DIN rail, ensure power supply to the module connectors is
turned off and remove the antenna and terminal connectors. After fitment, mount the antenna
connector and terminal connectors on RTru301 Device.
Step 1: Clip on the module on
to Part A of the rail
Step 2: Fix the module on to
Part B of the rail
Step 3: Press the red lock into
the DIN Rail until it clicks
Un-installing the RTru301 module from a DIN rail
NOTE
Before removing the RTru301 device from the DIN rail, ensure power supply to the module connectors
is turned off. Remove the antenna and terminal connectors.
Step 1: Pull the red lock down
from the DIN Rail.
Step 2: Pull the module away
from part B of the rail
Step 3: Remove the Module
from DIN Rail
15
5. TERMINAL CONNECTIONS
5.1 Sticker of RTru301 IoT Gateway
Figure 2 Front Sticker
Figure 3 Serial No Sticker
16
5.2 Connecting the RTru301
WARNING
Before carrying out wiring, turn off the power and check that the cables to be connected are not live because
there is a possibility of electric shock.
NOTE
1. All wiring must conform to appropriate standards of good practice and local codes and regulations. Wiring
must be suitable for voltage, current and operating temperature rating of the system.
2. Provide power from an external 24VDC power supply. Do not route power supply and I/O cables close to
each other.
3. Use a repeater after each set of 32 slaves connected to the RS-485 Port 1(Modbus Master) communication.
4. Unused terminals should not be used as jumper points as they may be internally connected, which may
cause damage to the unit.
5. Supply voltage must be below maximum voltage rating specified on the label.
Figure 4 RS485 Port 1 (Modbus Master) Connection Details
17
6. CONFIGURATION GUIDELINES
See the below table for RUN/Error LED indication
Table 4 RUN/ERROR LED Indication
No Error
RUN (Green) LED Glow
Configuration parameter memory not detected
Error(Red) LED will blink every 100ms
Configuration parameter file error
Error(Red) LED will blink every 500ms
Data logging memory not detected
Error(Red) LED will blink every 1500ms
RTC not detected
Error(Red) LED will blink every 3000ms
Selected SIM card Not Detected
Error(Red) LED Glow
6.1 Parameter Configuration
RTru301 IoT Gateway device offers a facility for users to configure parameters of the device using a web
server. Web server pages can be obtained in PC or system by sending an HTTP request
(http://192.168.100.110) to device on device IP address by a web browser such as Google Chrome®. The
default device IP address is 192.168.100.110. After getting a successful response from the device, the
webpage of the device is seen as shown in the image below. Ensure that the PC or system is in the same IP
address network and range.
The default Username and Password for web server login are:
Username: Admin
Password: Admin
The pages in web server are:
DEVICE INFO
GENERAL
COMMUNICATION
MQTT
INPUT- OUTPUT
HART®
MODBUS
SMS
CALIBRATION
18
6.1.1 Device Info
This page provides configuration information of RTru301 devices such as current hardware & software
versions, cellular modem IMEI No and SIM card no
Figure 5 Device Info Web Page
The device info Configuration Page provides the information of RTru301 devices such as current hardware
& software version, cellular modem IMEI No, SIM card No and current Time and Date.
Table 5 RTru301 Device Configuration Parameters
Parameter
Description
Software Version
Software version
Hardware Version
Current Hardware Version
IMEI No
IMEI Number of Cellular modem
SIM No
IMSI number of the SIM Which is use for the cellular communication
MAC Address
MAC address
Date/Time(GMT)
Shows the current Time and Date(GMT)
‘Load Para. From Local Disk’ button:
This button is used for loading the Parameters configuration file from the local disk by providing the path of
the config. file in the local system or PC.
‘Save Para. To Local Disk’ Button:
This Button is used to download the current parameter configuration in a file in the local system or PC.
19
6.1.2 General
The General Configuration Page is used to configure the web server login username and password, NTP
server configuration, SIM section and data logging memory option. Seen as show in the image below
Figure 6 General Web Page
Table 6 General Configuration Parameters
Parameter
Description
Format
Range
Default
Admin
Username
Username for Web server Login. It is required
only for web server login.
String
(R/W)
1 ~ 5
characters
Admin
Admin
Password
Password for Web Server Login. It is required
only for web server login.
String
(R/W)
1 ~ 5
characters
Admin
Device ID
Specifies the device ID. It is used for sending
an SMS with Device ID and Periodic Data
Frame Sending to MQTT Server with device
ID.
String
(R/W)
1 ~ 20
characters
FM-DEV-001
Device
Description
Specifies the device Description. It is required
only for identification of the device
String
(R/W)
1 ~ 20
characters
FM-DEMO-
DEVICE
NTP
server 1 URL
Specifies the NTP server URL. It is used for
synchronization of time of the device
String
(R/W)
1 ~ 256
characters
2.pool.ntp.org
NTP Server
Port 1
Specifies the NTP Port. It is used for
synchronization of time of the device. The
NTP Server Port 1.
Integer
(R/W)
1 ~ 65535
123
NTP
server 2 URL
Specifies the NTP server URL. It is used for to
synchronize the time of the device
String
(R/W)
2.pool.ntp.org
NTP Server
Port 2
Specifies the NTP Port. It is used to
synchronize the time of the device.
Integer
(R/W)
1 ~ 65535
123
Time Zone
It is used to set the time of a device based on
IST or UTC.
Option
IST/
UTC
IST
SIM Selection
Select the SIM card Option for Cellular
communication.
Option
Disable/
SIM1/
SIM2/
Both
Disable
Data Logging
Enable or disable the data frame logging in
case cellular network failure occurs. The
device sends the logged data when the
network is restored.
Option
ON/OFF
ON
20
NOTE
Logged data will be erased when the Data Logging option is set to Off
6.1.3 Communication
The Communication Page is used to configure the Ethernet parameter, SIM card parameter, serial
configuration and selection of Input and Output data sent to the MQTT server.
Figure 7 Communication Web Page
21
Table 7 Communication Parameters
Parameter
Description
Format
Range
Default
DHCP
IP address selection of RTru301
Option
ON/
OFF
OFF
IP address
IP address of RTru301 (in static mode
only)
XXX.XXX.XXX.X
XX(R/W)
1 ~ 15
characters
192.168.100.
110
Subnet
Mask
Subnet mask address of RTru301 (in static
mode only)
XXX.XXX.XXX.X
XX(R/W)
1 ~ 15
characters
255.255.255.
0
Gateway
Gateway address of RTru301 (in static
mode only)
XXX.XXX.XXX.X
XX(R/W)
1 ~ 15
characters
192.168.100.
254
SIM PIN1
PIN for your cellular network SIM card 1.
Use only when the SIM card is Locked.
String
(R/W)
1 ~ 5
characters
Empty
SIM1
Username
User name for your cellular network
account for SIM card 1. Use only when
required by your cellular service provider.
String(R/W)
1 ~ 20
characters
Empty
SIM1
Password
Password for your cellular network
account for SIM card 1. Use only when
required by your cellular service provider.
String(R/W)
1 ~ 20
characters
Empty
SIM1 APN
Access Point Name (APN) of the SIM card
1 that connects your device for internet
data
String(R/W)
1 ~ 30
characters
internet
SIM PIN2
PIN for your cellular network SIM card 2.
Use only when the SIM card is Locked.
String(R/W)
1 ~ 5
characters
Empty
SIM2
Username
User name for your cellular network
account for SIM card 2. Use only when
required by your cellular service provider.
String(R/W)
1 ~ 20
characters
Empty
SIM2
Password
Password for your cellular network
account for SIM card 2. Use only when
required by your cellular service provider.
String(R/W)
1 ~ 20
characters
Empty
SIM2 APN
Access Point Name (APN) of the SIM card
2 that connects your device for internet
data
String(R/W)
1 ~ 30
characters
internet
Modbus
Baud rate
Baud rate for Modbus communication on
RS485 Port 1
Option
9600/
19200/
38400/
57600/
115200
9600
Modbus
Parity
Parity for Modbus communication on
RS485 Port 1
Option
none/
even/
odd
none
Modbus
Data Bits
Number of data bits for Modbus
communication on RS485 Port 1
Option
7/8 Bit
8
Modbus
Stop Bits
Number of stop bits for Modbus
communication on RS485 Port 1
Option
1/2 Bit
1
Modbus Poll
Time(s)
Polling time for Modbus communication
on RS485 Port 1. This time is used to
decide when the next Modbus master
query is sent from the device to the
Modbus slave device.
Integer(R/W)
1 ~ 100
(sec)
3(sec)
Modbus
Timeout
(ms)
Response timeout for Modbus
communication on RS485 Port 1. This time
decides the waiting period of Modbus
slave response.
Integer(R/W)
1 ~ 10000
(ms)
1000(ms)
Send A/I
Data
Send measured analog input data to the
MQTT server periodically.
Check Box
Enable/
Disable
Enable
Send D/I
Send measured digital input data to the
Check Box
Enable/
Enable
22
Data
MQTT server periodically.
Disable
Send A/O
Data
Send measured analog output data to the
MQTT server periodically.
Check Box
Enable/
Disable
Enable
Send D/O
Data
Send measured digital output data to the
MQTT server periodically.
Check Box
Enable/
Disable
Enable
Send
HART®
Data
Send HART® master data can be sent to
the MQTT server.
Check Box
Enable/
Disable
Enable
Send
Modbus
Data
Send Modbus master data to the MQTT
server.
Check Box
Enable/
Disable
Enable
Send
Diagnostic
Data
Send diagnostic data to the MQTT server.
Check Box
Enable/
Disable
Disable
23
6.1.4 MQTT
The MQTT configuration web page is used to configure the MQTT server Parameter.
Figure 8 MQTT Web Page
The MQTT configuration web page is used to configure the MQTT server parameter.
24
Table 8 MQTT Parameters
Parameter
Description
Format
Range
Default
MQTT URL
URL for MQTT server
String(R/W)
1 ~ 256
characters
test.mosquitto.org
MQTT Port
MQTT Port number
Integer(R/W)
1 ~ 65535
1883
Client ID
Client ID for MQTT server
String(R/W)
1 ~ 256
characters
FM DEMO
CLIENT
Username
Username for MQTT server which is
required for MQTT server login.
String(R/W)
1 ~ 256
characters
Empty
Password
Password for MQTT server which is
required for MQTT server login.
String(R/W)
1 ~ 256
characters
Empty
Keep alive(s)
Keep Alive message time
Integer(R/W)
1 ~ 3600
(sec)
120s
Clean session
If the field “Clean Session” is
checked, the last MQTT messages
are deleted by the Server and the
Client in case of missing ACK. If
unchecked, then Server and the
Client hold the last MQTT messages.
In case of incorrect disconnection or
missing ACK, they try to send them
again since all the ACK messages are
exchanged correctly (valid only for
QoS 1 and QoS 2).
Check Box
Enable/
Disable
Disable
Will Flag
If the field “Will Flag” is checked, the
device will publish the Will topic at
the connection to the Server. With
this feature, in case of incorrect
disconnection, the Server will
publish this topic to all the MQTT
Clients that are subscribed to it.
Check Box
Enable/
Disable
Disable
Will Topic
Specify the will topic. It is used for
the Will message.
String(R/W)
1 ~ 256
characters
TEST/WILL
Will Message
Specify the payload of the Will
message.
String(R/W)
1 ~ 256
characters
Test Will
Message
Will QoS
Set the QoS type for which the Will
message is defined.
Option
0/
1/
2
0[ZERO]
Will Retain
In the field “Retained Will” the
device will send the Will message
with Retain flag enabled. In this
way, the server will hold the last
Will message.
Check Box
Enable/
Disable
Disable
Periodic Data
Topic
Specify the Periodic Published Topic
for the periodic data sent to the
MQTT server.
String(R/W)
1 ~ 256
characters
TEST/PERIODIC
Alert Topic
Specify the Alert Topic for the Alert
data sent to the MQTT server.
String(R/W)
1 ~ 256
characters
TEST/ALERT
QoS
In the field “QoS” the QoS type for
Periodically data sent is defined.
Option
0/
1/
2
0[ZERO]
Diagnostic
Topic
Specify the Diagnostic Topic for the
Diagnostic data sent to the MQTT
server.
String(R/W)
1 ~ 256
characters
TEST/DIAG
Subscribe
Topic
Specify the Subscribe Topic for the
Subscribe data sent to the MQTT
String(R/W)
1 ~ 256
characters
TEST/SUB
25
server.
Subscribe
Topic Max. QoS
Set the QoS type Subscribe Topic.
Option
0/
1/
2
0[ZERO]
Periodic Data
Publish Time
(min)
Set the periodic publish data
interval for periodic publish data
sent to the MQTT server
Integer(R/W)
1 ~ 1440
(minutes)
1 (minutes)
Diagnostic
Data Publish
Time (min)
Set the interval for diagnostic data
sent to the MQTT server
Integer(R/W)
1 ~ 1440
(minutes)
60 (minutes)
Server
Authentication
Enable or Disable the server
authentication. It is used for secure
server login.
Check Box
Enable/
Disable
Disable
Client
authentication
Enable or disable the Client
authentication.
Check Box
Enable/
Disable
Disable
Server
Certificate
Specify the server certificate. It
Applicable when Client
authentication enable
String(R/W)
1 ~ 4096
characters
Empty
Client
Certificate
Specify the client certificate. It
Applicable when Client
authentication enable
String(R/W)
1 ~ 4096
characters
Empty
Client Key
Specify the client key. It Applicable
when Client authentication enable
String(R/W)
1 ~ 4096
characters
Empty
‘Save Certificate’ Button:
This Button is used to save the server certificate, client certificate and Client key
NOTE
If the MQTT server does not receive the any payload from the RTru301 device within 1.5 times of the Keep
Alive time period, MQTT server disconnects the RTru301 device.
26
6.1.5 Input – Output
This Input-Output Configuration is used to configure the parameters of analog input, analog output, digital
input and digital output.
Figure 9 Input - Output Web Page
ANALOG INPUT
The following table lists configuration parameter for analog input channel 1 (4~20mA) and channel 2
(internal temperature measurement)
Table 9 Analog Input Parameters
Parameter
Description
Format
Range
Default
Interface
Enable
Enables or disables the analog
input source.
Check Box
Enable/
Disable
Enable
Zero
Specifies the zero value for the
analog input channel 1
Integer(R/W)
-1999
to
+20000
(CH1)
4000(CH-1)
Span
Specifies the span value for the
analog input channel 1
Integer(R/W)
0 ~ 20000
(CH-1)
20000(CH-1)
Hysteresis
Specifies the input value to keep
an alarm ON or OFF during High
and Low alarm states
Integer(R/W)
0 ~ 20000
(CH-1)
0 ~ 5 (CH-2)
2000(CH-1)
4(CH-2)
High Threshold
Specifies the input value that
generates a high alarm event when
High Alarm is ON
Integer(R/W)
4000~20000
(CH-1)
0 ~ 100
(CH-2)
15000(CH-1)
45(CH-2)
Low Threshold
Specifies the input value that
Integer(R/W)
4000 ~ 20000
5000(CH-1)
27
generates a low alarm event when
Low Alarm has occurred
(CH-1)
0 ~ 100
(CH-2)
10(CH-2)
SMS alarm
Enables or disables the SMS alarm
when an alarm occurs
Check Box
Enable/
Disable
Disable
Server Alarm
Enables or disables the server
alarm when an alarm occurs
Check Box
Enable/
Disable
Disable
SMS alarm
Group
Specify a group for the SMS alarm
received. for Ex.123 means the
alarm SMS send to Group No 1, 2
and 3 which are specified in SMS
web page
String(R/W)
1 ~ 5
characters
12345
SMS
Description
SMS alert message
String(R/W)
1 ~ 20
characters
AI-CH-1 (CH-1)
AI-CH-2 (CH-2)
NOTE
-The value of Low or High Threshold is in between the value of Zero and Span in analog input channel 1
-The range of Low or High Threshold for analog input channel 2 is 0 ~ 100
DIGITAL INPUT
The following table lists configuration parameter for digital input channel. The digital input channel can be
worked as ON/OFF or Counter Mode.
Table 10 Digital Input Parameters
Parameter
Description
Format
Range
Default
Interface
Enable
Enables or disables the digital input
source.
Check Box
Enable/
Disable
Enable
Mode
Digital input mode
Option
On/Off /
Counter
On/Off
Filter
Time(ms)
The Filter Time is the length of time
that a newly changed input to the
last state before it is accepted as a
valid input. It is used only in
ON/OFF mode. Applicable in On/Off
mode only
Integer(R/W)
0 ~ 10000
(ms)
0(ms)
Count From
Last
Enables or disables the digital input
count from the last stored value
Check Box
Enable/
Disable
Enable
Step alarm
count
Max. alarm count for sending alarm
SMS msg
Integer(R/W)
0 ~ 65535
0
SMS alarm
Enables or disables the SMS alarm
when an alarm occur
Check Box
Enable/
Disable
Disable
Server Alarm
Enables or disables the Server alarm
when an alarm occur
Check Box
Enable/
Disable
Disable
SMS alarm
Group
Specify a group for the SMS alarm
received. for Ex.123 means the
alarm SMS send to Group No 1, 2
and 3 which are specified in SMS
web page
String(R/W)
1 ~ 5
characters
12345
SMS
Description
SMS alert message
String(R/W)
1 ~ 20
characters
DI-CH-1(CH-1)
DI-CH-2(CH-2)
28
NOTE
The last value of digital input as counter will be erased when the last count option in digital input
configuration is disabled. In this case the digital input counter starts from zero.
ANALOG OUTPUT
The Table provides the configuration of the Analog output. The analog outputs can be generated based on
last stored value on device power ON/OFF
Table 11 Analog Output Parameters
Parameter
Description
Format
Range
Default
Interface
Enable
Enables or disables the Analog output
Check box
Checked/
Unchecked
Enable
Zero
Specifies the zero value for the analog
output channel
Number
4000
4000
[Fixed Value]
Span
Specifies the span value for the analog
output channel
Number
20000
20000
[Fixed Value]
Retained Last
Value
Enables or disables the analog output
generated based on last stored value
Check box
Checked/
Unchecked
Enable
NOTE
The last value of analog output will be erased when the last retained option in analog output configuration is
disabled (analog output value is set to zero)
DIGITAL OUTPUT
The Table provides the configuration of the digital output channel. The Digital output can be worked as
on/off or impulse mode. In Impulse mode it is in sink mode for a defined time interval.
Table 12 Digital Output Parameters
Parameter
Description
Format
Range
Default
Interface
Enable
Enables or disables the Digital output
source.
Check Box
Enable/
Disable
Enable
Mode
Digital output mode selection
Option
On/Off/
Impulse
On/Off
Impulse Time
Impulse Time of output
Integer(R/
W)
1 ~ 10000
(ms)
1000(ms)
Retained Last
Value
Enables or disables the digital output
generated based on last stored value
Check Box
Enable/
Disable
Enable
NOTE
The last value of digital output will be erased when the last retained option in digital output configuration is
disabled. In this case the digital output is set to the OFF state.
29
6.1.6 HART®
The HART® configuration parameter can be set in the HART® configuration page.
Figure 10 HART® Web Page
Table 13 HART® Parameters
Parameter
Description
Format
Range
Default
No of Clients
No of HART® slave device or HART®
Request Query for the HART®
communication.
Integer(R/W)
0 ~ 15
0[ZERO]
Query Time(s)
Query Time for HART®
communication. This Time is used to
decide when the next HART® query
is sent from the device to the HART®
slave device.
Integer(R/W)
1 ~ 120
(s)
5s
Query
Reponses Time
out(ms)
Query Response Timeout for HART®
communication. This time decides the
waiting period of HART® slave
response.
Integer(R/W)
100 ~
5000
(ms)
1000(ms)
Query
Attempts
Number of query retry counts for
HART®
Integer(R/W)
0 ~ 3
0[ZERO]
Polling ID
HART® slave device ID for HART®
communication.
Integer(R/W)
0 ~ 15
0 ~ 15
Manufacturer’s
Manufacturer’s ID of the HART®
String
30
ID
Device. This is a ‘read only’
parameter.
(Read only)
Device Type
Device type of HART® Device. This is
a ‘read only’ parameter.
String
(Read only)
Client ID
Shows the Client ID of HART® Device.
This is a ‘read only’ parameter.
String
(Read only)
Publishing
Interval
(min)
Specifies interval for HART® data
published on the MQTT server with
HART® data topic in minutes
Integer(R/W)
1 ~ 1440
(minutes)
1(minutes)
Publish Topic
Publish topic for HART® data
published on the MQTT server.
String(R/W)
1 ~ 256
characters
TEST/HTDEV1
Change ID
This button is used to change the
HART® Polling ID
‘Tab’
‘Get Device Data’ Button:
This Button is used to Read the Manufacturer’s ID, Device Type and Client ID of the HART® Device which are
configured.
6.1.7 Modbus
The Modbus Master configuration can be set in the Modbus configuration page.
Figure 11 Modbus Web Page
Table 14 Modbus Parameters
Parameter
Description
Format
Range
Default
No of Client
Number of Modbus slave
devices or Modbus queries for
Modbus communication.
Integer(R/W)
0 ~ 16
0
Slave ID
Modbus slave device ID for
Modbus communication.
Integer(R/W)
1 ~ 247
1 ~ 16
31
Function Code
Function code for Modbus
communication
Integer(R/W)
1 / 2 / 3 / 4 / 5 / 6
/ 15 / 16
3
Reg. Start
Address
Start address of Modbus query
for Modbus communication
Integer(R/W)
1 ~ 65535
1
Register
Length
Read Modbus register length
for Uint (unsigned integer) 16
Integer(R/W)
1 ~ 64
1
Data Format
Data format for Modbus
register read
Integer(R/W)
Bool / Int_16/
Uint_16/ Int_32 /
Uint_32 / Float /
Float_Swap /
Double /
Double_Swap
Uint_16
Publishing
interval (min)
Time interval for Modbus data
published on MQTT server
with Modbus topic.
Integer(R/W)
1 ~ 1440
(minutes)
1(minutes)
Subscribe
Topic
Subscribe topics for Modbus
query received from the
MQTT server.
Check Box
Enable/
Disable
Disable
Publish Topic
Specifies the publish topic for
Modus data published on the
MQTT server.
String(R/W)
1 ~ 256
characters
TEST/MBDEV1
6.1.8 SMS
The SMS page is used to specify user mobile numbers for receiving alert SMS messages
Figure 12 SMS Web Page
Table 15 SMS Parameters
Parameter
Description
Format
Range
Default
Mobile No
User mobile number to
receive alert on SMS
String(R/W)
1 ~ 13
characters
Empty
NOTE
-It is necessary to Press the ‘Save’ button after changing the any parameter in any web page. Saved
parameters will have effect only after a power ON/OFF recycle is done or by pressing the ‘Reboot’
button.
-The RTru301 device will reset after pressing the ‘Reboot’ button. If the ‘Reboot’ button is press
then after the RUN/ERR LED will be in the OFF state
32
6.1.9 Calibration
Figure 13 Calibration Web Page
Table 16 Calibration Parameters
Paramet
er
Description
Range
Analog
Input
Count corresponding to the current applied from the current
source
Integer(CH-1)
Number(CH-2)
Analog
Output
Current value measured from the current output (4mA / 20mA)
(Zero/ Span Calibration)
Number
33
7. INPUT OUTPUT INTERFACE CHECK
7.1 Cellular Communication
The Cellular and MQTT Configuration parameters are described in Section 6.1. Follow the step by step
procedure below to set up the cellular configuration:
- Carefully insert a pre-activated SIM card to the device.
- Now open the web server of the RTru301 device to configure SIM related parameters and MQTT
parameters.
- Select the SIM Option in the web server
- The APN must be configured to RTru301 device for making a data connection. An APN is provided by the
cellular network service provider.
- If required, set the Username, Password and SIM PIN for the inserted SIM card.
- Configure the NTP server URL and NTP Port for the RTru301 device time synchronization with UTC. The
RTru301 device sends an NTP request to the NTP server on the cellular network. If it receives a response
then the device synchronizes with UTC time. The RTru301 device sends an NTP request to the NTP server
every 12hrs for Time synchronization. Two NTP servers are provided for redundancy.
- Set the MQTT parameters for the RTru301 Device Data publish such as periodic, diagnostic, Modbus and
HART® Data.
- Select the Time format to send the Epoch timestamp with data published to MQTT server. i.e. UTC or IST
- Select the data logging option for the data logged in case of cellular network failure or server disconnection.
The RTru301 Device sends the logged data when the network or server connection is restored.
- Save all parameters of the RTru301 device by pressing ‘Save’ Button and press the ‘Reboot’ button to reset
the device.
- The IMEI and SIM nos. are shown in the device info web page when the cellular modem is powered on
successfully without any error.
- Check the connectivity of the network of the RTru301 device with help of RSSI and NET LEDs.
The RSSI or cellular signal strength can be observed based on the RSSI LED
Table 17 RSSI (Receiving Signal Strength Indication)
Good : >= -85 dbm
LED ON
Low : >= -100 to <= -86 dbm
LED blinking at 1s interval
Very low : < -100 dbm
LED OFF
The network LED shows the status of network connection and MQTT server connection.
Table 18 Network Status Indication
Both network and MQTT are connected
LED ON
No network connected
LED OFF
MQTT not connected
LED blinking at 1s interval
Cellular initialization is in progress
LED blinking at 200ms interval
34
7.2 Modbus Communication
Modbus is an industrial automation protocol used for sending and receiving digital information across a
single, external RS-485 serial bus. The maximum 16 number of Modbus slave devices connected to the
RS485 Port 1 of the RTru301 device or the device can read a maximum of 64 registers from the Modbus
slave devices.
The Modbus parameter configuration is described in Section 6.1.7. See the below step to configure Modbus
parameter to read Modbus registers from the slave devices.
The following settings must match with the externally connected Modbus slave devices. Select the
appropriate Modbus serial communication:
Figure 15 Modbus Communication
The RTru301 device sends the query to the slave device and waits for a response from the slave devices
based on the poll time and response time set.
For monitoring Modbus devices on an MQTT server, specify the no. of the client, slave ID, function code, start
address, register length, data format, publish interval and publish topic in the Modbus web page
configuration. Please refer Figure 16 for Modbus slave device configuration.
To read 5 Holding registers (function code 3) with addresses from 40001 ~ 40005, enter value 1 in the Reg.
Start address input box and value 5 in Reg. Length.
Figure 16 Modbus web page
Table 19 Modbus Register Length Data Format
Data format
Data length
Range
Lower Limit
Upper Limit
Bool
1 Bit
0
1
Int 16
1 Modbus Register
-32768
32767
Uint 16
1 Modbus Register
0
65535
Int 32
1 Modbus Register
-2147483648
2147483647
Uint 32
1 Modbus Register
0
4294967295
Float
2 Modbus Registers
1.401 e-45
3.403 e38
Float Swap
2 Modbus Registers
35
The Read data from the Modbus slave devices can be set to the MQTT server by enabling the Modbus data
send option in the communication webpage.
Apply the configuration changes by pressing ‘Save’ and ‘Reboot’ Button. By pressing ‘Reboot’ Button the
device is reset. The Modbus communication can be checked by monitoring the Tx and Rx LED activity on the
device. The RTru301 device sends the data to MQTT server which is defined in MQTT web page on Modbus
Topic based on defined publishing interval.
See the below example for the Float (ABCD) and Swap Float conversion (CDAB)
For Float Value: 10.4802
Modbus register 0:0x4127, Modbus Register1:0xaee6
For Swap Float Value: 10.4802
Modbus register 0:0xaee6, Modbus Register1:0x4127
See the below example for Double (ABCD) and Double Swap conversion (CDAB)
For Double Value: 10.4802
Modbus register 0:0x4024,
Modbus Register1:0xf5dc,
Modbus Register2:0xc63f,
Modbus Register 3:0x1412
For Double Swap Value: 10.4802
Modbus register 0:0xF5dc,
Modbus Register1:0x4024,
Modbus Register2:0x1412,
Modbus Register3:0xc63f
See the JSON format for the payload of Modbus Topic which are sent on MQTT server
{"ts":1628937275000,"values": {"IMEI":123456789123456,"ID":"FM-DEV 001","FRAME":0,
"ST":0,"S1_1":0,"S1_2":5}}
Table 20 JSON Key Description for Payload of Modbus Topic
ts
Time stamp of JSON data in epoch time in ms
IMEI
IMEI number of cellular modem in device
ID
Device ID
FRAME
Type of data in frame live data, log data 0=Live,1=Logged
ST
Status of Modbus slave 1 = connected, 0 = not connected
S1_1
Combination of Modbus slave id and register start address e.g. "S1_1
S1 = SLAVE ID 1, 1= Register number1.
S1_2
Combination of Modbus slave id and register start address e.g. "S1_1"
S1 = SLAVE ID 1, 2= Register number2
7.3 HART® Communication
The HART® (Highway Addressable Remote Transducer) Protocol is an industry standard protocol for
sending and receiving digital information across analog wires between field devices and control and
monitoring systems. It preserves the traditional 4 ~ 20mA signal, and provides simultaneous transmission
of digital communication signals on the same wiring. Thus enabling a bi-directional communication with
smart instruments without disturbing the 4 ~ 20mA analog signal. In that way primary process variables
and control signal information is carried by the 4 ~ 20mA, while additional process measurements, device
configuration and parameter information, calibration, and diagnostics information is accessible through the
HART® protocol.
HART® slave devices include sensors, transmitters and various actuators that respond to commands.
Basically the HART® data is superimposed on the 4 ~ 20mA current loop making use of the frequency shift
keying (FSK) principle, via a FSK modem integrated in field devices. This enables devices to communicate
digitally using the HART® protocol, while analog signal transmission takes place at the same time.
36
HART® devices have the capability to operate in one of two network configurations: Point-to point
connection or Multi drop mode. Using the polling address structure of the HART® protocol, the polling
address of the field devices will vary in a range of 0 ~ 4.
1. Point to Point
In point-to-point mode the digital signals are overlaid on the 4 ~ 20mA loop current. Both the 4 ~ 20mA
current and the digital signal are valid signaling protocols between the controller and measuring instrument
or final control element.
The polling address of the instrument is set to "0". Only one instrument can be put on each instrument cable
signal pair. One signal, generally specified by the user, is specified to be the 4 ~ 20mA signal. Other signals
are sent digitally on top of the 4 ~ 20mA signal. For example, pressure can be sent as 4 ~ 20mA,
representing a range of pressures, and temperature can be sent digitally over the same wires. In point-to-
point mode, the digital part of the HART® protocol can be seen as a kind of digital current loop interface.
2. Multi-drop
The HART® communication protocol enables the capability to connect several two-wire measurement
devices in a (typical) multi drop network configuration, depending on the protocol revision.
All the devices are supplied from one voltage source and with a constant current consumption (usually
4mA). The master represents the sum of all the analog signals belonging to the devices in the network.
The host distinguishes the field devices by their preset polling addresses that must be unique in a range of
1~4. This address can be set by sending a special command to the devices. Standard HART® commands are
used to communicate with field instruments to determine process variables or device parameter
information. The connection diagrams of HART® slave devices are as below:
Figure 17 2-Wire HART® Device Connection
Figure 18 3-Wire HART® Device Connection
37
Figure 19 4 Wire HART® Device Connection
Figure 20 Multi-Drop HART® Device Connection
Packet structure
Each command or reply is a message, varying in length from 10 ~ 12 bytes to typically 20 or 30 bytes.
HART® provides two telegram formats, long and short format, which use different forms of addressing. On
the other hand, the HART® message structure is equal for long and short format.
The request HART® packet has the following structure:
Figure 14 HART® Packet Structure
38
Preamble
This element consists of 5 ~ 20 characters. All bytes in these characters are set to the logic value 1, in such a
way that each character represents the hexadecimal number 0xFF.
Start delimiter
The start byte uses for recognizing a message’s start. It indicates which participant is sending (master, slave,
and slave in burst mode) and whether the short frame or the long frame format is used. In case the message
has the long format, the start byte will contain the hexadecimal value 82 when it is sent by a master. On the
other hand, the value 81 indicates that it is a "Burst mode" message.
Table 21 Start Delimiter
Code
Meaning
0x01
Burst Mode short access
0x02
Request short access
0x06
Response short access
0x81
Burst mode long access
0x82
Request long access
0x86
Response long access
Address
Specifies the destination address implemented in one of the HART® schemes. Each HART field instrument
must have a unique address. A message sent by a master contains the address of the target slave. When
a telegram/message is sent on the HART network, the field device that recognizes the address as its
own will read this message and send back a response.
Command
This is a one byte numerical value representing which command is to be executed
Number of data bytes
Specifies the number of communication data bytes to follow.
Status
The status field is absent for the master and is two bytes for the slave. This field is used by the slave to
inform the master whether it completed the task and the current health status.
Data
Data contained in this field depends on the command to be executed.
Checksum
Checksum is composed of an XOR of all the bytes starting from the start byte and ending with the last byte of
the data field, including those bytes.
The RTru301 IoT Gateway device Read four types of HART® variable: Primary Variable (PV), Secondary
Variable (SV), Third Variable (TV), and Fourth Variable (QV), unit of each variable and Loop current.
The RTru301 device sends a request to HART® slave device based on the Polling ID set. The RTru301
device sends a HART® request to next slave based on the time(in seconds) set in HART® Query Time
parameter. The Query response time is used to set the RTru301 waiting time for the response from the
HART® slave device. The Query attempt is used to set the no. of requests sent to the HART® slave device
when no response is received.
The button ‘Get Device Data‘ is used to show information of connected devices. The RTru301 Device can
change the Polling Address of the HART® slave device.
Follow the steps below to change the polling ID of any HART® slave device:
1) Write new Polling ID in ‘Polling ID’ input box that you want to change
39
2) Pressing the ‘Change’ button, the RTru301 device changes the Polling ID of HART® slave device
Figure 15 HART® Web page
The RTru301 Device send the Payload of HART® Publish Topic to MQTT server based on the defined
publishing interval (in minutes)
See the JSON format for the payload of HART® Publish Topic which are sent on MQTT server
{"ts": 1628937275000, "values": {"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"H1_ST": 0,"H1_V1": 0,"H1_V2": 0,"H1_V3": 0,"H1_V4": 0,"H1_U1": 0,"H1_U2": 0,"H1_U3": 0,
"H1_U4": 0,"H1_LC": 0}}
Table 22 JSON Key Description for Payload of HART® Topic
ts
Time stamp of JSON data in epoch time in ms
IMEI
IMEI number of cellular modem in device
ID
Device ID
FRAME
Type of data in frame live data, log data 0=Live,1=Logged
H1_ST
Status of H1=SLAVE ID, 1 = connected, 0 = not connected
H1_V1
Combination of HART® slave id and Primary Variable e.g. "H1_V1
H1 = SLAVE ID 1, V1= Value of Variable 1.
H2_V2
Combination of HART® slave id and Primary Variable e.g. "H1_V1
H1 = SLAVE ID 1, V1= Value of Variable 1.
H3_V3
Combination of HART® slave id and Primary Variable e.g. "H1_V1
H1 = SLAVE ID 1, V1= Value of Variable 1.
H4_V4
Combination of HART® slave id and Primary Variable e.g. "H1_V1
H1 = SLAVE ID 1, V1= Value of Variable 1.
H1_U1
Combination of HART® slave id and unit of Primary Variable e.g. "H1_U1"
H1 = SLAVE ID 1, U1= unit of Primary Variable
H2_U2
Combination of HART® slave id and unit of Primary Variable e.g. "H1_U1"
H1 = SLAVE ID 1, U1= unit of Primary Variable
H3_U3
Combination of HART® slave id and unit of Primary Variable e.g. "H1_U1"
40
H1 = SLAVE ID 1, U1= unit of Primary Variable
H4_U4
Combination of HART® slave id and unit of Primary Variable e.g. "H1_U1"
H1 = SLAVE ID 1, U1= unit of Primary Variable
H1_LC
Combination of HART® slave id and Loop current of device e.g. "H1_LC"
H1 = SLAVE ID 1
7.4 Analog Input Interface
There are two channels provided for analog input:
-
4 ~ 20mA analog input measurement
-
Device Internal Temp measurement (Using Diode)
Enable the RTru301 device to get the external sensor data using the analog 4 ~ 20mA input and read the
device internal temperature. The configuration of Analog input channel 1 and 2 can be described in Section
6.1.5
Scaled Unit by Zero and Span
The RTru301 Device Read the Row value from the sensor device in mA. The reading of Row data can be
scaled by Zero and span value.
Alarms
Use an alarm to send the alert report to server or on user mobile number when unusual changes occur in
external connected sensor devices. Alarm event occurs when the value of external sensor reading is above or
below the value specified in high or low threshold respectively.
High Threshold
Send alarm event when the reading value of sensor greater than the value specified in High Threshold
Low Threshold
Send alarm event when the reading value of sensor is less than the value specified in Low Threshold
NOTE
An alarm will be generated only once when A/I value cross its High or Low threshold and no additional
alarm will be generated if the A/I value remains above or below High/Low threshold. A new alarm will be
generated only when the existing alarm is cleared.
Hysteresis
An externally connected sensor value may sometimes fluctuate in the High or Low alarm condition. This
causes high or low alarms to be generated by the device and the device sends multiple alarm events to
server or user mobile number.
Hysteresis works with the high and low alarm thresholds to tell the device when to keep an alarm on
without sending additional alarm events or when to turn off an alarm event. Use this to avoid repeated
alarms during reading of sensor input value fluctuations.
For example, an external sensor input value increases to the high threshold and the device sends a high
alarm event. However, the sensor input value continues to increase and decrease repeatedly between
normal and high thresholds during this alarm condition. If you have not set a hysteresis range, the device
sends an alarm event every time the sensor input value reaches the high threshold.
Use an alarm to send the alert report to server or on user mobile number when unusual changes occur in
external connected sensor devices. An alarm event occurs when the value of external sensor reading goes
above or below the value specified in high or low threshold respectively. See the example below for
hysteresis works for the High and low alarm.
High hysteresis
If the high threshold is 15mA and the hysteresis value is 2mA, then the High alarm hysteresis is 13mA. This
means that the alarm turns ON when the sensor input value reaches 15mA and remains ON if the sensor
input value stays above 13mA. No additional alarm reports are sent during this alarm condition. The alarm
turns OFF when the sensor input value falls below 13mA.
41
Low hysteresis
If the Low threshold is 5mA and the hysteresis value is 2mA, then the Low alarm hysteresis is 7mA. This
means that the alarm turns on when the sensor input value reaches 5mA and remains ON if the sensor input
value stays below 5mA. No additional alarm reports are sent during this alarm condition. The alarm turns
OFF when the sensor input value is above 7mA.
The analog input parameter configuration described in Section 6.1.5. See the below step to configure analog
input channel measurement.
- Set the parameter for analog measurement. The analog input channel 1 and 2 can be calibrated by the
Calibration web page. For the calibration of analog input channel 1 and 2 refer to Section 8.
- Apply the configuration changes by pressing ‘Save’ and ‘reboot’ button. By pressing ‘reboot’ button the
RTru301 device is reset.
- The value of analog input channel 1 and 2 can be monitored on publishing periodic data based on a defined
publishing interval to MQTT server when the send A/I data option is enabled in the communication web
page.
- The RTru301 device will send the alarm event on SMS to SMS alarm group number or the MQTT server
based on the option selected.
- SMS format of the device sends to the user mobile number when High or Low alarm event occurs.
Figure 16 Analog Input Web page
Table 23 SMS Format - Analog Input
Device ID
SMS Description
AI-CH-<Channel No><:AI channel
value>
<DD/MM/YYYY,HH:MM:SS>
FM-DEV-001
AI-CH-1
AI-CH-1:19800
18/11/2021,12:30:45
See the JSON format for the payload of Periodic data Topic which are sent on MQTT server when the all input
and output (A/I, D/I, A/O and D/O) option are enabled
{"ts": 1628937275000,"values":{"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"AI1": 14000,"AI2": 29,"DI1": 0,"DI2": 0,"AO1": 5000,"DO1": 0,"DO2": 0}}
See the JSON format for the payload of Periodic data Topic which are sent on MQTT server when the only A/I
option is enabled
{"ts": 1628937275000,"values":{"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"AI1": 14000,"AI2": 29}}
Table 24 JSON Key Description for Payload of Periodic Data Topics for Analog Input
ts
Time stamp of JSON data in epoch time in ms
IMEI
IMEI number of cellular modem in device
ID
Device Id
FRAME
Type of data in frame live data, log data 0=Live,1=Logged
42
AI1
Value of A/I 1
AI2
Value of A/I 2
DI1
Value of D/I 1
DI2
Value of D/I 2
AO1
Value of A/O 1
DO1
Value of D/O 1
DO2
Value of D/O 2
See the JSON format for the payload of Alert topic which are sent on MQTT server
{"ts": 1637218845000,"values":{"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"ALERT": 0,"AI1": 1980}}
Table 25 JSON Key Description for Payload of Alert Topics for Analog Input
ts
Time stamp of JSON data in epoch time in ms
IMEI
IMEI number of cellular modem in device
ID
Device Id
FRAME
Type of data in frame live data, log data 0=Live,1=Logged
ALERT
Type of Alert (0: AI-1 ALERT,1 : AI-2 ALERT, 2 : DI-1 ALERT, 3 : DI-2 ALERT)
AI1 or AI2
Value of AI1 or value of AI2
Refer the value of analog input channel 1 in different conditions:
1) Measured current > 3.6mA && Measure current < 3.8mA
Considered as Under Measurement, value of Analog input channel 1 = 32765
2) Measured current > 20.5mA && Measured current < 21.0mA
Considered as Over Measurement, value of Analog input channel 1 = 32766
3) Measured current <= 3.6mA && Measured current >=21.0mA
Considered as Open Measurement, value of Analog input channel 1 = 32767
4) Measured current >= 3.8mA and Measured current <= 20.5mA
Valid analog input range
7.5 Digital Input Interface
The RTru301 device has two isolated digital input channels. These digital Input channels can be configured
as digital input (ON/OFF) or Pulse Counter.
Filter Time
The Filter Time is the length of time that a newly changed input to some channel should last for before it is
accepted as a valid input. It is used to eliminate input noise. The minimum and maximum values for Filter
time are 10ms and 10000ms respectively. This parameter is applicable in the ON/OFF mode only.
Figure 17 Digital Input Filter Time
The Digital input parameter configuration described in Section 6.1.5. To configure the digital input channel
follow the steps below:
- Set the Parameter of Digital Input channel in the web page. Such as Filter Time, SMS alarm, Server Alarm,
SMS alarm Group, SMS description. The count from the Last and Step alarm count used in counter mode of
Digital Input.
43
- Apply the configuration changes by pressing ‘Save’ and ‘reboot’ button. By pressing ‘reboot’ button the
device is reset.
- If the Digital Input selected as ON/OFF mode then it senses High and low logic levels. A true event from
High to Low or Low to high will be considered based on Filter Time in ms.
-If the Digital Input selected as counter mode, the counter will start to count from the last stored value of
counter if the ‘count form last’ is enabled, otherwise the count will start from the Zero
-The SMS and Server alarm will be generated based on the Step alarm count and counter Roll over. The roll
over value of the counter is 4294967294.
- The value of Digital input channel 1 and 2 can be monitored on publishing periodic data based on a defined
publishing interval to MQTT server when the send D/I data option is enabled in the communication web
page.
- The device will send the alarm event on SMS to SMS alarm group Number or the MQTT server based on the
option selected.
- SMS format of the device sends to the user mobile no when a digital input alarm event occurs.
Figure 18 Digital Input Web page
Table 26 SMS Format - Digital Input
Device ID
SMS Description
DI-CH-<Channel No>:1-High,0-Low
<DD/MM/YYYY,HH:MM:SS>
FM-DEV-001
DI-CH-2
DI-CH-2:1
18/11/2021,12:30:45
See the JSON format for the payload of Periodic data Topic which are sent on MQTT server when the all input
and output (A/I, D/I, A/O and D/O) option are selected
{"ts": 1637218845000,"values":{"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"AI1": 32767,"AI2": 29,"DI1": 0,"DI2": 0,"AO1": 5000,"DO1": 0,"DO2": 0}}
See the JSON format for the payload of Periodic data Topic which are sent on MQTT server when the only D/I
option is selected
{"ts": 1637218845000,"values":{"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"DI1": 0,"DI2": 0}}
Table 27 JSON Key Description for Payload of Periodic Data Topics for Digital Input
ts
Time stamp of JSON data in epoch time in ms
IMEI
IMEI number of cellular modem in device
ID
Device Id
FRAME
Type of data in frame live data, log data 0=Live,1=Logged
AI1
Value of A/I 1
AI2
Value of A/I 2
DI1
Value of D/I 1
DI2
Value of D/I 2
AO1
Value of A/O 1
DO1
Value of D/O 1
DO2
Value of D/O 2
44
See the JSON format for the payload of Alert topic which are sent on MQTT server
{"ts": 1637218845000,"values":{"IMEI": 860936050053176,"ID": "FM-DEV-123","FRAME": 0,
"ALERT": 2,"DI1": 1}}
Table 28 JSON Key Description for Payload of Alert Topics for Digital Input
ts
Time stamp of JSON data epoch time in ms
IMEI
IMEI number of cellular modem in device
ID
Device Id
FRAME
Type of data in frame live data, log data 0=Live,1=Logged
ALERT
Type of Alert (0: AI-1 ALERT,1 : AI-2 ALERT, 2 : DI-1 ALERT, 3 : DI-2 ALERT)
DI1 or DI2
Value of DI1 or Value of DI2
7.6 Digital Output Interface
The RTru301 device has two isolated sink type digital output channels. The digital output channels can be
configured as digital output (ON/OFF) or Impulse Mode. The RTru301 device can retain the status of digital
output channel during Power ON/OFF. In Impulse mode the output is in sink mode for the defined impulse
time (ms).
The Digital output parameter configuration is described in Section 6.1.5. The Digital Output status can be
changed by sending SMS to device or command to subscription topic of device from the MQTT server. The
Digital Output can be monitored on a periodic frame of MQTT server. The RTru301 device will send the
Digital output value periodically based on the defined publishing interval of MQTT when the send D/O data
option is enabled in the communication web page. Apply the configuration changes by pressing ‘Save’ and
‘reboot’ Button. By pressing ‘reboot’ button the RTru301 device is reset.
Figure 19 Digital Output Web page
See the SMS format for changing the status of any digital output channel of RTru301 device
Table 29 SMS Format - Digital Output SET/RESET
SET
&DO<Channel No> #<SET/RESET>
&DO1 #SET
RESET
&DO<Channel No> #<SET/RESET>
&DO2 #RESET
See the SMS format for generate the impulse on any digital output channel of RTru301 device
Table 30 SMS Format - Digital Output Impulse
Impulse generated &DO<Channel No> #IMPULSE
&DO1 #IMPLUSE
See the Format of Topic published by MQTT server (Subscription Topic of Device) for changing the status
(ON/OFF) of any digital output channel
Table 31 Format of Topic Published by MQTT Server- Digital Output SET/RESET
SET
{"IMEI":<IMEI No>,
"<DO1/DO2>":"<SET/RESET>”}
{"IMEI":123456789123456,
"DO1":"SET"}
45
RESET
{"IMEI":<IMEI No>,
"<DO1/DO2>":"<SET/RESET>”}
{"IMEI":123456789123456,
"DO1":"RESET"}
See the Format of Topic published by MQTT server (Subscription Topic of Device) for generating impulse of
any digital output channel
Table 32 Format of Topic Published by MQTT Server - Digital Output Impulse
SET
{"IMEI":<IMEI No>,"<DO1/DO2>":"<IMPULSE>”}
{"IMEI":123456789123456,
"DO1":"IMPULSE"}
Note: The User receives the Invalid command response in SMS when they send the ON/OFF SMS command
to the RTru301 device and the RTru301 device is configured on Impulse mode through the webpage or vice
versa
See the JSON format for the payload of Periodic data Topic which are sent on MQTT server when the all input
and output (A/I, D/I, A/O and D/O) option are enabled
{"ts": 1628937275000,"values":{"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"AI1": 19800,"AI2": 29,"DI1": 0,"DI2": 0,"AO1": 5000,"DO1": 0,"DO2": 0}}
See the JSON format for the payload of Periodic data Topic which are sent on MQTT server when the only
D/O option is enabled
{"ts": 1628937275000,"values":{"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"DO1": 0,"DO2": 0}}
Table 33 JSON Key Description for Payload of Periodic Data Topics for Digital Output
ts
Time stamp of JSON data in epoch time in ms
IMEI
IMEI number of cellular modem in device
ID
Device Id
FRAME
Type of data in frame live data, log data 0=Live,1=Logged
AI1
Value of A/I 1
AI2
Value of A/I 2
DI1
Value of D/I 1
DI2
Value of D/I 2
AO1
Value of A/O 1
DO1
Value of D/O 1
DO2
Value of D/O 2
7.7 Analog Output Interface
The RTru301 device has one analog output channel (4 ~ 20mA). The device can generate the analog output
current based on last retained value during Power ON/OFF.
The Analog output parameter configuration described in Section 6.1.5. An analog output current can be
generated by sending an SMS to RTru301 device or via a command to subscription topic of device from the
MQTT server. The RTru301 device will send invalid command response over SMS when it receives an SMS
command with analog value other than 3600 and 21000 or in between them. The analog Output can be
monitored on a periodic frame of the MQTT server. The RTru301 device will send the analog output value
periodically based on the defined publishing interval of MQTT when the send A/O data option is enabled in
the communication web page. Apply the configuration changes by pressing ‘Save’ and ‘reboot’ button. By
pressing ‘reboot’ button the device is reset.
46
Figure 20 Analog Output Web page
See the SMS format for analog output generation
Table 34 SMS Format - Analog Output
18mA analog output generation
&AO #<Analog output value>
&AO1 #5000
See the MQTT Frame format for analog output generation
Table 35 Format of Topic Published by MQTT Server - Analog Output
18mA analog
output generation
{"IMEI":<IMEINO>,
"AO1":<value>}
{"IMEI":123456789123456,
"AO1":5000}
See the JSON format for the payload of Periodic data Topic which are sent on MQTT server when the all input
and output (A/I, D/I, A/O and D/O) option are enabled
{"ts": 1628937275000,"values":{"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"AI1": 19800,"AI2": 29,"DI1": 0,"DI2": 0,"AO1": 5000,"DO1": 0,"DO2": 0}}
See the JSON format for the payload of Periodic data Topic which are sent on MQTT server when the only
D/O option is enabled
{"ts": 1628937275000,"values":{"IMEI": 123456789123456,"ID": "FM-DEV-123","FRAME": 0,
"DO1": 0,"DO2": 0}}
Table 36 JSON Key Description for Payload of Periodic Data Topics for Analog Output
ts
Time stamp of JSON data in epoch time in ms
IMEI
IMEI number of cellular modem in device
ID
Device Id
FRAME
Type of data in frame live data, log data 0=Live,1=Logged
AI1
Value of A/I 1
AI2
Value of A/I 2
DI1
Value of D/I 1
DI2
Value of D/I 2
AO1
Value of A/O 1
DO1
Value of D/O 1
DO2
Value of D/O 2
47
8. CALIBRATION
8.1 Analog Input Channel 1 (4 ~ 20mA)
- Connect the 4 ~ 20mA analog input source to analog input terminal of device.
- Apply 4mA analog input to the Analog input terminal of Device. The measured input value will be displayed
on ‘PV’ input box on the calibration web page. Click on the ‘calibrate 4mA’ button. Refer the Figure 21
- Apply 20mA analog input to the Analog input terminal of Device. The measured input value will be
displayed on ‘PV’ input box on the calibration web page. Click on the ‘calibrate 20mA’ button. Refer Figure 21
- Now the calibration of analog input channel 1 can be done.
8.2 Analog Input Channel 2 (Temperature)
- The internal temperature value can be displayed on ‘PV’ input box in the calibration web page.
- Enter the actual temperature in the ‘Apply’ input box and press the ‘Calibrate Amb.Temp’ button. Refer
Figure 21
- Now the calibration of analog input channel 2 can be done.
Figure 21 Calibration - Analog Input
8.3 Analog Output Calibration
- Connect the current measurement device with the A/O terminal of the device
- Tick on the select box of O/P CAL Zero and then enter the measured value in O/P CAL Value which is
measured by the current measurement device. Subsequently, press the ‘Write Cal. Zero’ button.
- Tick on the select box of O/P CAL Span and then enter the measured value in O/P CAL Value which is
measured by the current measurement device. Subsequently, press the ‘Write Cal. Span’ button.
- Now the calibration of the analog output channel can be done.
Figure 22 Calibration - Analog Output
48
9. REPLACEMENT OF BATTERY
9.1 Replacement of Battery from Battery Holder
-
If the Epoch Timestamp value is received on MQTT server in the nearest range of 1420108200000 in
consecutive payload of periodic data topic, then check the Data and Time of RTru301 device on
device info page of webserver.
-
Do a power ON/OFF cycle at least 3 times and check the Time and Date of RTru301 device at every
Power ON/OFF cycle . If it shows the GMT time ‘Thu, 01 Jan 2015 10:30:00’, then check the RTC
battery voltage.
-
Switch off the external power supply connected to the RTru301 device.
-
-If the RTru301 device is mounted on Din rail then remove from the Din rail. Refer the procedure for
un-installing the module from a DIN rail.
-
Open the RTru301 Device and remove the battery with plastic tweezer. Refer STEP 1 in the figure
below.
-
Measure the Battery voltage.
Battery voltage:
Good battery: >= 3VDC
Low battery: < 2.8VDC (Replace battery)
- If the battery voltage is low, replace the battery. Always use a battery that is compatible with the existing
used part no (CR2032)
Figure 23 Battery Replacement instructions
Removing the battery from the holder
Inserting a new battery
STEP 1: Pull and Remove Battery from the
holder as per direction shown below
STEP 2: Check +/- polarity before and then
Insert new battery in holder as per
direction shown below
49
10. TROUBLESHOOTING TIPS
Power supply healthy red LED does not glow
-
Check power source and connection
-
Check red LED mounting and assembly
Server (192.168.100.110) is not detected
-
Check that the Ethernet cable connecter is properly fitted and Link and Activity LEDs glow
-
Check RUN/ERR LED must indicate healthy status
50
11. REVISION HISTORY
Initial release: V1.0 09022022
Copyright Notice
© All rights reserved. Any reproduction or distribution in part or as a whole without written permission of
Forbes Marshall Pvt. Ltd., its associate companies or its subsidiaries (“FM Group”) is prohibited.
Information, designs or specifications in this document are subject to change without notice. Responsibility
for suitability, selection, installation, use, operation or maintenance of the product(s) rests solely with the
Customer and/or user.
Forbes Marshall Pvt. Ltd.
B-85, Phase-II, Chakan Industrial Area
Sawardari, Chakan
Tal: Khed, District: Pune
Maharashtra, India – 410501
Tel: +91-21-35393400
Website: www.forbesmarshall.com
Email: support@forbesmarshall.com
|
"Aqua4Trans User’s Manual | R2, Dec 2023 \n1 \n \nUser’s Manual \nAqua4Trans \nR2, Dec 2023 \n \(...TRUNCATED)
|
" \n \n \n1 | P a g e \n \n \n User’s Manual \n Microcon \n \n \nR0, (...TRUNCATED)
|
README.md exists but content is empty.
- Downloads last month
- 6