FlowScanner User Guide

FlowScanner Valve Diagnostic
System User Guide
Preliminary Manual
D101939x012
FlowScanner, FlowStor, RatRace, Fisher, Fisher-Rosemount, and

Managing The Process Better are marks owned by Fisher Controls
International, Inc. or Fisher-Rosemount Systems, Inc. All other marks
are the property of their respective owners.
Fisher Controls International, Inc. 1/97;

All Rights Reserved
FlowScanner User Guide
While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfactory results from re-
liance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, e pressed or implied, regarding the
performance, merchantability, fitness or any other matter with respect to the products, nor as a recommendation to use any product or process in
conflict with any patent. Fisher Controls reserves the right, without notice, to alter or improve the designs or specifications of the products de-
scribed herein.
2
Contents
Section Title Page
1 Introduction
1.1 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 FlowScanner Description
2.1 Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.2 FlowScanner, Transducers, Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 FlowAux Software Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.1 The Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Theory of Operation
3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 FlowScanner Startup and Shutdown

4.1 Background Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Startup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Wonder Plus (1 DIR +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Setting Up for a Test

5.1 Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Setting Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Defining Nametags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.1 Filling in a New Nametag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3.2 Saving and Printing Nametags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.3 Retrieving a Nametag File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.4 Using Drive G for Nametag Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3.4.1 Storing Nametags on Drive G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3.4.2 Recalling Nametags from Drive G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3.4.3 Erasing Valve Nametag from the Screen . . . . . . . . . . . . . . . . . . . . . . . 28
5.3.5 Exiting the Nametag Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4 Making Physical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4.1 Measuring Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4.1.1 Transducer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4.1.1.1 Transducers for Sliding-Stem Valves . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4.1.1.2 Transducers for Rotary Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3
5.4.1.2 Transducer Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4.1.3 Travel Feedback Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.4.2 Measuring Pneumatic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4.2.1 Installing Test Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4.2.1.1 Temporary Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4.2.1.2 Permanent Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4.3 Supplying and Measuring the Control Signal . . . . . . . . . . . . . . . . . . . . . 41
5.4.3.1 Command Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4.3.2 Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4.4 auxiliary Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.5 Setting Test Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.5.1 Dynamic Scan Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.5.2 Static Point Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5.3 Step Change Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5.4 Stepped Ramp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5.5 Step Study Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5.6 Pressure Channel Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5.7 auxiliary Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.5.8 Storing a RUNTEST File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6 Running a Test in Control Mode
6.1 Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2 Changing the Travel Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.3 Setting Transducer Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4 Disabling Automatic Zero of Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.5 Graphing Measured or Commanded Current . . . . . . . . . . . . . . . . . . . . . . 48
6.6 Specifying Test Line Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.7 Selecting to Hold or Zero the Output at the End of the Test . . . . . . . . . 49
6.8 Controling the Valve Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.9 Recording the Static End Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.10 Zeroing Travel and Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.11 Scaling auxiliary Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.12 Starting and Stopping the Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.13 Recording Test Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.14 Saving Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.15 Exiting the Test Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.16 Disconnecting from a Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7 Running a Test in Monitor Mode
7.1 Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.2 Changing the Travel Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.3 Setting Transducer Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.4 Disabling Automatic Zero of Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4
7.5 Zeroing Travel and Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.6 Scaling auxiliary Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8 Displaying and Analyzing Test Results

8.1 Display Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.1.1 Starting the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.1.2 Choosing Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.1.3 Returning to the MENU Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.1.4 Printing Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.1.5 Capturing Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.1.6 Graph Cursor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.1.7 Zooming a Graph View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.1.8 Marking Data Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.1.9 Graph Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.1.9.1 Possible Data Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.1.9.2 Limiting Analysis Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.1.10 Dynamic Scan Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.1.11 Measurement vs. Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.1.11.1 Miscellaneous Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1.12 Static Point Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.1.13 Step Change Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.1.14 Stepped Ramp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.1.15 Step Study Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2 Transferring Data to the Report Module . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.3 Copying and Displaying from the Display Program . . . . . . . . . . . . . . . . . 74
8.3.1 Saving Data to a New Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3.2 Saving Data as an ASCII File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3.3 Compressing Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9 Quick Reports
9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.2 Procedures
9.2.1 Retrieving Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.2.2 Saving Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.2.3 Printing Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10 Parts List
11 Appendices
11.1 Appendix A: Data Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.2 Appendix B: Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11.3 Appendix C: Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5
11.4 Appendix D: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11.5 Appendix E: Connectors for Diagnostic Tesing . . . . . . . . . . . . . . . . . . . . 97
11.6 Appendix F: Tech Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
11.7 Appendix G: Related Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12 Glossary
13 Index
6
1 Introduction
1.1 Scope of Manual

This manual describes: how to setup the FlowScanner, run tests in
control and monitor modes, analyze the test results, run reports, and
includes a complete parts list.
1.2 Description
The FlowScanner Valve Diagnostic System is a portable test device
used to evaluate a control valves current operating condition without
disassembly and to recommend any necessary corrective action. It
can also be used during setup and calibration before a valve is
placed in service to ensure that the valve will function as intended.
2 FlowScanner Valve Diagnostic System

Description
2.1 Hardware Description

The FlowScanner Valve Diagnostic System from Fisher Controls is a
portable, microprocessorbased diagnostic and calibration system
specifically designed for use with process control valves. The FlowS-
canner System analyzes each pneumatic valve assembly as a com-
plete process control package. This system also analyzes individual
components such as the I/P transducer, positioner, actuator, volume
booster, and other accessories. The FlowScanner System then de-
termines critical valve parameters such as bench set, seat load,
valve stroke, packing and bearing friction, and other relevant aspects
of valve performance.
For more information about the FlowScanner System, contact the
Fisher Controls sales representative or sales office.
7
2.1.1 Specifications
FlowScanner System Hardware
Processor: 486DX2 50 MHz, or better
Random Access Memory: 16 MB
Hard Drive: 500 MB, or greater
3.5-inch Diskette Drive: high density 1.44 MB
Display: Monochrome LCD fold-up screen (standard), or Color, LCD (optional(1))
Keyboard: 82 keys with membrane cover
Operating System Software

MS-DOS operating system with DOS shell, Windows for Workgroups 3.11 and
pointing device, FlowScanner software installed and configured for testing sliding
stem and rotary valves
Power Supply
AC Power: 90 to 250 volts ac, 5060 Hz
Internal Battery: 7 amp-hour 12 volt Gel-cel provides 3 to 4 hours operation per
charge(1). Charges internally from AC source in approximately 4 hours.
Inputs
15 inputs:
6 pneumatic channels accept up to 100 psi signals,
2 pneumatic channels accept up to 30 psi signals,
system records data on any 6 channels5 auxiliary channels accept 10 to +10 volt dc
signals, common ground
Monitor control signal accepts 0 to 55 mA or 0 to 10 volts dc, use to monitor FlowS-
canner system control signal or an external control signal
Travel, linear up to 30 inches (sliding-stem) or 360 degrees (rotary)
Control Signal Output

FlowScanner system provides a control signal of 0 to 25mA,
0 to 55mA, or 0 to 10 volts dc
Computer Outputs
External VGA color monitor port
Parallel printer port
Two RS-232 serial ports
8
Specifications Continued
Accuracy
Control Signal Output Accuracy
Range Loop Command Accuracy Measurement Accuracy
0 to 25 mA 0.02 mA 0.03 mA
0 to 55 mA 0.03 mA 0.03 mA
0 to 10 Vdc 0.01 volts 0.01 V
Travel Input Accuracy

Range Resolution Overall Accuracy
0 to 2 inch 0.0001 inch 0.0001 inch
(0 to 50.8 mm) (0.0025 mm) (0.0025 mm)
(0 to 101.6 mm) (0.0025 mm) (0.0025 mm)
0 to 25 inch 0.0001 inch 0.0001 inch 0.012% full scale
(0 to 635 mm) (0.0025 mm) (0.0025 mm) 0.012% full scale)
(0 to 812.8 mm) (0.025 mm) (0.025 mm) 0.05% full scale)
Rotary 0.0075 degree 0.0075 degree
Pneumatic Input Channel Accuracy

Accuracy w/10 Min. Warm-Up
Pressure Range Resolution Accuracy w/2 Min. Warm-Up
& Within 20 Min. of Re-Zero
0 to 100 psi 0.04 psig 0.1 psig + 0.2% of reading 0.1 psig + 0.7% of reading
0 to 689.65 kPa) (0.27 kPa) 0.68 kPa + 0.2% of reading 0.68 kPa + 0.7% of reading
(0 to 206.90 kPa) 0.07 kPa) 0.2 kPa + 0.2% of reading 0.20 kPa + 0.7% of reading
Note: Also configurable to kg/cm2, Bar
Housing
Haliburton metal case with O-ring seal
Hazardous Area Classification

None
9
Specifications Continued
Pressure Connections
Tubing: 1/8-inch OD, 1/16-inch ID (Parker p/n NB2-031, no substitutes)
Removable Fittings: Parker Prestolok
Permanent Fittings from Factory:
Swagelok quick connect (p/n B-QC4-B-2PM)
(1/4-inch chrome-plated brass)
Swagelok plug, body protector (p/n B-QC4-BP)
(1/8-inch mating fitting)
Note: for Stainless steel, change first alpha character, B to SST
Approximate Weight
35 pounds (15.9 kg)
Options
spare battery and external charger package; remote pressure scanner adapter
with 25 feet (7.6 m) of cable; removable keyboard with LCD display and 5 feet of
cable; input conditioning card with 5 isolated input channels, configurable 0 to 55
mA or 0 to 10 Vdc; ValveLink Type VL2020 software(includes HART modem)
1. The optional color LCD display shortens average battery life to two hours due to increased power consumption
10
2.1.2 FlowScanner, Transducers, Tool Kit
The accessory kit contains the necessary hardware required to facili-
tate setup and data collection. The kit allows for the ease of trans-
ducer attachment to any operated valve (sliding stem or rotary) re-
gardless of manufacture. The following items are included in the kit:
Rugged polyethylene case
25-inch Celesco travel transducer (sliding stem valves)
C25 DRC travel transducer (rotary valves)
Travel transducer mounting brackets (4)
Adjustable jaw vice-grip (Bessi Clamp)
Std. 10-inch vice-grip (travel feedback arm)
SPI Fisso Support Arm
Flex Coupling
Double stick tape
1/8-inch pressure tubing
Pressure fittings
Attachment screws
Assortment of wrenches
Assorted screwdrivers
2.2 FlowAux Software Description

FlowAux software for the Fisher FlowScanner Valve Diagnostic sys-
tem is designed to allow all normal valve testing plus additional data
acquisition on the 3 to 5 auxiliary input data channels. FlowAux can
be installed on a FlowScanner without replacing the original (2.3)
system software. FlowAux creates new subdirectories on the hard
disk and is run from new commands, so the original FlowScanner
programs can still be used.
11
The distribution disk contains installation programs for the FlowScan-
ner. It can only legally be installed on systems for which a license
was purchased.
Note
The software package contains two programs: a sliding
stem application and a rotary valve application.
Although these programs vary in appearance, they are
similar in function, and the differences merely reflect
the operational differences between the two valve
styles. Because the two programs function so
similarily, this manual will try to cover both versions and
only mention one or the other programs when specific
differences are applicable to the discussion.
A main menu starts when either the SLIDAUX.BAT or ROTAUX.BAT

files are run. These files are placed in the 1APP directory of the
FlowScanner. The other portions of the FlowScanner programs are
selected from the main menu by moving a highlight bar with the key-
pad arrow keys.
2.2.1 The Main Menu
FlowAux Main menu
The main menu screen selects the various FlowScanner programs:
12
StartLook ator Change a Valve Nametag
Identify the valve, actuator, accessories and plant site
SelectViewor Change a Test Setup
Select the test type and enter testing parameters
Display and Analyze Test Data
Review test results and manipulate the data as necessary
Prepare a Test Report
Display test data in report format
Format a Data Disk
Format a floppy diskette for data storage
Record Data Drive and Operating Defaults
Set default preferences for operation and data storage
The up and down arrow (cursor) keys will move the highlight bar to
the different choices, and pressing Enter will select the highlighted
choice. AltV will toggle video between color and monochrome, and
AltS will check space on a data disk. You will notice that every
menu item and selection choice has one letter that is highlighted, you
can type that letter either by itself, or incombination with the Alt key,
to make that selection.
3 Theory of Operation
3.1 Description
The FlowScanner is a data acquisition system used as an integral
part of a condition-based maintenance program or as a valve trou-
bleshooting device. The FlowScanner system allows multiple data
acquisition inputs that a FlowScanner system operator can use to
determine the overall efficiency of the control valve asset.
Note
Best results are obtained if the system is operated by a
Fisher factory-based engineer/technician or a Fisher
factory-trained person.
13
The first step in determining a control valve assets efficiency always
starts with a review of the application. Based on the operation histo-
ry of the valve in question, a determination of the type of test to be
run is made. This is typically a dynamic error band test. For a de-
scription of test types, see section 9. Serial cards and customer re-
cords are collected and reviewed to determine the valve construction
and operating parameters. Any potential application problems are
identified at this time (e.g., is the right valve being used for the right
application).
The next step involves a FlowScanner survey of the valve in ques-
tion. This is normally a two-minute stroking test (test times vary de-
pending on type of test and size of actuator). See section 6, for test
setup guidelines. The test can be performed with the valve in control
mode or monitor mode. The system normally measures the pressur-
es at the positioner guage block via quick connect fittings. If no
quick connection are installed on the valve, you can use tee connec-
tions into the instrumentation line. Valve travel is measured off the
valve stem with a digital encoder. A control signal connected to the
valve input (mA, volt, psi) strokes the valve through one cycle. The
system then generates signature data curves and a summary re-
port covering parameters like: benchset, seat load, valve stroke,
packing friction, bearing friction, stroking time, dynamic response,
actuator spring rate, air supply (pressure & volume) positioner dy-
namic response and I/P dynamic response.
This data can then be interpreted by a factory-trained engineer/tech-
nician to determine the overalloperating efficiency of the valve as-
sembly and can be used to determine the necessary corrective ac-
tion.
For additional information concerning data interpretation, ask your
local Fisher Representative or Sales Office about Fisher Education
Center Courses, #1425 and #1426.
14
A6204-1/IL
FlowScanner Diagnostic System Test Connection Schematics
15
4 FlowScanner Startup and Shutdown
4.1 Background Information

The hard drive for a FlowScanner is partitioned into a C: partition
and a D: partition. The C: partition contains the operating system,
the FlowAux program directory, and the other application programs
that are needed for the computer. The D: partition is used for data
storage for the FlowScanner. With the D: partition, there are three
directories that are created during the software installation. One is
the \TEST subdirectory, the second is the \RAMRAUX directory, and
the third is the \RAMSAUX directory. On the C: drive, the software
creates the \FLOWAUX top level directory, beneath that is created a
subdirectory called \SLIDSTEM and a subdirectory called \ROTARY.
The software also creates a top level directory called \1APP. Within
the \1APP directory, there are two startup files, ROTAUX.BAT and
SLIDAUX.BAT.
When a FlowScanner starts up, the CONFIG.SYS file and the AU-
TOEXEC.BAT files are run. The CONFIG.SYS file initializes two
RAM disks. (A RAM disk is a portion of the computers RAM that
operates like an additional hard drive). There are two advantages of
using RAM disks instead of the hard drive: 1) much faster program
access and 2) less power consumption. When the RAM disks are
initialized, they are recognized as drive E: and drive F:.
There is also a command in the FlowScanners AUTOEXEC.BAT file
that substitutes the D:\TEST directory as drive G:. The FlowScanner
program can only access data at the root directory of any drive. By
making the substitution, you can store data within a subdirectory on
the D: drive by selecting the G: drive as the data directory.
4.2 Startup Procedures

There are two versions of the FlowAux program, for sliding stem
valves and rotary valves. The following discussion refers to the slid-
ing stem valve program, but these procedures are applicable for the
rotary valve program also.
16
From the FlowScanners main menu, choose the letter O or go down
to Record Data Drive and Operating Defaults to get to the Operat-
ing Defaults display. The upper left hand choice is Program Drive
and for a FlowScanner this should be drive E:. The Data Drive
should be drive A:, if using the floppy disk or drive G:, if you are stor-
ing data to the hard drive. The third line down says Temporary Stor-
age (RAM disk). This should be drive F: for a FlowScanner.
To start the sliding stem version of the FlowAux program, you need
to run the file, SLIDAUX.BAT, found in the C:\1APP directory. First,
the sliding stem executable programs and support files are copied
from the C:\FLOWAUX\SLIDSTEM directory to the E: RAM disk.
You will see the command lines scroll across the screen as these
files are copied. Next, any data stored in D:\RAMSAUX from the last
test is copied to the F: RAM disk. After all the files are copied to the
RAM disks, the FlowAux MAINFS.EXE program is executed.
While you are running the FlowAux program, updated versions of the
various files are being created (e.g., test setups and calibration files
for the current session). These new files reside in the RAM disk and
will be lost, along with their settings and configurations, if the FlowS-
canner is powered off without following the proper shutdown proce-
dures. (At this point, test data has already been stored to the A: or
G: data drive, so this data would not be lost.) To preserve these files
when testing is done, you need to copy the contents of the RAM
disks back to the hard drive.
4.3 Shutdown Procedures

As mentioned above, you must copy the data in the RAM disks back
to the hard drive before powering off the FlowScanner, to avoid los-
ing data from the current session. This is done by selecting Prepare
for System Shutdown from the Main Menu (or by pressing Alt-X).
This initiates the system shutdown, which copies the files from the
RAM disks back to the hard drive directories.
17
The rotary version of the software uses the same procedures de-
scribed above. The difference is that the program files are executed
from the C:\FLOWAUX\ROTARY directory instead of the C:\FLO-
WAUX\SLIDSTEM directory. The contents of the RAM disks are
stored in the D:\RAMRAUX directory instead of the D:\RAMSAUX
directory. The same A: or G: data drive is sued for both sliding stem
and rotary valve files. The rotary program executes MAINROT.EXE
after the files are copied to the RAM disks instead of MAINFS.EXE.
Besides these minor differences, the startup and shutdown proce-
dures are the same.
4.4 Wonder Plus (1 Dir +)

The FlowScanner uses Microsoft DOS v6.22 as an operating sys-
tem. To facilitate the use of the computer by non-computer literate
users, there is a DOS menu program called Wonder Plus or 1 Dir
+ that simplifies the startup procedures. When a FlowScanner is
first booted up, it performs a memory test and then starts MS-DOS.
After the CONFIG.SYS and AUTOEXEC.BAT files execute, the
Wonder Plus program starts. The Wonder Plus interface appears as
a series of boxes filled with various types of information about the
computer, such as: memory usage, file listings, etc. Function keys
are across the bottom of the screen. The names of the files in the
current directory are listed in the left-hand box. The path to the cur-
rent directory is displayed across the top of the Wonder Plus screen.
When the program first starts, the path says C:\1APP. By using the
up and down arrow keys, you move the word to the left-hand col-
umn that says Compose. You move Compose down to select
either the SLIDAUX.BAT or ROTAUX.BAT depending on the version
of the program you want to run. Press the <Enter> key to start the
selected .BAT file.
When the session is finished and the the shutdown procedure is
completed (the RAM disk files have been copied back to the hard
drive), the screen displays the contents of the C:\1APP directory. At
this point the FlowScanner can be safely powered off.
18
5 Setting Up for a Test
5.1 Quick Reference

More detailed instructions follow this section, but here is a quick
overview of the operating sequence to test and report on a valve:
1. Check to see that all switches are off. Start the system according
to the instructions in section 4.0 of this manual.
2. Check that Operating Defaults are set properly.
3. If necessary check or recalibrate the pressure scanner or control
current with the Calibrate program from the main menu. This is nor-
mally necessary only once or twice per year.
4. Verify that operating defaults are set properly.
5. Insert a data disk, and format it if it is unformatted. The Format
menu choice will let you choose between 720 KB and 1.44 MB for-
mats. You can purchase preformatted diskettes and save time.
6. Select the Valve Nametag program and fill in all data for the na-
metag. Items marked on screen with an asterisk (*) are used in
analysis, and must be filled in for the program to calculate results. If
preferred, the nametag can be saved blank with only a TAG num-
ber assigned for file name, and the rest of the data filled in after test-
ing. However, before the data can be analyzed the nametag data
must be completed and the revised data read into the analysis pro-
gram. Save the Nametag to the data disk and print it if desired. It is
often faster to complete this ahead of time from the serial card.
7. Return to the main menu and select Test Setup. Pick a prede-
fined setup (stored on the system hard disk) for a standard test, or
complete all entries for a new setup. Be sure to specify the travel
transducer used, and assign the pressure channels to use for each
parameter. If auxiliary input channels are used fill in descriptive
names for the channels to be used.
8. Save the setup / valve combination to the RUNTEST file as
prompted when exiting the Setup screen to the Main Menu.
9. Select the Test program from the main menu. Before applying
pressure Zero the pressure readings with AltZ.
10. Connect the pressure tubing from the system to the valve test
points (as defined in step 4). For repeated testing you may install
test connections behind the positioner gauges.
19
11. Mount the travel transducer to the valve assembly so it mea-
sures the stem travel. Typically the transducer is mounted to the
actuator casing.
12. Connect the control cable to the I/P.
13. Connect the control cable to the FlowScanner system.
14. Using the keypad arrow keys stroke the valve to assure all is
connected properly. Check that the pressure readings agree with the
labels, and that the travel reading returns closely to zero. (Some-
times you may not want to stroke the valve first, if testing for sticking
or a condition which could be affected by repeated stroking.)
15. Run the test. (F9 starts the test.)
16. Save the data to disk. (It is also possible to view the data from
the RAM disk before deciding to save to the data disk.)
At this point you can either view the results and make adjustments
while connected to the valve, or disconnect from the valve. The data
can be analyzed later if you want to test other valves first. The anal-
ysis and printing can be done on a suitable desktop PC, using
RatRace Desktop Analysis Software, if desired. We recommend
at least a cursory review of the graphs while still connected to the
valve to insure that the data was properly collected and stored.
17. Return to the main menu and run the Display and Analyze pro-
gram to view the data. Connect the printer and print any graphs (F5
or F6 to print) and analyses desired.
18. Save the analysis data to a report file.
19. Return to the main menu and run the report program. Read in
the test report file and add comments to the results as indicated.
Print the quick report if desired.
20. Save the report with comments to the data disk.
21. Return to the Main Menu and select Prepare for System Shut
Down before shutting off the power. This saves the information
stored temporarily in memory to the hard drive for retrieval when you
restart the program.
22. Shut off the System as described in section 5.0 for that model.
5.2 Setting Defaults

When first using FlowScanner, the Operating Defaults must be set.
The Operating Defaults choice from the Main Menu lets you set the
20
default data drive, nametag file type (by Serial number or Tag num-
ber), whether or not to use a data RAM disk, whether or not to auto-
matically save the test data upon test completion, whether or not to
automatically analyze and print the graphs, and what type of graph-
ics printer to expect, and what engineering units to display. The Op-
erating Defaults screen looks like this:
Operating Defaults Screen
The program drive is set automatically when the program is started.

The program drive can no longer be changed in the defaults screen.
Set the data drive to the letter for the 3 1/2 Floppy drive. (Typically
A on FlowScanners)
Data is normally saved by TAG number instead of a Serial number,
but either can be used. If saved as a serial number only numeric
digits can be entered. (The actual disk file will be named by an en-
coded number, but the popup menus will show the serial number as
entered.) The F2 key will popup the menu to select either TAG or
SERIAL defaults. This determines where all programs will look for
the nametag files.
The Temporary Storage drive on a FlowScanner should be set to F
but on a desktop it is used only if you have created a RAM disk for
that purpose. This allows the programs to run slightly faster. To dis-
able temporary storage set the RAM disk to X.
The Auto Save Data and Auto Print Graphs are normally set to No.
If set to Yes, the data will be automatically saved after it is taken
and graphs will automatically be printed on analysis.
Press the F2 key and pick the type of printer you will normally use to
print graphs. (This setting has no effect on text printing for reports.)
21
You can override this setting from the Printer menu in the Display
and Analyze program.
Select the units to use for pressures, linear travel, and force from the
three popup menus. (F2 recalls all menus when the cursor is on the
field location.) For pressures the possible choices are: psi, kPa,
kg/cm2 and bar
Displayed Travel Units can be set to inches or mm , and Displayed
Force Units can be set to pounds (LBS), Newtons (N), or
DecaNewtons (DN).
The video mode can be toggled between Color and Monochrome by
pressing AltV. The mode set when exiting the defaults screen will
be used by all programs.
After setting the defaults, AltX will save the default file and return to
the main menu.
5.3 Defining Nametags

The software needs to know details about the valve in order to ana-
lyze results. This information is entered as a valve nametag. The
information from the nametag file is read each time the test
data is selected, so corrections may be made to the nametag
after testing, and they will be used in subsequent analysis.
However, a nametag file must be saved for reference before a
test can be run on a valve.
Sliding Stem Valve Nametag Screen
The nametag screen appearance and fields will differ slightly be-
tween the Rotary and Sliding Stem programs to reflect the operation-
al differences between the two valve styles
22
Rotary Valve Nametag Screen
The units shown on the various fields will match the units selected in
the operating defaults screen. The file is always saved in US units,
but the display and printouts will match the default units.
The cursor should be flashing on the first character of the Plant
Site field.
Items marked on screen with an asterisk (*) are used in analy-
sis, and must be filled in for the program to calculate results.
5.3.1 Filling in a New Nametag

The nametag is filled in three sections: The valve data, the actuator
data, and the accessory data. First fill in the Valve data. Move be-
tween sections by pressing the PgDn and PgUp keys.
If you question what is required for a field, pressing the F1 key will
bring up a help screen describing what is needed.
F1 Help Screen for Body Style Field
23
The Plant site is a reference field (not required) for your later identifi-
cation of the data.
Pressing Enter after an entry will move to the next field, or you can
move between fields with the up and down cursor keys.
An identifying description can be entered in the Description field.
The TAG number is also used as the filename to store the nametag
data on the disk. The first 8 characters only are used for the file-
name, and illegal characters (spaces, periods, etc.) are replaced by
underscores in the file name. If possible, be consistent by using only
letters and numbers in the TAG # field. This is the only field required
to take test data
Enter the Serial Number in its field (the serial number field will only
accept numerical characters, no alphabetic characters allowed) If
the accessories also have serial numbers they can be reference in
the Comments fields (accessed by pressing AltC).
The Body Type field will pop up a menu list of Fisher body types.
Sliding Stem Body Type Pop-Up Menu
Move through the list with the Up & Down arrow keys. Press Enter
when the desired choice is highlighted to enter it into the field. For
nonFisher types press the Esc key to exit the menu and allow you
to type in an entry.
Once an entry has been made the menu will not pop up automatical-
ly when you move back to the field. It can be recalled by pressing
the F2 key when the cursor is on the field. (This is true for all fields
which have popup menus.)
Next fill in the body size and class from the popup menus in the
next fields.
24
The trim fields can be filled with any text string, as this field is not
used for later calculations. They are typically used to describe the
the materials of construction, characteristics or special designs.
Select the flow direction, and indicate if flow tends to open or close
the valve.
On the Sliding Stem program, the field for BALANCED or UN-
BALANCED construction may be selected automatically if the body
type and size so indicate. If the software cant decide the construc-
tion a menu will be offered, otherwise the field is filled in and
skipped.
Select the port diameter, stem diameter, and packing type from the
next menus.
The Friction fields will normally be filled in by the software. (For the
EHD, the added friction for the piston rings is filled in after the line
pressure entries.)
Select the leak class and seat type from the menus. If the valve is
on Boiler Feedwater service, select the Feedwater leak class. This
will use the Feedwater tables from Fisher Catalog 14 to specify the
seat load.
Pressing F1 with the leak class menu visible will bring up a table of
standard leak classes for Fisher valves: Enter the specified inlet
pressure and outlet pressure in the units selected.
Sliding Stem Leak Class Help Screen
The required seat load will then be calculated and filled in, based on
the previously entered data. See Section 3.1.
Enter the specified travel. Fractions entered will be converted to
decimal.
25
The stoking time fields are for reference if there is a customer re-
quirement.
When the Valve section is complete, press PgDn to move to the Ac-
tuator section, and select the actuator type and size from the me-
nus. Also select whether actuator air pressure opens or closes the
valve. These entries are used in determining seat load and friction.
Enter the specified benchset from the nameplate. This will be
compared to the measured bench set later.
The software will fill in the effective area for Fisher actuators on the
menu, if the Type and Size were selected from the pop-up menus.
For other types the effective area must be manually entered before
the valve is tested, as it is used in calculations.
Press PgDn again to move to the accessories fields and select the
I/P type and fill in the output range.
Select the I/P input type (use psig if no I/P is used).
Fill in the I/P resistance if the control current will be monitored
through the I/P voltage.
Select the positioner model (reference only).
Specify whether the valve is in the Open or Closed position when
zero control signal is applied. This field overrides all other choices to
label the graphs.
Note any other accessories in the Other fields.
Enter longer comments (i.e., 2 lines or >50 characters) by pressing
AltC for a comment window.
5.3.2 Saving and Printing Nametags

Pressing F10 will save the completed nametag to the data disk un-
der the TAG # as a filename (unless the operating default is set to
Serial Number). The tag can also be saved by accessing the File
menu (AltF); where existing nametag information can also be read
off the disk and displayed or changed. From here it can be saved as
either a nametag or serial number.
The nametag can be printed by pressing F6 or AltP. You will then
choose to print to the screen (for preview) or to the printer. Be sure
the printer is properly connected and turned on before trying to print.
5.3.3 Retrieving a Nametag File

Nametag file already stored on the data disk can be read back in
from the File menu, selected by (AltF). Select either Tag Number
26
or Serial Number from the menu (Field data is normally saved as a
Tag Number), and a list of nametags found on the disk under that file
type will appear. The Sliding Stem program will not show Rotary na-
metags and viceversa, and if you selected Tag Number files any
saved as Serial Numbers will not show on the list. Use the cursor
keys to select the file you want and press Enter to read the file and
display it on screen. You can make changes and save the file again,
and the changes will be reflected when you analyze data or print re-
ports. If you want to set up another test for a valve already tested
you must read in the nametag before setting up the test.
5.3.4 Using the Drive G for Nametag Storage

If you have defined a data area of a hard drive or network drive as
Drive G, it can be used to store a large group of Nametag files so
they can be retrieved for any valve whenever they are needed. The
software can currently access up to 500 sliding stem plus 500 rotary
valve nametags. There are some special procedures to make this
storage easier.
5.3.4.1 Storing Nametags on Drive G
To store the tags only on drive G first set the Operating Defaults (off
the Main Menu screen) to use drive G as the data drive while you fill
in and save the nametags. Once all the nametags are stored, set
the operating defaults back to the floppy drive as the data drive.
To fillin and store nametags on both a floppy disk and the hard
drive, leave the Data Drive set to the floppy drive and fill in the na-
metag. Pressing F10 saves it to the Floppy disk (as either a Tag
Number file or Serial Number file as set in the Defaults), and press-
ing F8 saves to G.
If you have a group of nametags on a floppy disk you can use DOS
to copy files with the extension T@G, SER, RRG and SRR from the
floppy to drive G.
5.3.4.2 Recalling Nametags from Drive G
You can recall nametags from Drive G even if you are using the
floppy drive to store data. Start with a blank nametag and type ei-
ther in the tag number or serial number under which the tag is
stored, leave the cursor on that field and press F9 and the tag will be
read in. (Pressing F9 causes the program to look for either the tag
number or serial number depending on which field has the cursor.)
The File menu also has a choice which will list the tags on the hard
27
drive by either Tag number or Serial number. If you are saving data
to floppy disks, save the nametag to the floppy after calling it up from
drive G.
5.3.4.3 Erasing Valve Nametag from Screen
If you have made a mistake in entering the nametag data, you can
erase the data from the screen and start again from scratch by
pressing Alt-F
5.3.5 Exiting the Nametag Screen

Exit the nametag program by pressing AltX. From the exit menu
you can go directly to the Setup Test screen, go back to the main
menu or .
5.4 Making Physical Connections

5.4.1 Measuring Travel
5.4.1.1 Transducer Selection
A variety of transducers and mounting techniques are available for
the different types of valves that may be encountered.
Because travel is a key diagnostic parameter, it is essential that a
solid connection be established when mounting the transducer.
W6671
Complete Family of Transducers for the FlowScanner
28
5.4.1.1.1 Transducers for Sliding-Stem Valve
Celesco Cable Transducer
W6670 W6673
Celesco Cable Transducers
The long stroke transducer comes in two varietites and can measure
up to 25 inches. The 25-inch Celesco is the standard transducer
provided in the accessory tool kit. The resolution of this transducer
is0.0001 inches. The 50-inch Celesco is also available, with a reso-
lution of 0.001inches. The transducer should be mounted so that
stem movement will extend the cable and so that the cable is parallel
to the stem. The cable must be securely attached to the feedback
arm. The transducer is typically mounted to the actuator casing so
the stretching of the yoke legs is detected at shutoff
Linear Transducer
W6675
2-inch DRC
The DRC transducer (also available) will measure stem travel less
than 2 inches. The resolution of this transducer is .0001. The trans-
29
ducer must be mounted so that stem travel will deflect the probe.
The transducer must be securely mounted with the probe parallel to
the valve stem and so that it can move freely with the movement of
the valve stem. Nonparallel mounting will cause the probe tip to
move slightly on the position feedback extension. If this surface is
not flat, some error will be introduced as the tip moves across the
surface. This can be detected if the travel reading does not return to
zero (within .0001) after the valve is stroked. A small error will not
affect the evaluation but will show up in the graphs.
The transducer mounting position should provide some precom-
pression of the probe beyond its free position and provide adequate
coverage of the stroke range. The travel reading can be zeroed from
the keyboard.
5.4.1.1.2 Transducer for Rotary Valve
W6672
Rotary Transducer
The rotary transducer measures 360 of rotation and has 0.0075

resolution. The transducer must be mounted perpendicular to the
valve shaft. A slight offset can be compensated for by the flexible
coupling. A probe with a plate for mechanical connection or a suc-
tion cup is used to connect to the shaft. Error may be introduced if
the suction cup slips. This can be eliminated by the use of double
sided tape to secure the cup to the shaft.
30
5.4.1.2 Transducer Mounting
25-inch Celesco Transducers
The 25-inch Celesco cable transducer is the standard linear trans-
ducer provided in the accessory kit. It can be used to measure up to
25 inches of travel at a resolution of 0.0001 inches. For optimum
accuracy, the transducer must be mounted such that the cable mo-
tion is parallel to the valve stem motion. To facilitate this alignment,
special slotted mounting brackets are included in the accessory kit.
Also for extremely fast Stroking Speed Tests (Step Change Test), it
is important that the transducer is mounted such that the tranducers
cable is being extended, not retracting.
Attach Travel Transducer Bracket (TA0101-A) to the Celesco trans-
ducer via the 1/4-20 x 3/4 flat head stove bolts. Attach the drilled
hole end of the slotted angle bracket (TA0103-A) to the hex adapter
on the expandable-jawed vice-grip (Bessi Clamp) with a 3/8-16 x 1
cap screw. Clamp the Bessi Clamp onto the the actuator (diaphragm
case, barrel, or yoke legs). Attach the travel transducer to the
slotted portion of the angle bracket using 5/16-18 x 1 carrige bolt and
wing nut. Clamp the 10-inch vice-grip to the stem connector or posi-
tioner feedback arm. DO NOT clamp directly to the valve stem, for
this will cause damage to the stem finish and, consequently, damage
the stems packing. Attach the transducer cable to the vice-grip us-
ing the S-hook provided. It is sometimes necessary to attach a
1-inch Cantilever C-clamp to the vice-grip to facilitate this hook-up.
Utilizing the slots of the mounting bracket, align the transducers
cable parallel with the valve stem. Verify that all connections are
tight. Attach the transducer cable.
Multipurpose Clamp (Preferred Method)
Use adjustable cantilevered Cclamps to clamp the transducer
mounting assembly to the diaphragm casing, yoke, bonnet, or other
available mounting surfaces.
Clamp the 4 1/2-inch cantilevered Cclamp to the appropriate clamp-
ing surface. Firmly tighten the Thandle.
Extension studs may be oriented at any angle through the use of
swivel joints to facilitate transducer mounting. Assemble additional
studs and swivel joints, as needed, to obtain proper orientation and
position. Tighten all jam nuts and swivel joints to eliminate slipping.
Clamp the 2-inch multipurpose clamp on the base of the transduc-
er. Thread an extension stud into the adapter on the clamp.
31
Connect the extension stud from the transducer to the extension
stud from the large clamp using a swivel joint.
Position the completed assembly to the required transducer orienta-
tion and firmly tighten all connections.
Verify alignment and readjust position as necessary until the trans-
ducer cable is properly aligned with the feedback platform.
Connect the transducer cable to the feedback platform.
2-inch DRC Transducer
Multipurpose Clamp (Preferred Method)
Use adjustable cantilevered Cclamps to clamp the transducer
mounting assembly to the diaphragm casing, yoke, bonnet, or other
available mounting surfaces.
Select the appropriate cantilevered Cclamp for the required clamp-
ing surface. Mount and firmly tighten the Thandle.
Attach an extension stud to the transducer bracket and firmly tighten.
stud from the clamp using a swivel joint.
ducer probe tip is properly aligned with the feedback platform.
Rotary Transducer
The C25 DRC is the standard rotary transducer supplied in the ac-
cessory kit. It can measure 360 degree rotation with a resolution of
0.0075 degrees. The travel is to be measured at the end of the
valve shaft, if possible. Normally, the most convenient place to con-
nect is to the travel indicator plate. Some positioner are mounted
directly in line with the shaft and, thus, the connection must be made
on the positioners indicator plate. The transducer should be
mounted perpendicular to the valve shaft. Two flex couplings are
used to compensate for any offset. The connection is made using
double stick tape.
32
Attach the rotary travel transducer bracket (TA0102 to the C25 DRC
Transducer. Attach the drilled hole end of the slotted angle bracket
(TA0103-A) to the hex adapter on the expandable jawed vice-grip
(Bessi Clamp) with a 3/816 x 1 cap screw. Attach the Bessi Clamp
to the valves bonnet or actuator. Install travel transducer mounting
post (TA0104) to the flex coupling on the tranducer. Install flex cou-
pling (17A8307 X012) to the mounting post. Tighten connections.
Attach the rotary transducer to the slotted angle bracket using the
SPC Fisso Support Arm. Attach the double-stick tape to the flex
coupling and stick the transducer perpendicularly and centered to the
valve shaft end utilizing the three pivot points of the Fisso Support
Arm. Lock the arm in position usng the locking knob. Verify that all
connections are tight. Attach transducer cable.
Multipurpose Clamp
Adjustable cantilevered Cclamps are provided in the accessory kit
to clamp the transducer mounting assembly to the diaphragm cas-
ing, yoke, bonnet, or other available mounting surfaces.
Clamp the 4 1/2-inch cantilevered Cclamp to the appropriate clamp-
ing surface. Firmly tighten the Thandle.
The most convenient place to connect to the shaft is on the actuator
indicator plate. Some positioners (PMV, 3710, etc.) are mounted
inline with the shaft and the only available travel feedback connec-
tion is the positioner indicator plate. When using the positioner indi-
cator plate for feedback, inspect the positionervalve connection to
insure there is no problem. Mechanical stop between the valve and
positioner may not be detected using this system for feedback, how-
ever, in some instances it is the only available feedback source.
stud from the large clamp using a swivel joint.
ducer is properly aligned and the probe is firmly connected to the
indicator plate.
33
Actuator Cover Plate Bolt Hole
Remove one bolt from the actuator side cover plate.
Select the appropriate extension stud and screw directly into the ac-
tuator side cover plate bolt hole from which the bolt was removed.
Firmly tighten the jam lock nut against the actuator housing.
stud from the actuator cover plate bolt hole using a swivel joint.
Attach the assembled rotary probe (See Section 5.4.1.3 under
Mounting the Travel Feedback Platform).
ducer is properly aligned and the probe is firmly connected to the
indicator plate.
5.4.1.3 Travel Feedback Connection

Existing positioner connector arms provide the most convenient
method for transducer feedback connections. A temporary connec-
tor arm or adapter can be installed to facilitate testing. Permanent
test connections are based on the actuator type and the accessories
encountered.
Celesco Long Stroke Transducer
The feedback platform provides the means to displace the spring
loaded cable as the valve is stroked. This connection should be
firmly established to minimize the effects of vibration or looseness in
the assembly. Several techniques for mounting are presented as
general guidelines for mounting with selection based on the accesso-
ries encountered. Since there are an infinite number of valve/acces-
sory combinations, it is not possible to describe all the means re-
quired to mount the transducer. These guidelines should provide
some ideas; the individual technician may have to devise alternate
methods based on these suggestions.
34
Using existing positioner connector arm:
Verify that no obstructions exist in the positioner linkage and that the
transducer can be mounted parallel to the valve/actuator stem.
Clamp a pair of vise grips to the connector arm.
Clamp the crocodile clip with SHook (included in the kit) to the vise
grips. Be sure it is a firm connection so the cable from the transduc-
er does not snap loose.
Connect the cable eyelet to the SHook.
Adding a temporary positioner connector arm:
Verify that the transducer can be mounted parallel to the valve/actua-
tor stem.
Select the appropriate connector arm based on stem diameter.
Loosen the valve/actuator stem jam nut and slide the connector arm
between the lock nut and jam nut. Firmly tighten the jam nut.
Clamp a pair of vise grips to the connector arm.
Clamp the crocodile clip with SHook (included in the kit) to the vise
grips. Be sure it is a firm connection so the cable from the transduc-
er does not snap loose.
Connect the cable eyelet to the SHook.
Adding a permanent positioner connector arm:
Selection is based on the actuator type and size and the accessories
involved. Refer to Fisher Instruction Manual for 3582 Series Valve
Positioners, Form 5054 (Key 48) for the actuator type and size.
Follow the steps in C above.
2-inch DRC Transducer
The feedback platform provides the means to displace the spring
loaded probe of the DRC transducer as the valve is stroked. This
connection should be firmly established to minimize the effects of
vibration or looseness in the assembly. Several techniques for
mounting are presented as general guidelines for mounting with
selection based on the accessories encountered. Since there are an
infinite number of valve/accessory combinations, it is not possible to
describe all the means required to mount the transducer. These
guidelines should provide some ideas; the individual technician may
have to devise alternate methods based on these suggestions.
35
Using existing positioner connector arm:
Select the appropriate transducer based on required stroking range
and mounting space.
Verify that no obstructions exist in the positioner linkage and that the
transducer can be mounted parallel to the valve/actuator stem.
Position the transducer tip against the travel pin locking nut and en-
sure that an adequate perpendicular landing surface is provided by
the locking nut.
In some instances, it may be necessary to attach a beam clamp to
the connector arm to obtain proper transducer orientation or ade-
quate landing surface. Attach the fixture as far away from the valve
as possible without impeding the travel pin or rotary shaft arm mech-
anism of the positioner.
Adding a temporary positioner connector arm:
Verify that the transducer can be mounted parallel to the valve/actua-
tor stem.
Select the appropriate connector arm based on stem diameter.
Attach a beam clamp to the end of the connector arm to provide a
landing surface for the transducer probe.
Loosen the valve/actuator stem jam nut and slide the connector arm
between the lock nut and jam nut. Firmly tighten the jam nut.
Adding a permanent positioner connector arm:
Selection is based on the actuator type and size and the accessories
involved. Refer to Fisher Instruction Manual for 3582 Series Valve
Positioners, Form 5054 (Key 48) for the actuator type and size.
Follow the steps in C above.
Rotary Transducer
The travel indicator scale provides a means for position feedback for
the rotary transducer. This connection should be firmly established
to minimize the effects of vibration or looseness in the assembly.
The use of pliable suction cups, double sided tape, and/or flexible
couplings is recommended.
Flexible couplings
If the screws in the indicator plate are not corroded to the point that
removal is impossible, remove the indicator plate and reattach it.
36
Use the flexible coupling provided in the accessory kit to connect to
the knob on the indicator plate.
There are two couplings in the kit. One has a 3/8-inch opening on
both ends; the other has a 1/4-inch opening on one end. Select the
proper coupling to fit the knob on the indicator plate.
5.4.2 Measuring Pneumatic Pressure
Note
These transducers are for pneumatic use only. DO
NOT USE THESE TRANSDUCERS TO MEASURE
LIQUID PRESSURE
The pneumatic pressure transducers are located in the Flowscanner

case and connect to the valve through 1/8-inch nylon tubing and con-
nector fittings. The Parker Prestolok fittings used with the tubing
connect simply by pushing the tubing into the fitting. The tubing is
released by pressing the gray collar around the tubing inlet and si-
multaneously pulling the tubing out. These fittings do not have inter-
nal check valves so the pressure must be shut off before disconnect-
ing. The Prestolok fittings can be mated to existing connections on
the valve and accessories.
Most valves can be fully tested by measuring the Supply, Instrument
(I/P), and Output pressures available at the positioner gauge block.
Top and bottom actuator pressures must be measured for piston ac-
tuators. Volume boosters should be measured separately from the
output pressure.
5.4.2.1 Installing Test Connectors

5.4.2.1.1 Temporary Installations
Positioners with Gauges
Remove the gauges for supply, instrument, and positioner output.
Select the appropriate Parker Prestolok fitting:
37
A. 1/8 x 1/8 MNPT (68 PL 22)
B. 1/8 x 1/4 MNPT (68 PL 24)
C. 1/8 x 1/8 FNPT (66 PL 22)
Install the fittings in the gauge ports on the gauge block.
Fisher Type 3570 Positioners require the use of a combination of the
68 PL 22 and the 66 C 22 Parker fittings on the bottom cylinder
and instrument connections.
Tighten fittings and connect 1/8-inch nylon tubing to Flowscanner
transducer channels.
Verify the installation matches the assigned channels on the test
setup parameters.
Positioners with Schrader valves (tire valves)
Connect the 1/4 MNPT Parker Prestolok fitting to the Type SS52
clipon chuck for the required number of installations.
Tighten fittings and connect 1/8-inch nylon tubing to Flowscanner
transducer channels.
Verify the installation matches the assigned channels on the test
setup parameters.
Tubing Tee Connections
In cases where there is no gauge block available for taking pressure
readings, temporary tees must be installed in the tubing to access
the required pressures. Install the Parker Prestolok fitting in the tees
and connect the Flowscanner tubing to the Parker fitting.
Permanent Tee fittings are recommended if repeat tests are going to
be performed on the valve. See section 5.4.2.1.2, Permanent Instal-
lations, for appropriate fittings.
5.4.2.1.2 Permanent Installations
Permanent connections are used to provide a way to quickly connect

the Flowscanner to obtain test pressures for a valve that will be sub-
jected to repeat tests over an extended period of time. See section
11.5 (Appendix E) for a complete description of connectors for diag-
nostic testing. Listed below are a brief description of several recom-
mended permanent connections.
38
Note
Contact your local Fisher Representative to obtain
required parts or assistance in making permanent
connections
New valves purchased from Fisher can have permanent connections

installed at the factory. Contact your local Fisher Representative for
this option on new purchases.
Type SS52 ClipOn Chuck Automotive Tire Valve. Refer to
3570 Series Pneumatic Valve Positioners Instruction Manual, Form
1837 for general guidance.
Automotive Tire Valve Test Connection 1N908899012
Service Tee 1P312321992
Pipe Nipple 1B218826232
Pipe Tee 1C597547362
Adaptor 1H447099022
Swagelock Quick Disconnect
Body QC4B2PM
For a complete ordering number use SS for 316 stainless steel or B
for brass as a prefix to the number shown above.
This number represents a quick connect body with 1/8-inch male
NPT threads.
Install this part in the gauge block or in a tee inserted in the gauge
block.
The tee is required if the gauges are to be installed. The tee may be
omitted and the body installed alone. gauges can be connected by
using the fitting described below.
For more detailed information concerning this option, contact your
local Fisher representative.
Stem QC4S2PF
For a complete ordering number use SS for 316 stainless steel or B
for brass as a prefix to the number shown above.
39
This number represents a quick connect stem with 1/8-inch female
NPT.
Insert a Parker Prestolok fitting (68PL22; see I.A.2.a above) in the
stem. Connect the Flowscanner tubing to the Parker fitting.
Snap the stem into the body installed in the block.
Caution
In order to install the temporary fittings, the supply
air and instrument signal to the valve must be
removed for a short period. This could cause the
valve to move. Be sure all personnel are clear of
the valve and operations is aware that the valve
may move.
Note
Contact your local Fisher Representative before
ordering fittings for permanent installation. He can
assist you in assuring the proper part numbers for your
installation.
40
5.4.3 Supplying and Measuring the Control Signal
Control (I/P) Signal
Connecting to the I/P Transducer
The control cable is a 20-foot long, 2 wire cable with spade lugs or
alligator clips on one end and a Lemo connector on the other end.
The spade lugs or alligator clips are used for connecting to the stan-
dard barrier strip on an I/P. Connect the Lemo connector to the port
labeled I/P on the Flowscanner.
When connecting the Flowscanner to the I/P, disconnect the control
leads in order to isolate the I/P from the control circuit.
Adding an I/P Transducer
In the event that a test is required on a valve that does not have an
I/P, use an I/P with the appropriate ranged bellows and a 67AF regu-
lator.
Determine the tubing size for connecting to the positioner. For
valves without positioners, connect directly to the actuator.
Make the appropriate temporary tubing connections from the supply
air to the I/P Regulator assembly.
Make the appropriate temporary tubing connections from the I/P to
the positioner (or actuator).
Use the FlowScanner and I/P to provide the test instrument input
signal.
5.4.3.1 Command Mode

The command mode is the typical means of operation with the
FlowScanner. It allows the FlowScanner to command the current
signal to the valve and control the test that is being conducted. The
power for the instrument is provided by the FlowScanner.
5.4.3.2 Monitor Mode

Monitor mode allows the FlowScanner to sense the signal being sent
to the valve, but the movement of the valve is being done by the
control system. When the monitor mode is used, the resistance of
the I/P must be known in order for the current to be properly calcu-
lated. The system monitors the current signal and the valve is
moved by the operator of the control system. See section 8 for com-
plete details.
41
5.4.4 Auxiliary Inputs
Signals can be monitored from transmitters or other devices in the
process to gain added information on how the valve is controlling.
These sensors can be monitored by paralleling the wires off of the
sensor and the current or voltage back into the system.
5.5 Setting Up Test Parameters

The FlowScanner has been made flexible enough to run a variety of
tests, but normally only a few standard tests will be used. However,
before running a test the nameplate must be loaded into memory
and the Setup screen completed, which passes the data to the Test
program.
The Setup Test screen looks much like the Nametag Screen:
Setup Test Screen for Sliding Stem
The current valve ID (TAG or SERIAL #) will be shown at the top left
window if a valve is in memory.
The Setup Number is used to save and recall standard setups. Use
a descriptive name like SCAN50 or SCAN100 for 50 and 100 second
dynamic scan setups.
You can recall a standard setup from the program drive from the file
menu (AltF). Setups are stored on the hard drive so they will be
available for other data disks. If there are setup files on the disk the
names will be displayed across the top of the screen. Use the cursor
(arrow) keys to highlight the desired setup and press Enter. That
setup will then be loaded into the setup screen.
42
Use the Description field to explain what the setup is for.
The Test Type field has a menu with 5 choices. It defaults to Dy-
namic scan. To select another press the F2 key while the cursor is
on the field. However, first we will cover how to set up a dynamic
scan test.
5.5.1 The Dynamic Scan

The Dynamic Scan test ramps the current at a controlled rate be-
tween two defined output levels. Data is recorded during both up-
stroke and down stroke, and may be analyzed for a good indication
of valve condition. It is the normal FlowScanner test for valves.
The Output type field defaults to milliamps. The Volts choice is for
010 volt E/P loops. The software also supports 10 to +10 E/P for
control only. If 1050 mA loops are used select milliamps. Switch-
ing to the 50 mA range is automatic if output levels above 25 mA are
selected.
The output function defaults to Control I/P instead of Monitor I/P.
(For controlling the valve from the control room while the system
monitors the I/P voltage. See the section 8 on Monitor Mode
Testing for more on this topic.)
Select the proper travel Transducer from the menu (press F2). (This
can be changed in the Test program if required.)
The normal first test is to linearly ramp current from 4 to 20 mA to be
sure you test for seat load and travel under control room range. If
the control range is other than 420 use the actual controller limits.
Limits may now be set in 0.1 mA increments.
The appropriate scan time should be selected based on the actuator
size. Pressing F1 (Help) accesses a table giving you the recom-
mended scan times for your actuator size. The pause time is equal
to approximately 50% of the selected scan rate. Thus, a 50 sec
test requires approximately 150 seconds to complete.
43
The calibrated times may vary somewhat; but the analysis software
will display the actual elapsed time on the graphs.
5.5.2 Static Point Test

A Static Point test duplicates a traditional lab deviation cycle test
for hysteresis plus dead band, pausing at several levels on the up
and down stroke to allow the valve to reach static conditions. Per
the SAMA requirements the test limits should be selected to avoid
hitting travel stops on the ends of travel. For example, a wellcali-
brated 420 range valve would normally be tested at 4.5, 8, 12, 16
and 19.5 mA steps, with a ramp rate of 1 mA/sec and a pause time
of from 20 to 60 seconds. Large valves with graphite packing may
require longer pause times because a static condition must be re-
peated after each step change. If the pause time is too short, the
results will continue to improve as the pause time is increased.
5.5.3 Step Change Test

The Step Change test is used to check stroking speed and valve dy-
namic response. This test makes an instantaneous change in out
put between two levels while recording data on valve response.
Minimum pause time is about 20 seconds.
5.5.4 Stepped Ramp Test

The Stepped Ramp test performs a ramp up and down test as a se-
ries of small steps. This may be used with steps down to 0.01 mA to
test for valve response and resolution. You would normally select a
starting output level within the valves normal operating range (eg. 12
44
mA), a number of steps to make up (eg 20), a step size (e.g., 0.08),
a pause time at each step (e.g., 5 seconds), and the number of
times to perform the ramp (e.g., 2). No automatic analysis is done
on the datasimply view the elapsed time graphs and compare in-
put steps to output step response. This test is often used with the
process variable recorded on an auxiliary channel.
5.5.5 Step Study Test

The step study test is used to check valve resolution and response
quickly. A series of increasing small step sizes is defined (eg. .08,
.16, .32, and .8 define 0.5%, 1%, 2%, and 5% steps for a 420 mA
loop) to be run at different nominal loop output levels (eg. 12 mA or
50%). A pause time is specified for each step (eg. 10 seconds), and
the normal procedure is to mirror the steps; that is to step up, back,
and then down and back from the nominal output level. This type of
test can quickly show an approximate deadband for valves, especial-
ly with the process variable recorded on an auxiliary channel.
5.5.6 Pressure Channel Assignments

Press PgDn to access the pressure channel assignment window.
For each pressure you need to measure on the test assign a pres-
sure channel. Normally the Supply Pressure, Instrument (I/P), and
Positioner Output pressures are assigned. (The Positioner Output
pressure is used in analysis for the Actuator Pressure if another
channel isnt assigned to it.) Up to 6 channels can be assigned. Ad-
ding channels slows the tests and increases the size of the data
files, so dont assign unneeded channels. For pressure return piston
actuators assign the return pressure as well. The sixth pressure has
a blank name if you need to measure some other pressure de-
scribe it in this field and assign a channel.
45
5.5.7 Auxiliary Inputs
The Auxiliary inputs can be used to collect data simultaneously with
the control signal, valve travel, and valve pressure channels. Filling
in a description for one or more auxiliary inputs causes the Test pro-
gram to display and record information on the channels with a de-
scription. These can be displayed by the FlowAux display program.
This might be used for recording line pressure, flow rate, or other
variables.
If more than one auxiliary channel is measured the control signal and
travel data can be displayed simultaneously with either the valve
pressures or the auxiliary channel data. You select which to display
when reading the data for display; so you can alternately look at both
data sets.
If only one auxiliary channel is measured, and the 6th (user defined)
pressure channel is not used by the pressure scanner, the auxiliary
channel data is store in its place and can be displayed with all the
rest of the valve data.
You can enter other comments with AltC, print the setup information
(AltP), and save the setup file (F10 or AltF) as in the Nametag
Menu. Normally you only need to save the Setup file if you want to
use it for other tests the RUNTEST file will pass the setup screen
data to the Test program.
5.5.8 Storing a RUNTEST File

Exit the Setup Screen by pressing AltX. The exit menu will allow
you to exit to the Nametag program or go to the main menu. If you
havent saved the setup file for later use, but have made changes a
popup window will ask if you want to save it.
Note
If you exit to the main menu a popup window will ask if
you want to use this setup and nametag data for the
next test. If you answer Yes the information will be
ADDED to the RUNTEST file.
46
All saved Setup and Nametag combinations will still be available
from the TEST program, so you can save several different setups for
later testing.If you dont see this window it probably means there is
no Nametag in memory, and the test will not be setup to run.
Pressing Alt-F gives you four menu options: 1) Retrieve Test Setup
from File, 2) Save Test Setup to File, 3) Erase Test Setup from Disk
or 4) Erase Test Setup from Screen.
6 Running a Test in Control Mode
6.1 Quick Reference

Refer to section 6.1 for test procedures
6.2 Changing the Travel Transducer

If the travel transducer shown is not the one you wish to use, press
AltT to toggle the choice to the other models. Stop when the one
shown is the one you want to use, and stroke it through a known dis-
tance to verify the calibration.
6.3 Setting Individual Transducer Resolution

Celesco cable transducers have an individual calibration marked on
the nameplate that can give slightly better accuracy than the default
setting. To set this for the specific transducer used select the Oth-
er menu choice:
6.4 Disabling Automatic Zero of Travel

The system is normally set to zero the travel transducer automatical-
ly when the F9 key is pressed to start a test. This is fine as long as
you are starting with zero signal and the valve is at one end of the
travel. However, sometimes tests are run over a partial stroke, and
the signal is manually increased to some partly open level before the
F9 key is pressed. When the travel automatically zeros, the true
zero point is lost, and you dont know how far the valve moved be-
fore the test was started.
47
To run a test this way you should first disable the AutoZero of the
travel transducer. To do so pick the Other menu from the top of the
screen (AltO). This menu appears:
Select Disable AutoZero Travel and the automatic zero function is
shut off.
When the AutoZero function is shut off, the az disappears from
next to the travel transducer line on the screen.
Changes made in the Other menu to AutoZero Travel are saved as
default, even if the system is shut off
6.5 Graphing Measured or Commanded Current

The FlowScanner measures the actual current on the control loop
through a resistor and an instrument amplifier. There are cases
where it would be better to record the Commanded Current and
graph it than to use the Measured Current. This might be true in
these situations:
Examining Very Small signal steps
We have sometimes used signal steps of 0.1 mA to find a valves
resolution. When looking at very small signal changes the accuracy
of the commanded signal is actually slightly better than the mea-
sured signal, as the measured signal is a 12bit conversion of a 55
mA span (55 mA divided by 4095 or 0.0134 mA resolution), while the
commanded current (25 mA range) is a 12bit conversion of a 25
mA span (25 mA divided by 4095 or 0.0061 mA resolution). There is
also always a small amount of flutter or noise on the measured sig-
nal which doesnt appear on the commanded signal. Thus in this
case the graphs are cleaner and more accurate if the Commanded
signal is used.
Using a High Impedance I/P transducer
At least one I/P transducer (Moore) is being marketed which has a
much higher impedance than those we normally find. An impedance
of 600 Ohms means that as the signal approaches 20 mA the driving
voltage reaches 10 to 12 volts. (Most I/Ps are in the <200 Ohm im-
pedance, so the driving voltage is under 5 volts at full current.) The
way the FlowScanner measurement circuit was designed a drive
voltage this high can cause the Measured Signal to drop suddenly
even though the true loop current continues to increase. This is due
to the input to the instrument amplifier getting too close to its supply
48
voltage. There is a circuit fix to cure this problem which requires re-
turning the FlowScanner for modification. To work around the prob-
lem you can instead record and graph the Commanded current.
The (*) next to the Measured Current line shows that it will be re-
corded and graphed normally. To change and record the Comman-
ded Current pick the Other menu from the top of the screen:
Pick the Graph Commanded Current choice to record and graph the
commanded signal instead of the measured signal.
After selecting the Commanded current the (*) changes to that line of
the screen to show which will be recorded:
To change back again pick the Other menu and select Graph Mea-
sured Current to change back.
6.6 Specifying Test Line Pressures

If the valve is tested in line, and the line pressures are not zero psig,
you should enter the inlet and outlet pressures so the valve unbal-
ance can be allowed for in analysis. If the test line pressures are
different from the nametag service pressures the service seat load
will still be corrected for the unbalance. Select the Other menu
from the top of the screen (AltO), and select Enter Line Pressur-
es. Type in the Inlet pressure as an integer (whole number only).
Press Enter and the cursor will move to the Outlet pressure field.
Type in the outlet pressure and press Enter. These pressures will be
used to compensate for the valves unbalanced area in force calcula-
tions.
6.7 Selecting to Hold or Zero the Output at Test End

By default the output control signal (in Control Mode) will instantly be
dropped to zero at the end of the test, or if the test is aborted in mid
test. However there may be times when it is better to hold the signal
at its last level when stopping a test, allowing you to manually ramp
the signal back down. This might be true if you were testing a valve
in a liquid process line and didnt want the valve to suddenly slam
shut if the test were aborted.
49
Warning
This practice applies to in-process testing
To have the control signal held at its last output at the test end, se-
lect the Other menu and select Hold Signal at Test End from the
menu. This setting is saved each time you leave the test program,
and will be set the same next time you use the Test program.
An indicator then appears at the end of the Commanded Current line
to show it will be held:
Warning
Whenever you leave the Test Program, the I/O card
is powered down, so the control signal will still
drop to zero at that time, even if youve selected to
hold the signal at the time the test ends.
6.8 Manual Control of the Valve

At this time you can control the output signal and stroke the valve
through the keyboard. The left and right arrow keys on the keypad
will step the output current up and down. Pressing the arrow key
alone changes it in small steps; while holding the Ctrl key and press-
ing the arrow key will change it in larger steps. Thus you can quickly
move near a value, and then fine adjust to the value you want.
The manual control is useful for stroking the valve to check the track-
ing of the travel transducer, and also for setting the zero and span of
the I/P and positioner (if needed).
50
Note
It is recommended to manually stroke the valve
before testing to ensure proper setup.
With FlowAux the F3 and F4 keys can also be used to jump the cur-
rent to the end limits set for the active Dynamic Scan test. F4
pressed by itself will jump the output to 95% of the specified signal
range. AltF4 will jump to 100% of the range. F3 will jump to 5% of
the range, and AltF3 will jump to 0%.
If an E/P (voltage loop) is used and the setup specifies a negative
voltage, the software then sets its lower manual limit to 10V output.
6.9 Recording the Static End Points

In a Dynamic Scan test the software will analyze the test data to find
the end points of the control signal and I/P output pressure when the
valve reaches zero and maximum travel. However, because the
data is recorded onthefly without waiting for the travel to equalize
to the control signal, the end points found are dynamic end points
which are different from the actual static calibration.
The test program allows you to manually find the static end points
and record these values in a file, which is later read automatically
into the Quick Report. This data is stored along with the test files
under the same test name, so the data must be saved after the end
points are manually marked.
It is important to understand that the zero signal (normally 4
mA) end point is not the point at which the valve begins to
move as the signal is increased. It is instead the point at which
the valve stops moving as the signal is decreased. Many times
valves are incorrectly calibrated so they begin opening as the
signal reaches 4 mA. Due to the hysteretic error in all instru-
ments and valves the valve will then never close as the signal
is reduced to 4 mA. Likewise the correct full signal (normally
20 mA) end point is also the point at which the valve stops
moving at the signal is increased.
51
While you are connected to a valve in Control mode for a Dynamic
Scan test, you can call up the Mark Static End Points routine from
the Other menu (AltO) or directly by pressing AltE (for End
Points). You will then see the following screen:
At this point use the Ctrlleft arrow key to increase the output signal
(or press F4 for 95%) until close to the signal where the travel stops.
Then use the left arrow key alone to increase the signal just until the
actual pressure reaches full supply pressure. Be sure to wait long
enough for the travel to equalize to the signal. Then press the Enter
key to record those values for the control signal and I/P output pres-
sure.
After the enter key is pressed the screen will change to allow record-
ing the zero signal end point: Here use CtrlRight Arrow to drop the
signal (or press F3 for 5%) close to the point where the valve stops
moving at low signal. Then use the Right arrow key alone to reach
the point where actual pressure reaches zero, and press Enter again
to record the signal and I/P output pressure at this end point.
At this point the values are saved in memory. When the test files are
saved, these values will be saved under the same test name.
6.10 Zeroing the Travel and Pressures

Set the travel at zero by pressing the End key on the Keypad. (It will
normally zero automatically when the test is started, unless Auto-
zero has been disabled from the Other menu.)
If the pressure zero points have drifted, open all lines to atmosphere
and press AltZ to adjust zero.
6.11 Scaling Auxiliary Channels

The Auxiliary channels are voltage inputs, and are normally cali-
brated 010 Volts. It is possible to calibrate any channel in other
units, but this then becomes a permanent system calibration until it is
re calibrated. Since the scaling of a channel may change with each
test, we have revised FlowAux to allow scaling auxiliary channels to
other units and ranges at the time a test is run. The data is recorded
with the new units and scaled calibration so it will show up on
graphs, but the system calibration remains unchanged, and it reverts
to its official calibration when the test program is exited.
To scale a channel in engineering units using this method you need
to know the desired units; the scaling slope in units/volt, and the in-
tercept value of scaled units at zero volt input.
52
For example it you are recording a flow meter output you might want
to scale the readings to GPM.
Normally the test screen would show readings in Volts:
To scale the units select the Scale Units choice on the Other
menu:
The system then asks which input you wish to scale:
Select the channel and then input the units and scaling factors:
If this were a 420 mA flowmeter being measured across a 250 ohm
termination, with a range of 0 to 500 GPM, the voltage range would
be 1 volt at 4 mA at 0 GPM and 5 volts at 20 mA at 500 GPM so
slope would be 500 GPM/(51)V or 125 GPM/V, and the intercept at
zero volts would be 125 GPM:
The screen then shows the realtime values in the units and scale
requested:
If the scaling is not correct the channel may be reset or rescaled by
repeating the procedure. If you leave the Engineering Units de-
scription at V the scaling is reset to nominal volts.
Any or all of the auxiliary input channels may be rescaled in this
manner for any test.
The data is recorded with the scaled inputs and may be displayed
with the FlowAux software.
6.12 Starting and Stopping the Test Sequence

When all is set to start the test sequence, press the F9 key. The test
sequence will start and the output current will ramp up to the starting
value. The specified stroking time determines how quickly the cur-
rent ramps up. The output (control) current is always displayed dur-
ing a test; and the status boxes at the bottom of the screen will flash
TESTING and indicate if the current is changing up or down.
The Stroking time selected also determines how much time is avail-
able between data readings to display information on the live screen.
If the 10 second scan is selected there is only enough time to display
the changing output current. The travel and pressures will not be
shown until the test is over. During the 20 second scan the changing
travel will also be shown; and as the stroking time increases the
pressures are added to the display.
During the test 8000 readings are recorded for each pressure, cur-
rent, and travel channel. As the scan time increases multiple reads
53
of the pressure scanner are made for each point to average out pos-
sible electrical noise.
At the conclusion of a test the data will be temporarily stored in the
RAM disk and the screen status block will show COMPLETED and
will prompt Press F10 to Save Test Data.
If readings are being taken on the auxiliary channels the saving is
done automatically. Because of the data space available in memory,
the system will also pause at midtest to save the first half of the
data. Then testing on the second half will resume.
Whenever a test is in process, pressing any key on the keyboard will
abort the test sequence, zero the output current, and discard any
data in memory. Pressing F9 will restart the test from the beginning.
6.13 Recording Test Commands

The Other menu at the top of the screen has an Enter Test Com-
ment choice that will let you enter a 40 character comment about
the test either before or after a test (but before the data is saved) to
help identify the test later. This comment will show up when select-
ing the test data for display.
The Enter Test Comment screen will now also automatically appear
at the end of a test, after data reading is complete. You should enter
a comment and save the data.
Note
The test comment is a valuable tool to help you identify
the test later
6.14 Saving Test Data

Pressing F10 will save the test files to the designated data drive
(data disk or G drive). This will take about 20 seconds, as the files
are arranged to save disk space. If the data is saved in the RAM
disk it is possible to exit without saving to the data disk and review
the graphs. You can then save the data from the Display program
File menu under save data to new disk.
54
6.15 Exiting the Test Program
After saving the test data you can either select another test from the
File menu, or exit to the main menu. Viewing the data is done from
the Display program after you Exit the Test program. Press AltX to
get the Exit menu, and exit to the main menu.
Warning
When exiting the test program, the data card is
reset and powered down. This means all output
will also drop to zero, and relay switching may
occur on the output cables. If this will cause any
problem, disconnect the cables before exiting the
test.
6.16 Disconnecting From a Valve

First disconnect the output cable and travel transducer from the front
panel. Then detach the pressure tubing (cut the pressure if check
valve fittings arent used). Carefully remove the travel transducer
and disconnect the output cable from the I/P.
7 Running a Test in Monitor Mode
7.1 Quick Reference

Refer to section 5.1.
7.2 Changing the Travel Transducer

If the travel transducer shown is not the one you wish to use, press
AltT to toggle the choice to the other models. Stop when the one
shown is the one you want to use, and stroke it through a known dis-
tance to verify the calibration.
55
7.3 Setting Transducer Resolution
Celesco cable transducers have an individual calibration marked on
the nameplate that can give slightly better accuracy than the default
setting. To set this for the specific transducer used select the Oth-
er menu choice:
7.4 Disabling Automatic Zero of Travel

The system is normally set to zero the travel transducer automatical-
ly when the F9 key is pressed to start a test. This is fine as long as
you are starting with zero signal and the valve is at one end of the
travel. However, sometimes tests are run over a partial stroke, and
the signal is manually increased to some partly open level before the
F9 key is pressed. When the travel automatically zeros, the true
zero point is lost, and you dont know how far the valve moved be-
fore the test was started.
To run a test this way you should first disable the AutoZero of the
travel transducer. To do so pick the Other menu from the top of the
screen (AltO). This menu appears:
Select Disable AutoZero Travel and the automatic zero function is
shut off.
When the AutoZero function is shut off, the az disappears from
next to the travel transducer line on the screen.
Changes made in the Other menu to AutoZero Travel are saved as
defaults even if the system is shut off.
7.5 Zeroing the Travel and Pressures

Set the travel at zero by pressing the End key on the Keypad. (It will
normally zero automatically when the test is started, unless Auto-
zero has been disabled from the Other menu.)
If the pressure zero points have drifted, open all lines to atmosphere
and press AltZ to adjust zero.
7.6 Scaling Auxiliary Channels

The Auxiliary channels are voltage inputs, and are normally cali-
brated 010 Volts. It is possible to calibrate any channel in other
units, but this then becomes a permanent system calibration until it is
re calibrated. Since the scaling of a channel may change with each
56
test, we have revised FlowAux to allow scaling auxiliary channels to
other units and ranges at the time a test is run. The data is recorded
with the new units and scaled calibration so it will show up on
graphs, but the system calibration remains unchanged, and it reverts
to its official calibration when the test program is exited.
To scale a channel in engineering units using this method you need
to know the desired units; the scaling slope in units/volt, and the in-
tercept value of scaled units at zero volt input.
For example it you are recording a flow meter output you might want
to scale the readings to GPM.
Normally the test screen would show readings in Volts:
To scale the units select the Scale Units choice on the Other
menu:
The system then asks which input you wish to scale:
Select the channel and then input the units and scaling factors:
If this were a 420 mA flowmeter being measured across a 250 ohm
termination, with a range of 0 to 500 GPM, the voltage range would
be 1 volt at 4 mA at 0 GPM and 5 volts at 20 mA at 500 GPM so
slope would be 500 GPM/(51)V or 125 GPM/V, and the intercept at
zero volts would be 125 GPM:
The screen then shows the realtime values in the units and scale
requested:
If the scaling is not correct the channel may be reset or rescaled by
repeating the procedure. If you leave the Engineering Units de-
scription at V the scaling is reset to nominal volts.
Any or all of the auxiliary input channels may be rescaled in this
manner for any test.
The data is recorded with the scaled inputs and may be displayed
with the FlowAux software.
8 Displaying and Analyzing Test Results

8.1 Quick Reference
NOTE FOR STEVE COLWELL:
if this section is needed, the following sections need to be renum-
bered
57
8.1 Display Program Overview
The Display program reads the test data files and gives you graphic
displays of the test results. These graphs can be analyzed and
printed directly to the printer. The program will analyze the graphs to
numerically summarize the performance of the overall valve assem-
bly, the I/P transducer, the positioner, and the Actuator and Valve
combination. These calculated results can be printed as part of the
printed graphs or can be saved to a Report file on the disk where the
report program can print a summary report with your comments
about the results included.
8.1.1 Starting the Program

Select Display and Analyze Test Data from the main menu. Then
Press Alt-F and select the appropriate menu item to retrieve your
test results. When FlowAux finds test data it will present a list of test
names for selection, and the following screen will be seen:
Test Data Screen
The most current data will be highlighted.

Older versions of the FlowScanner software looked for the list of
tests in a file named FSTEST.DAT (or RSTEST.DAT for Rotary)
where all test files were listed. With this release the list comes from
looking for a DTA file for each test. If you have older data which
did not create DTA files those tests may not appear. The
FileRetrieve menu in the Display program has a choice for Select
Test from FSTEST file which will allow you to read the older data.
58
8.1.2 Choosing Test Data
Select the data you want to display with the Up and Down arrow
keys. If the data disk has more than 10 tests saved you can page
through the test list in groups of 10 tests before selecting data. The
most recent page of tests is shown first. The Test comment for the
highlighted test is shown at the bottom of the test list window. Press
Enter when the test you want is highlighted.
If the test recorded data on the auxiliary inputs (A E) as additional
data files the screen will then prompt for whether you wish to view
the pressure scanner data or the auxiliary channel data with the con-
trol signal and travel: At this time you select which to view on graphs.
You can always reload the test data and view the other channels in
a few seconds.
The status blocks at the bottom of the screen will show that it is
reading data. When looking at standard valve test (not the auxiliary
channels) when the data is in memory the screen will change to look
like this:
The Setup summary on the left can be replaced with the keystroke
help screen by repeatedly pressing the PageUp key.
If the test data is for a Dynamic Scan, page one of the graphs menu
will be automatically shown. This page contains the graphs normally
analyzed for this test.
If the test data is for a Static Point, Step Change, Step Ramp, or
Step Study test the second page of available graphs will be pres-
ented with the overall valve plot selected.
59
If the auxiliary channel data was selected, the names given to the
auxiliary channels on the test setup will instead be shown on the
graph menu.
8.1.3 Returning to the MENU Screen

While in the graphics screen pressing the ESC key, the F2 (MENU)
key, or AltX will return you to the graph menu and reset the graph
parameters.
8.1.4 Printing Graphs

Graph printing to Epson, IBM, HP, or Diconix printers is provided. If
you are using a different printer than selected in the Main Menu De-
faults you can change it from the Printer menu off DISPLAY MENU
screen. Then display the graph. Pressing F5 will print a 1/3 to 1/2
page graph on most of the printers; and pressing F6 will print a full
page graph on most of the printers. When printing, pressing ESC
will abort the printout, and other keys will be ignored.
8.1.5 Capturing Graphs

If the FlowScanner programs were started from Windows, simply
pressing the Print Screen key will copy the graph to the Windows
clipboard. However it would normally have a black background and
would not print well. So before capturing the graph inverse the
screen by pressing AltI. The graph will then capture with a white
background. After the graph is captured, switch to Windows by
pressing AltTAB, and run your Windows Word Processing or Paint
program. Insert the graph by pressing ShiftIns. You can then
switch back to the FlowScanner graph just as you left it and keep
both application running to add multiple graphs to a report if you
want.
60
8.1.6 Graph Cursors
The graph cursors are moved with the keypad arrow keys. Pressing
an arrow key will grab the cursor which will move into the graph in
the direction pressed. So pressing the left arrow key will move the
rightside cursor into the frame. The value showing the location of
the cursor will appear at the bottom right of the screen. (Bottom left
for the left border cursor.) The left and right keys will both be at-
tached to the first cursor moved so it can be positioned back and
forth. Pressing the Insert key will freeze that cursor in position
and allow the opposite cursor to be selected. The Top and Bottom
cursors are likewise moved by the up and down arrow keys, and dis-
play
their value just above the left and right cursor values. The Insert
key freezes all cursors in their positions, and will allow the display to
zoom into the frame enclosed by all four cursors. Pressing Ctrl-rt.
arrow or Ctrl-lft. arrow moves the cursors quickly to the right and left.
PageUp and PageDn move the cursors quickly from the top and bot-
tom.
8.1.7 Zooming a Graph View

Zooming and resetting the display is done by pressing Enter or F9 to
replot the graph to the frozen cursor positions; so first locate all four
cursors, pressing Ins for each one; and then press Enter. The graph
borders will rescale to the zoomed limits; and all data points will be
reviewed, plotting only the portion that is within the border limits.
61
AltF9 will reset the view to the original scale, as will returning to the
menu screen.
8.1.8 Marking Data Points

When zoomed in to a high magnification it is useful to check the data
point density, to see how many readings are being represented.
Pressing AltP will cause the data points to be circled when the
graph is replotted by pressing F9 or <Enter>. AltP again will
toggle the marks off the next time the view is replotted.
8.1.9 Graph Analysis
Note
Always start the analysis from the Full Graph View
Press AltF9 if you have zoomed in. If the cursors have been
moved, many of the
62
graphs will attempt to analyze the area between the cursors, which
will give incorrect results if not used carefully (see below).
The Total Valve; I/P; Positioner; and Valve graphs have analy-
sis routines defined. Between 10% and 90% of Travel for Deg.
Friction, Spring Rate and Bench Set and 2% of Travel for Seat
Load. Start the analysis by pressing F3 or F4. The program will try
to set the cursor limits appropriately, and will analyze between the
cursors. The numerical results of the analysis are shown on the top
right section of the graphics screen. This is the Total valve analysis:
The Total Travel number shows the distance the valve stroked during
the test. The Zero Travel and Full Travel numbers show the points
where the valve reached the limits of movement under the stroking
speed conditions. Because the valve may not have caught up with
the changing control signal, these limits may not match actual static
calibration results.
The Dynamic Error Band numbers indicate the combined Hysteresis,
Dead Band, and Slewing (Dynamic) Error for the valve under the
stroking speed conditions. Because the Slewing Error increases as
stroking speed increases the numbers will be higher than a static
deviation cycle test, and will increase as stroking speed increases.
Always use the same stroking speed when comparing like valves.
The Average value is given as most representative of the perfor-
mance, and the Minimum and Maximum show the consistency over
the stroke.
The Linearity number is Independent Dynamic Linearity based on
best fit to the data.
Sometimes the graph covers numerical results. To avoid this, the
63
shift, Alt, and Ctrl keys pressed with the F4 key will locate the nu-
merical printout in the other corners of the graph.
8.1.9.1 Possible Data Problems
Analysis Errors
The analysis can give misleading results in some cases. The actua-
tor is normally checked between 10% and 90% of the travel, to avoid
discrepancies often encountered in the pressure as the stem motion
starts. These effects show up as a bulge in the curve near the ends
of travel. If this bulge extends into the analyzed area the bench set
and friction calculations may be off. Judgment must be used to
decide if the bulge is really due to friction (possibly from gal-
ling) or to a restricted line between the positioner and actuator,
causing a high pressure reading that doesnt reflect the actua-
tor pressure.
The analysis limits can be changed to avoid such effects by first tog-
gling the analysis off (press F4 again), and then moving the cursor at
that end of the graph in past the curve discrepancy area. Then ana-
lyze again.
The bench set is determined by extending the nominal curve to the
travel limits based on the least squares data fit of the analysis area.
If one end point is offset due to a data problem the slope of the line
will be slightly wrong.
8.1.9.2 Limiting the Analysis Range
The software attempts to locate the correct range of the graph to
analyze, but strange data may be better analyzed by limiting the
analysis to a different range. If the left and right cursors are moved
in to the limits desired before analyzing, the results will be based on
the range between those limits:
The next three graphs listed on the first page of the graph menu
show additional information about the performance of the com-
ponents of a valve assembly,
64
8.1.10 Dynamic Scan Tests
I/P Plot
A6886*A/IL
The I/P plot of a dynamic scan shows the calibration and perfor-
mance of the I/P and may help isolate performance problems related
to the I/P or the Positioner. Since I/P performance depends on the
volume of air it must deliver, the performance generally looks worse
if no positioner is used (typically show a wider separation between
the I/O and Down stroke). This is because the I/P must supply the
total volume needed by the actuator.
This graph plots the output pressure of the I/P as a function of the
control signal. This plot is typical of an I/P when used with a posi-
tioner:
Positioner Plot
65
This plot is labeled Positioner to agree with a complete valve as-
sembly, but actually shows the response of the valve to its pressure
signal whether or not a positioner is used. It plots valve travel as a
function of the pressure out of the I/P transducer. Because I/P
performance is usually quite good, this plot looks very similar to the
Total Valve plot, with slightly better numbers in the analysis:
Net Pressure Plot
One very useful plot from the Dynamic Scan test is the plot of Net
Actuator Pressure as a function of Travel. It may seem like the axes
are backwards on this graph, but we are using it to solve for forces
on the valve, which are determined from the actuator pressures, so
they are plotted on the Y axis.
For a spring and diaphragm valve, the plot analyzes like this:
From this graph we determine the average, minimum, and maximum
friction over the analyzed stroke. The range indicates how consis-
tent the friction is and wide variations usually indicate valve prob-
lems. The spring rate is calculated and can be compared to that
specified for the actuator. The total travel is repeated for reference.
The bench set for the actuator does not include valve friction, so the
analysis removes the friction to determine the true bench set. As
friction changes the bench set does not change, although the friction
does change the stroking range of the valve. The seat load is found
under the test conditions, and if the service conditions are entered in
the nametag the seat load under service conditions is also calcu-
lated. This can be compared to the required seat load from the na-
metag.
66
Seat Load Calculation : Automatic and Manual
The net pressure vs. travel graph will automatically calculate the seat
load based on the pressure change between the end of the closing
stroke (which could be either end of the graph depending on whether
zero signal is open or closed) and the pressure at a point near where
the plug contacts the seat. It draws a small circle around the two
pressure points it uses. This works well for most valves and tests,
but sometimes test data is such that you may feel the points it auto-
matically picks could be improved. You can override the automatic
selection of pressures by moving the top and bottom cursors to the
pressures you think it should have selected before you analyze the
graph. If either the top or bottom cursor is moved in from the edge
of the graph before analyzing, the seat load calculation will be based
on the pressure difference between the two cursors. Sometimes the
ending pressure is directly at the bottom of the screen, and you can
leave the bottom cursor in place, but it must be moved to the lowest
actual pressure if that is not the bottom screen position. The top cur-
sor will always have to be moved down.
Seat Condition
Although the Dynamic Scan test doesnt perform an actual leak test,
zooming in on the seating action shows how the plug wedges into
the seat ring and gives an indication of the trim condition:
The stairstep appearance of the plug moving into the seat is actu-
ally caused by the digital resolution of the travel sensor. If it had infi-
nite resolution a smooth trace would be shown. New seats tend to
have a sharper break in the curve as the plug contacts the seat.
This profile degrades into a more gradual curve with wear.
Different types and sizes of valves will have different profiles.
You should always compare any results to a similar type and
size for reference.
67
8.1.11 Measurement vs. Time
If you cursor down past the graph selections on the first page of the
graph menu, the following page of graph choices will appear:This
page of graphs displays the recorded variables on the Y axis vs.
elapsed time on the X axis. Any combination of variables can be
plotted, from 1 to all measured variables. By default all recorded
channels will be selected for the Y axis when this page of graphs is
selected. When multiple variables are plotted the traces are identi-
fied by letter symbols such as i for current or an for Actuator Net
pressure.
Measurement vs Time Graph Showing Multiple Variables
On Dynamic Scan tests this screen is most often used to check the
crossover pressures of piston actuators. Plot the Actuator Stroke,
Actuator Return, and Net Pressure data at the same time: Check the
manufacturers specs for the positioner used. If the crossover pres-
sures are too low the valve may have control problems that are not
otherwise obvious.
Toggling YAxis Selections
The variables selected to display on the Y axis can be changed by
toggling the Y selection on or off. Move the highlight bar to the vari-
able you want to change and press the SPACE bar (or the letter Y).
This will toggle the Y selection on or off.
You may want to toggle off the pressures and display only the signal
and the travel on the Y axis, to examine overall response and strok-
ing time.
68
Displayed Y-Axis Scale
If a combination of pressures and either signal or travel is selected to
plot, the Y axis legend will call out the combination, and the scale will
show the pressure values.
If only pressures, or only nonpressure variables are plotted,
the Y axis legend and scale will match the location of the High-
light bar on the graph menu.
Stroking Time or Elapsed Time display
If the F3 or F4 key is pressed with an elapsed time graph on the
screen, the elapsed time between the cursor positions (left and right)
will be displayed on the screen. For stroking time evaluation run a
step change test, and plot the signal and travel vs. time. Zoom in on
the closing step as needed, and set the left cursor on the start of the
signal change, and the right cursor on the end of the travel change.
Then press the F4 key and the graph will show the stroking time.
Press F6 to print the graph.
Recording Stroking Time in a Text File
It is possible to record the analyzed stroking times in a text file for
use by other programs. After analyzing a signal & travel vs. time
graph for stroking time on both directions, return to the Graph menu
screen and press F10 to save.
The time difference on the left portion of the graph is recorded as
First Time = X.XXX Sec. and the time difference on the right side of
the plot is Second Time = X.XXX Sec.
8.1.11.1 Miscellaneous Graphs
Moving the selection cursor past the bottom of the elapsed time
graph choices brings up the third page of graph choices the miscel-
laneous graphs.
On this page of graphs any variable can be selected as the X axis
variable, and any combination of 1 or more variables can be selected
as the Y axis variables.
Select the X axis variable by moving the highlight bar to your choice
and pressing the letter X.
Select the Y axis variables by moving the highlight bar and pressing
Y (or SPACE).
69
As with the elapsed time graphs the highlight bar position determines
the Y axis legend and scale for plots, so leave the highlight bar on
the variable desired for the label.
With multiple plots only the horizontal axis can be zoomed.
Unless the graph plotted matches one defined on the first graph
page, no analysis is defined for these graphs.
8.1.12 Static Point Test
A6886*B/IL
When Static Point Test details are first read into memory, the Control
Signal and Travel choices on the elapsed time menu will be selected
automatically. Just press Enter to display the overall valve graph,
and analyze it by pressing F4:
This gives the static test results that compare to published specifica-
tions for valves. By toggling off the Travel selection and picking the
I/P output pressure the I/P performance can similarly be analyzed.
Then the positioner/valve performance can be analyzed by toggling
off the Control Signal plot, and toggling on the Travel plot to go with
the I/P output pressure
.
70
8.1.13 Step Change Test
A6886*C/IL
The Step Change test is performed to determine the Stroking

Speed or Response Time of the valve assembly. The Display Pro-
gram defaults to page 2 (Elapsed Time Display) in which both signal
and travel will be plotted for the analysis of this test. For precise re-
sults, it is recommended that the area of interest (increasing or de-
creasing signal) be zoomed-in on by moving the left and right cursors
near this region and then pressing the Enter key. The next step is to
move and lock the left cursor at the exact location in which you can
detect a signal change and the right cursor at the point of completed
travel. By pressing the analysis key (F3 or F4), the time between the
cursors is displayed. This is the elapsed time (stroking speed) it
takes the valve to respond to an abrupt signal change. Pressing F5
or F6 will provide a printed copy of the results.
71
8.1.14 Stepped Ramp Test
A6886*D/IL
The Stepped Ramp test is performed to measure the response or

controllability of the process variable (i.e., pressure, flow, level, tem-
perature, etc.) to the valves signal change and is expressed in per-
centage. The Display Program defaults to page 2 (Elapsed Time
Display) on which you plot the control signal and the process vari-
able (normally measured on an auxiliary channel). Because the in-
put signal is stepped systematically in steps of equal value and that
the stepping direction is changed a minimum of three times, the
valves hysteresis and deadband can be captured. To manually ana-
lyze this data (there is no auto analysis) simply count the number of
signal changes required to obtain an output (process variable)
change. Multiplying this number times the percent of change per
step equals the percent of response of the valve assembly. For ex-
ample, if the test was performed at 0.5% step increments (0.08 mA
for a 4-20 mA signal range) and it took four of these steps to achieve
a change in process, you would call this 2% control. Hence the pro-
cess tolerance, in this example, could not be held any closer than
2%.
72
8.1.15 Step Study Test
need data for this test to include graph
The Step Study test is performed to measure the response or con-

trollability of the process variable (i.e., pressure flow, level tempera-
ture, etc.) to the valves signal change and is expressed in percent-
age. The Display Program defaults to page 2 (Elapsed Time
Display) on which you would plot the control signal and the process
variable (normally measured on an auxiliary channel). Because this
test systematically steps an input signal up and down at changing
increments, the total hysteresis and deadband of the assembly can
be captured. In this display, you look for what degree of signal
change is required for the output (process) to follow.
For example, if you see that there is minimal to non change in output
with a 1% signal change, but the output mirrors the input with a 2%
signal step, you would classify this assembly as being between a 1%
and 2% device. There is no auto analysis of this test.
8.2 Transferring Data to the Report Module

The Quick Report is only defined for Dynamic Scan tests. For
Static Point, Step Change, Stepped Ramp and Step Study tests,
the printed graph is the report. As each Dynamic Scan graph is
analyzed the calculated results are saved in memory from the most
recent analysis of that graph. This data can be written to a file for
transfer to the report program for summary printout with your added
comments.
Pressing F10 once from the graph menu will display a screen show-
ing which graphs have been analyzed and which have not. Check to
73
see that the appropriate graphs have all been analyzed for the
construction of the test valve.
Pressing F10 again will store the results on the data disk where the
report program can read them later. The results are stored under a
TESTNAME.QRP file.
Exit the Display program back to the main menu.
8.3 Copying and Displaying from the Display Program

The Display program is also used as the way to copy test data from
one disk to another, to save data in ASCII format for use by other
analysis methods, and to store data files in compressed ZIP files
for archiving and uploading to the BBS system. The Display pro-
gram FileSave menu lists these options to save data:
8.3.1 Saving Data to New Disk

This choice simply saves the test data in memory (ready to display)
to the data drive. It is used if you didnt save the data in the Test
program and want to save it to a data disk, or to copy data from one
disk to another. To copy data, first read in the test you want to copy
from the original disk. Then insert the disk on which you want to put
the test data and select this choice. Read the help screen to verify
this is what you want and press F10 to save the data to the new
disk.
8.3.2 Saving Data as an ASCII File

The FlowScanner does not use ASCII format for test data because it
is inefficient and takes up too much space. However data can be
exported in ASCII format for use in spreadsheets and other analysis
programs. To export data in ASCII first read in the data from the
original data disk. Then insert a new disk with enough free space
(each ASCII data file may be 500 kb) and select this choice from the
FileSave menu.
8.3.3 Compressing Files

FlowScanner data is normally saved in multiple files in typed binary
format. Each test will take at least 5 data files, plus the nametag
data. As a result the files may take up to 100 kb disk space and sev-
eral files must be transferred if you want to copy tests or send them
by modem. The FlowScanner can make use of the PKWare utilities
74
to compress a set of test files into a single file for transfer. To do this
the temporary storage drive (RAM DISK or TRAM directory) is used
to hold the test data while PKZIP does its work. Normally you
should store data in the FlowScanner format, but when you need to
transfer files, or archive groups of tests on a hard disk, you can use
these utilities to compress them.
To use these utilities you must have PKZIP.EXE and PKUNZIP.EXE
stored on you disk in the DOS search path. (The DOS directory
works well.) PKZIP is installed on all FlowScanners and is also
available on the FlowScanner BBS.
Like the other file saving formats, the test data you want to ZIP must
first be loaded into memory. There are three ZIP saving options:
Save as ZIP File by Test
This is the only option which can be read directly back into the dis-
play program. A single ZIP file with the extension .ZPD (Zipped
Data) is created on the data drive holding all the test data in memory
(and the Nametag) under the filename TESTNAME.ZPD where
TESTNAME is the same datetime name created when the test was
done.
Save as ZIP file by TAG
This option first creates a ZPD file by TESTNAME, and then adds it
to a file named by the valve nametag as TAGNAME.ZPT where
TAGNAME is the first 8 digits of the TAG number from the nametag.
If you choose this option for several tests on the same valve, they
will all be added to the single TAGNAME.ZPT file. If you have tests
from more than one Nametag with the same first 8 digits, they will be
grouped in the same file. Once you save tests in this format, you
must extract the TESTNAME.ZPD files manually with PKZIP before
the Display program can read them back in.
Save as ZIP file by Serial
This option first creates a ZPD file by TESTNAME, and then adds it
to a file named by the valve nametag as SERIAL#.ZPS where SE-
RIAL# is the HEX value of the Serial number from the nametag. If
you choose this option for several tests on the same valve, they will
all be added to the single ZPS file. Once you save tests in this for-
mat, you must extract the TESTNAME.ZPD files manually with
PKZIP.
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9 Quick Reports
9.1 Overview
The Quick Report should include both the summary printout of the
analyzed data with your added comments, and any appropriate
prints of graphs that you printed from the display program. You
should also attach a printout of the Nametag information, printed
from that program. The summary report reads in the analyzed data
and the nametag data and formats it in a table. You then can put
comments next to any line of the table explaining the significance of
the numbers.
9.2 Procedures
9.2.1 Retrieving Data
Select the Report program from the main menu, being sure the data
disk is in the drive. From the initial screen select the File menu
(AltF) and select Retrieve Test results.
Then select the test name desired from the list at the top of the
screen, and press Enter to read in the data. The calculated data
from the Display program will appear in the Specified and Measured
Columns, with Comments section ready for your input: If the Static
End Points were manually recorded when the test was run, those
values will appear in the Comments lines next to the Dynamic End
Points: You can add to these static calibration notes, or add addition-
al comments in the report Comment fields.
The screen isnt long enough to show the entire report, so it is dis-
played in sections. The first part shown is the overall valve control.
The cursor will be on the first comment field. You can enter a com-
ment and move the next field. You can move between comments
with the Up and Down arrow keys. After filling in the comments on
this first screen, press the PgDn key to move to the second section
Valve and Actuator Data.
Fill in the Comments on the Valve and Actuator combination as on
the previous screen, and PgDn will show the last section, Positioner
Data and I/P Transducer Data.
After filling in this screen of comments the first screen will reappear.
The PgUp and PgDn keys will let you look through the completed
report for review.
76
Pressing AltC will open a comment window where you can enter a
couple of concluding comments to print at the bottom of the report.
9.1.2 Saving Reports

The completed report, with comments, should now be saved to the
data disk by pressing F10 (or from the file menu). This will save it as
a FlowScanner report, formatted for use with either this Quick Report
or the formal report package. If you do not save the report before
exiting the report program your comments will be lost.
Because the report is saved to a FlowScanner report file, retrieving
the test results will again bring up the data without the comments. If
you want to retrieve a report with comments, select the Get Saved
FlowScanner Report from the File Menu.
9.2.3 Printing Reports

F6 or AltP will print the report; either to the screen for preview, or to
a printer, if attached. While the report is printed as TEXT and not in
graphics mode, the lines on the report are printed in the IBM ex-
tended character set. If the printer is not set up to use this character
set it will instead print whatever extended characters it has, which
may produce very strange looking characters in the report. Most
printers can be set to use the IBM or PCUS, or graphics (instead
of italics) character set, which will produce the lines as shown on the
screen.
77
10 Parts List
FlowScanner parts and toolkit parts can be ordered through your local Fisher Represen-
tative or Fisher Sales Office.
ITEM PART NUMBER
Accessory Kit, Complete T13845T0012

Adapter, Hex T13886T0012
Adapter, Rotary T13885T0012
*Battery T13846T0012
Cable Kit, 50-inch transducer T13924T0012
*Cable, Current Output T13847T0012
Cable, Current Output, 25-foot Extension T13848T0012
Cable, Pressure Scanner 25-foot Extension T13849T0012
*Cable, Travel Transducer T13850T0012
Cable, Travel Transducer, 25-foot Extension T13851T0012
Case, Shipping T13904T0012
Case, Tool T13888T0012
Charger, Battery, External T13852T0012
Clamp, 2.5-inch w/adapter T13899T0012
Clamp, 1-inch T13902T0012
Clamp, 4.5-inch w/adapter T13898T0012
Clamp, Bessey T13923T0012
Fitting, Parker 1/8 tube x 1/4 MNPT T13891T0012
Fitting, Parker 1/8 tube x 1/8 FNPT T13890T0012
Fitting, Parker 1/8 tube x 1/8 MNPT T13889T0012
Fitting, Parker 62PL2 T13892T0012
Fitting, Parker 66C22 T13893T0012
Fitting, Parker 68C22 T13894T0012
Guide, Cable, 50-inch transducer T13925T0012
I/P, 060 PSI Output T13853T0012
Rod, 1/2 x 10 T13900T0012
Rod, 3/8 x 8 T13895T0012
Swivel Joint, 1/4 x 3/8 T13896T0012
Transducer, Travel, 2-inch T13858T0012
*Transducer, Travel, 25-inch (BEI Style) T13862T0012
*Transducer, Travel, Rotary T13861T0012
*Tubing, Parker T13887T0012
*Recommended spare parts
78
11 Appendices
11.1 Appendix A: Data Management

11.1.1 Transferring Data
Normally with the FlowScanner, the data disk is either the A: floppy
or the G: hard disk. When data for a FlowScanner test is stored,
there are basically two types of data files. One is the name tag which
is created from the Start, Look at, or Change of Valve Name Tag
choice from the Main Menu. If Tag Name in the Operating Defaults
is listed as TagName, the name tag will be saved on the data drive
as XXXXXXXX.T@G (or XXXXXXXX.RRG for rotary) where
XXXXXXXX is the first eight characters in the tag name field. If
Serial Number is selected, the file name will be in the format YYY-
YYYYY.SER (or YYYYYYYY.SRR for rotary) where YYYYYYYY
is a hexadecimal conversion of the serial number field.
The other data file type is the data files gathered during a FlowScan-
ner test. The file names for the data files all have the format
MMDDHHMM.ZZZ where the eight character filename is the
month, day, hour, and minute the test was started and the ZZZ
suffix is DTA, DNT, DN1, UPT, and UP1 for sliding stem
valve tests (or DTR, DNT, DN2, UPT, and UP2 for rotary
valve tests). If the graphs have been analyzed, a
MMDDHHMM.QRP quick report file is also present. Also saved are
the RUNTEST.DAT file that was created when you did the name tag
and test setup. There is also a DEFAULT.DAT or SETTINGS.DAT.
You may run out of space in the middle of a test or want to take files
from several data disks and put them on one composite data floppy.
This discussion of data management is concerned with moving files
from one data disk to another.
Transferring the Name Tag to a New Floppy Disk
To transfer a name tag, insert the floppy disk that contains the
source name tag. Open the Name Tag program, then select Re-
trieve Valve Name Tag from the File menu. When you press <En-
ter>, the program reads the source data disk and displays the list of
available valve name tags. Select the desired name tag by moving
the selection field up or down with the arrow keys, then press <Em-
ter>. This copies the valve name tag information to he Valve Name
Tag program. At this point, remove the source disk and insert the
79
destination disk. Select Save the Valve Name Tag to File from the
File menu to copy the contents of memory to the destination data
disk.
Transferring the Test Data to a New Floppy Disk
To tranfer the test data from one floppy data disk to another, insert
the source data disk. Open the Display program, then select File
Retrieve from the File menu. Select Test to Display and press
<Enter>. This activates the program to read the source disk and
display the available tests on the disk. Select the desired test by
moving the selection field up or down with the arrow keys, then press
<Emter>. Ths loads the selected test data into the Display program.
At this point, remove the source disk and insert the destination disk.
Select Save Data to New Disk from the File Save menu, then
press <Enter>. This copies the contents from the program memory
to the destination data disk.
Tranferring the Name Tag to a New Data Drive
To transfer the name tag to a new data drive, open the Name Tag
program, then select Retrieve Valve Name Tag from the File menu.
When you press <Enter>, the program reads the source data disk
and displays the list of available valve name tags. Select the desired
name tag by moving the selection field up or down with the arrow
keys, then press <Emter>. This copies the valve name tag informa-
tion to he Valve Name Tag program. Exit the Name Tag program,
then open the Operatig Defaults screen to change from the source
data drive to the destination drive. Exit the Operating Defaults
screen and reopen the Name Tag program. Since the name tag data
is still listed in this screen, you can save it to the new data drive by
selecting Save Data to New Disk from the File Save menu and
pressing <Enter>.
80
Tranferring the Test Data to a New Data Drive
To transfer test data from one data drive to another, begin by ensur-
ing that the Operating Defaults screen is referencing the source
data drive. Open the Display Program and select Tests to Display
from the File Retrieve menu.. Select the desired test and press <En-
ter> to load the data into the Display Program. Exit the Display
Program and open the Operating Defaults screen to change the
data drive to the destination drive letter. Exit the Operating De-
faults screen and reopen the Display Program. Since the test data
is still in memory, you can save it to the new data drive by selecting
Save Data to New Disk from the File Save menu and pressing
<Enter>.
11.1.2 Data Storage Tips

Typically, field tests are stored on a floppy diskette. In practice, this
has been the most effective way to store and transfer FlowScanner
test information. One 3.5-inch, 1.44 Mb floppy will store approxi-
mately 16 tests. The number of tests that can be stored per disk
depends on the test types and the number of parameters being mon-
itored. Proper labeling should be used in order to identify the tests
stored on each disk. A common practice should be developed so
labeling is uniform throughout a particular site. After testing is com-
pleted, the floppy disks are typically stored for later comparisons or
the information is transferred to a permanentarchive such as a desk-
top personal computer or local area network (LAN).
Even though there is a hard disk on the FlowScanner, saving data to
it should only be temporary. If used for permanent storage of test
data, you are putting all your eggs in a portable basket, which is
used in various environments in the field and usually by more than
one person. Data should be transferred, if the FlowScanner is used
for storage. After testing is complete, the data should be stored in a
more secure format such as, floppy disk, desktop PC hard drive or
LAN. FlowStor Data Archive software was developed to address
this need. Refer to Section 11.7, Appendix G: Related Products for
more information on FlowStor.
81
11.2 Appendix B: Software Installation
The distribution disk contains the programs in selfextracting com-
pressed format with an installation program to install them on your
hard disk. This creates a FLOWAUX directory with SLIDSTEM and
ROTARY subdirectories for the programs, TRAMS and TRAMR
directories for temporary storage of base data, and TEMPS and
TEMPR directories for temporary storage of other data. It will also
place SLIDAUX.BAT and ROTAUX.BAT files in either the 1APP di-
rectory (on FlowScanners) or the root directory (on Desktop PCs) to
start the programs.
FlowScanners copy the programs to a RAM disk to shut down the
hard disk to save battery power.
To install, place the distribution disk in the floppy drive, and run the
INSTALL.EXE program on the floppy disk. The install program will
check the hardware to see if it is a FlowScanner, and will ask where
you want to install the programs.
11.2.1 Starting the Programs from DOS and Windows

Starting from DOS
The ROTAUX.BAT and SLIDAUX.BAT files created on the hard drive
will start either the Rotary or Sliding Stem programs.
Starting from Windows
You can use the Windows DOS prompt or use the Program Manager
(or other Windows shell, like Norton Desktop) to add a Rotary and
Slidstem icon to a program group. For the Rotary program select
the \FLOWAUX\ROTARY sub directory as the starting directory and
MAINROT.EXE as the program. For the Sliding Stem programs
(SLIDSTEM) select the \FLOWAUX\SLIDSTEM directory and the
MAINFS.EXE as the program. The details of creating the program
group vary with the Windows shell used, so follow normal proce-
dures for your shell. Then just click on the icon to start the pro-
grams. (Icon files are installed for the programs.)
82
11.3 Appendix C: Trouble Shooting
Troubleshooting Overview
The FlowScanner is a complex assembly of computer hardware,
data acquisition and sensor hardware, computer operating software,
data acquisition software and analysis software. If a problem occurs,
it is first necessary to determine whether it is a hardware or software
problem, and which part of the hardware or software is involved.
This section will help you isolate the problem to a specific area.
Available Technical Support

Technical Support is available through the MRO Field Support Group
at the Fisher-Rosemount Technical Center, Marshalltown, IA 50158.
If your FlowScanner does not respond to the field troubleshooting
guide, please call one of the numbers below, for instructions on re-
turning the unit.
MRO Group secretary: (515) 754-2227
MRO Group Administrator: (214) 548-3145
Fisher Main Office:(515) 754-3011
A Return of Material Authorization (RMA) number will be issued to
track the system. The return address is:
Fisher Controls Inc.
310 E. University Dr.
McKinney, TX 7506980004
Mark: Attn RMA #
The FlowScanner must be shipped in the original shipping case pro-
vided with the unit.
Major Component Groups

For troubleshooting lets define the FlowScanner into the following
groups of components (or files):
1. Battery and Power Supply
2. Computer Platform
3. Keyboard
4. Disk Drives
5. Data Acquisition and Sensors
6. LCD and Video Displays
83
7. Printer and RS232 outputs.
8. Computer Operating Software
9. FlowScanner Data Acquisition Software
10. FlowScanner Analysis Software
As we discuss various potential symptoms, well try to isolate the
problem to one of these groups.
Suggested Tools
We would suggest the following tools for assisting with locating and
repairing problems:
1. Phillips and Slotted screwdrivers
2. Digital volt meter several vendors have small, shirtpocket
sized units at negligible costs.
3. Access to a VGA monitor if LCS is blank
4. Battery Charger for Gel Cell Batteries
Avoiding Trouble
If the system has been shipped or dropped, check it over BEFORE
turning it on. Open the cover, fold up the screen, and look for any
signs of damage or bent parts. Pick the unit up (flat) and tip it in all
directions, listening for sounds of anything loose. If you hear sus-
pect noises, DONT TURN IT ON! Contact Marshalltown Technical
Support for Instructions. You may be instructed to take out the 10
top panel screws and lift the system out of the case. Look for loose
screws, cable connectors, circuit boards that have popped out of
sockets. If it looks OK, turn it on and check it out.
Note
Taking the unit apart without approval of the MRO
Technical Support Group will void the warranty.
Problem History
Overall, the FlowScanner has proven to be a rugged and reliable
system. However, there have been a few problems reported.
84
Where problems have been traced to hardware design we have
made changes to eliminate items of hardware that were not as reli-
able as required. The Power Supply, Computer Section, data ac-
quisition section, and LCD screen power supply have all been rede-
signed or resourced for the greatest reliability.
The majority of problems have been due to shipping damage. The
FlowScanner components are rugged, but must be protected from
excessive shock. Several units have been shipped with the outside
protected from damage, but without effective shock cushioning, re-
sulting in sometimes severe internal damage with no sign of external
problems.
Note
Never ship a FlowScanner without the plastic,
foamlined shipping case.
Shipping on pallets or padded with peanuts or paper has proven

inadequate, and damage is likely.
Fortunately, shipping damage has usually been connectors or fasten-
ers coming loose, and reassemble has normally restored the system
to operation.
In the most severe case, a unit was shipped strapped to a pallet,
covered by a box. The exterior was undamaged, inside, the LCD
screen was smashed, most keys had popped off the keyboards, sev-
eral wire connectors were detached, circuit boards had popped
loose, and even chips had popped out of the main computer
boards. As the unit was needed for a customer demonstration (out-
side the USA), we talked through the identification of loose parts and
how to fit it back together, and with an external monitor replacing the
LCD screen the unit worked properly.
Other repeat problems have involved mysterious erasing of com-
puter system files from the hard disk, and viruslike damage to the
hard disk partition table. These problems almost always stemmed
from someone trying to use the FlowScanner for some other com-
puter use. While it is a very capable computer, it is setup specifical-
85
ly for FlowScanner operation, and changing that setup can cause
problems.
Symptoms and Possible Areas to Check

1. DEAD No signs of life No power LED, no meter indication
Battery Connections Remove cover and check.
Battery Check with DVM, or try spare
2. Battery Drains and doesnt charge
AC Power Indicator Should be ON with AC connected
AC cord If no power indicator AC Power Supply Remove DC pow-
er assy. and check for 15VDC at connector.
DC Power Supply If it has + 15V in and battery contacts are dead,
replace the DC assembly.
3. Unit has power, but LCD stays blank
LCD Assembly Check contrast adjustment, LCD switch.
LCD Assembly Turn System Off, plug in VGA Monitor and check
for output. If VGA image, check LCD cable to top panel and ribbon
cable to video module.
4. Drive C not ready message, or seizes with Loading... on
screen
SETUP info. changed enter computer setup program & check drive
type for Hard Disk 1. Should be type 17 for 40 megabyte drive, or
refer to cmos configuration document for larger drive.
Hard Drive Damage of virus damage Replace hard drive and return
to us for evaluation.
5. FlowScanner software doesnt run, Heads Parked mes-
sage appears instead
RAM disks missing check CONFIG.SYS file on hard disk. Copy
CONFIG.BAK or CONFIG.OLD to CONFIG.SYS and reboot.
6. Will Not Access any files on Floppy Disk
Disk Defective or Not Formatted try disk in another PC.
Drive Type set wrong in SETUP should be 1.44 MB drive.
Defective Drive Replace with 1.44MB drive.
7. FlowScanner locks up when trying to run a TEST.
86
Data Disk not formatted
RUNTEST.DAT file not created on data disk see software manual.
Operating Defaults set incorrectly check that data drive letter is
assigned to A.
8. Measured Current doesnt track Commanded Current
Cable not connected or broken lead with an open loop the mea-
sured current reading is unpredictable.
Unit not calibrated for output range separate calibration is done for
025 and 055 ranges.
9. Travel Transducer dead no reading when moved
Bad cable connection check continuity
No power to transducer check for + 5 V at cable connector red
lead to black lead.
Bad transducer or connector As transducer is stroked there should
be +5V to 0V toggle between the white and black cable leads and
the green and black cable leads. If not, try new cable, new transduc-
er.
10. Text Printouts have strange characters instead of lines and
boxes
Printer not set for IBM extended character set or IBM emulation.
11. Graphs dont print or print garbage
Printer Type set incorrectly on operating defaults.
Bad printer cable.
Printer set for wrong emulation.
Did not wait for image to process On LaserJets (and Deskjets) the
image is preprocessed for about 30 seconds before printing starts.
Esc can abort before the printout starts.
12. Quick Report is missing data
Test Type not Dynamic Scan the Quick Report is only used for Dy-
namic Scan tests; other test types print graphs with analysis.
Graphs Not Analyzed First the QRP file is written using information
from the analysis of the basic 4 graphs.
13. Comments Missing from Quick Report File
FlowScanner Report not saved after entering comments (select off
file menu).
87
Retried QRP file instead of Old FlowScanner Report.
No room on disk for FlowScanner Report File.
14. Analysis incorrect, fitline not drawn to data spread
Auto Analysis not finding range property, set analysis range manually
with cursors. Some data conditions can cause the software to ana-
lyze the curve beyond the linear region. Set the left and right cursors
to just inside the linear region before analyzing.
NonLinear cam in the positioner A nonlinear cam will not analyze
to a linear fit, so the zero and span numbers may be off, and of
course, linearity numbers will be high. Note the end points manually
on the printout.
15. Benchset calculation appears incorrect
Actual Travel different from nominal travel The BenchSet is based
on the nominal travel entered on the Nametag. The analysis first fits
the midline curve to the data and then located the end of the curve
at the upper travel stop. An X is drawn on the FIT line at the point.
Then a X is drawn at the nominal travel point, and pressures at
these points are used for the bench set.
Fit line extends into nonlinear area If a high friction area or pilot
spring area is included in the autoanalysis region the fit line can be
skewed. Move cursors to the ends of the linear region before ana-
lyzing.
Nametag mislabeled for OPEN position The bench set is calcu-
lated from the upper travel stop. If the wrong position is identified
the bench set will be off.
16. Seat Load calculation incorrect
Curve shape not typical and points taken not representative of the
pressure buildup. Circles are drawn around the points used for the
seatload calculation. If they are not in the right place, use the top
and bottom cursors to identify the correct pressures before analyz-
ing.
Unbalance area or Pressure Tends To entry wrong on nametag,
this will make the service seat load incorrect.
Wrong Service Pressures entered on Nametag Enter the service
pressures at shutoff as closely as possible. If they arent known at
all, dont enter any pressures, as the calculation could be misleading.
88
11.4 Appendix D: Calibration
When installed on a FlowScanner the FlowAux programs offer to
copy the standard software (2.3) calibration for use with FlowAux.
When recalibration is done after installing FlowAux, the FlowAux pro-
grams are calibrated separately from the 2.3 programs, and results
are kept in different directories. The file formats are identical, and
you can copy the calibration files (TSCAL.DAT) from C:\FLOWS-
CAN\SLIDSTEM to C:\FLOWAUX\SLIDSTEM if you want to avoid
separate calibration.
If the FlowScanner has 10 V to +10 V output it is still only neces-
sary to calibrate the output from 0 to +10 V; since the negative volt-
ages are done simply by reversing polarity of the output.
Calibration is all done in the software and should be necessary only
once or twice per year, or as often as the site requires.
The pressure calibration does shift as the system warms up, so the
system should be left at the CALIBRATE screen for 20 minutes be-
fore calibrating. The warmup affects primarily the zero calibration,
which is easily reset at test time.
Note
Zero shift is the most common pressure calibration drift.
The zero point can be recalibrated without affecting the
slope and linearity by pressing AltZ when all pressure
ports are open to atmosphere. In the calibration
program, the new zero reference can be saved by
pressing F10 after adjusting the zero point. (The zero
can also be set during the TEST program, but the new
zero is not saved from the TEST program.)
When you enter the calibration program the system accesses the
data card and displays live readings of all channels.
As in the other programs the menus at the top of the screen are ac-
cessed by holding the Alt key and pressing the highlighted letter of
the menu name. (AltF opens the File menu.)
89
Print/View
Data on the calibration including the master meter description and
serial number, person calibrating, and all master meter readings and
FlowScanner readings is kept on the hard disk and may be viewed or
printed on demand. AltP opens the menuto look at old calibrations.
The last choice, View/Print All Calibrations will show on-screen a
complete summary of the calibration records stored on the system
hard disk. This will be split into several screens of information. At
the bottom of the last screen it will say Press P to Print the calibra-
tion record or any other key to continue. This will print to a printer
attached to the printer port (LPT1).
Any other choice from this menu will simply show the part of the cal-
ibration requested, and give a chance to print that record.
Calibrate/Check..
The Calibrate/Check menu is selected to compare system readings
to a master gauge or instrument, calculate new calibration constants,
and compare results using both the old and new calibrations. Then
you can decide whether to record the new calibration constants or
keep the old ones. (Sometimes you may want to check the calibra-
tion when a master instrument meeting your accuracy standards is
not available. In such a case you would go through the procedure
and verify that the calibration agrees, but would not record the less
accurate new calibration.)
If the calibration password is not set, AltC opensthe Calibrate/Ceck
menu. From this menu you can calibrate the complete pressure
scanner, the 25 mA, 55mA, and 10V control loops, the auxiliary in-
puts, single channels of the pressure scanner, and check the travel
encoders. Details of these procedures are given later in this section.
Reset..
The Reset menu allows you to delete the calculated calibration of
any channel and substitute generic values. The Travel encoders are
most accurate if you use the reset values rather than calculating new
values. The other channels are not very accurate using the RESET
values, and should be re calibrated if reset. The main use of this
menu is to recover from an accidental bad calibration that may make
re calibrating otherwise difficult.
90
Options..
A calibration password may be set from the Options menu. If a
password is set the system may not be calibrated unless the pass-
word is verified. If you reenter the password from the Options
menu it clears the password again.
Calibration Methods
Calibration of all I/O functions is done using a 5point calibration to
an external master gauge or meter. Pressure inputs are calibrated to
a secondorder fit, and all other functions are done to a linear, least
squares fit to the 5 points.
To calibrate the pressure measurement system the following is re-
quired:
1. An adjustable pressure source or 5 preset pressures.
2. An accurate master gauge connected in line with the FlowS-
canner system so the pressure can be read simultaneously.
3. A pressure source of 100 psig to operate the calibration
valve in the FlowScanner.
4. The necessary 1/16 x 1/8 plastic tubing and fittings to con-
nect to the pressures and gauges.
To calibrate the Current Loop (420 mA) output you will also need an
accurate current meter and an I/P (or 150 Ohm load resistor).
The auxiliary channels are 010 volt inputs and are calibrated to a
master meter.
The travel transducers are digital encoders which do not require cal-
ibration, but the calibration procedures can be used to check accura-
cy and operation.
Control Signal Output Accuracy

Range Loop Command Accuracy Measurement Accuracy
0 to 25 mA 0.02 mA 0.03 mA
0 to 55 mA 0.03 mA 0.03 mA
0 to 10 Vdc 0.01 volts 0.01 V
91
Travel Input Accuracy
Range Resolution Overall Accuracy
(0 to 50.8 mm) (0.0025 mm) (0.0025 mm)
(0 to 101.6 mm) (0.0025 mm) (0.0025 mm)
(0 to 635 mm) (0.0025 mm) (0.0025 mm) 0.012% full scale)
(0 to 812.8 mm) (0.025 mm) (0.025 mm) 0.05% full scale)
Rotary 0.0075 degree 0.0075 degree
Pneumatic Input Channel Accuracy

Accuracy w/10 Min. Warm-Up
Pressure Range Resolution Accuracy w/2 Min. Warm-Up
& Within 20 Min. of Re-Zero
0 to 689.65 kPa) (0.27 kPa) 0.68 kPa + 0.2% of reading 0.68 kPa + 0.7% of reading
(0 to 206.90 kPa) 0.07 kPa) 0.2 kPa + 0.2% of reading 0.20 kPa + 0.7% of reading
Note: Also configurable to kg/cm2, Bar
The FlowScanner accuracy is expected to be as follows, if properly

warmedup and calibrated to a master gauge or instrument at least
3 times as accurate as the FlowScanner. (Some company stan-
dards require even higher accuracy of the master instruments in or-
der to claim the stated accuracy of the FlowScanner.) Calibrating to
less accurate masters can result in miscalibrating the FlowScanner.
(You obviously cant calibrate to 0.01 mA with an instrument that only
reads to 0.1 mA.) Digital pressure gauges should resolve at least
0.01 psig.
The system should be warmedup at least 20 minutes before cali-

brating, and should be calibrated at near the ambient temperature for
which it will be used. The pressure scanner exhibits noticeable drift
during poweron warmup in the Test or Calibration mode. The drift
decreases with time, and is most noticeable in the first 5 minutes of
reading pressures. To reach stated accuracy allow the unit to warm
up in the Test or Calibrate program for at least 10 minutes, rezero
immediately before each test or other measurement, and take read-
ings within 25 minutes of each rezero.
92
Overview:
Calibrating Pressures
Normally all pressure channels are 0100 psig range and all pres-
sure channels are calibrated at once. The internal calibration valve
is switched to connect the port marked CAL to all 8 transducers
internally. Five pressures are applied to the CAL port covering the
needed range. For each pressure the actual applied pressure is
read from the test master gauge, and this correct value is manually
entered into the system. Pressing the Enter key causes the system
to record the entered value and the current readings for each of the
8 channels. After all pressures are entered, the actual readings from
the 8 channels can be reviewed (PgDn) and compared to readings
using the new calibration constants. If the new calibration is better,
pressing F9 saves the new constants to the calibration file for default
use. Then the calibration valve is switched back to the RUN mode
for test.
If the highaccuracy transducer option is installed channels 7 & 8 are
030 psig range and are isolated from the other channels to avoid
over pressure during calibration. From the Options selection on the
Calibration menu the software is told whether 7 and 8 are 030 or
0100 psig range. If 030 is selected the scanner calibration only
calibrates channels 16, and channels 7 & 8 are individually cali-
brated later.
Calibrating Current
The current loop is calibrated by connecting the system in series with
an I/P (or approximately 150 Ohm resistor) and a current meter.
Connecting directly to a current meter without a load in the loop is
not recommended. This procedure calibrates both the current con-
troller and the measured loop current. Separate calibrations are
done for the 025 and 055 output sections.
Calibrating Voltage
The voltage output and auxiliary inputs are calibrated by controlling
the voltage with the cursors and recording the readings of a master
meter.
Full Calibration Procedure:

1. Select the Calibration program from the main menu. The old
pressure calibration (if any) will be used for the pressure displays. If
93
any channel numbers are flashing it means there is no valid calibra-
tion on file for that channel and the displayed values are known to be
inaccurate.
2. First calibrate the pressure scanner. From the Calibrate... menu
(AltC) select the pressure scanner. Instructions will be shown on
the left side of the screen. Page through them with the PgDn key, or
skip them by pressing Enter.
3. Connect the 100 psig air source to the port marked C1. Apply
pressure for a few seconds. A click should be heard as the shuttle
valve shifts to the calibrate position. The pressure can now be shut
off and disconnected.
4. After paging through the instructions (PgDn) a screen of informa-
tion about the master gauge and the person doing the calibration is
presented. Fill in this screen and press PgDn.
5. Leaving CAL port disconnected (to atmosphere) type in a 0 and
press Enter. This records a zero reading on all channels.
6. Connect the master gauge and pressure source to the CAL port,
and adjust the pressure source to 4 more pressures spanning the
range to be calibrated.
7. As each pressure becomes stable type in the reading of the mas-
ter gauge and press Enter to read all the channels and record the
master reading.
8. Press PgDn to see a summary of the proposed calibration. If you
wish to use the results for the system calibration press F9 to record
the calibration.
9. Shut off and disconnect the test pressures. Connect the 100 psig
air source to the port marked C2 to switch the transducers back to
the individual ports on the front panel. Then disconnect this line.
10. If the high accuracy transducers are installed on channels 7 & 8,
or if you want to recalibrate a single channel, from the Calibrate...
(AltC) menu select Calibrate a Single Pressure Channel, and re-
peat the process except leave the scanner in normal operation so
each channel is connected to its own input.
11. Then calibrate the current loop. From the Calibrate... menu
(AltC) select either the 025 mA loop or the 055 mA loop. Instruc-
tions will be shown on the left side of the screen showing how to
connect a current meter in series with a load to the output cable.
94
12. After paging through the instructions (PgDn) a screen of in-
formation about the master meter and the person doing the calibra-
tion is presented. Fill in this screen and press PgDn.
13. Using the left and right cursor keys (or Ctrlleft and Ctrlright for
fast changes) adjust the current so the external meter reads approxi-
mately 4 mA. Then enter the actual reading from the master current
meter and press Enter. The internal reading is recorded as the Enter
key is pressed, and the system assumes it should equal the master
instrument reading.
14. Repeat this for the other 4 readings, spanning the range to the
maximum current for the loop (20 or 50 mA). Be sure to press Enter
to record each reading.
15. Press PgDn to see a summary of the proposed calibration. If
you wish to use the results press F9 to record the calibration.
16. Repeat for the other current range (each must be calibrated to
use).
17. Likewise calibrate the Voltage output, and then calibrate each of
the auxiliary inputs.
18. After calibration is complete DO NOT JUST SHUT THE SYS-
TEM OFF or the new calibration will be lost. Exit the calibration pro-
gram and select Prepare for Shutdown from the FlowScanner Main
Menu. This saves the calibration from temporary storage to the hard
disk.
95
Additional Notes:
In this program the left and right arrow keys on the keypad control
the current loop output. Thus it is possible to use an I/P unit to con-
trol the calibration pressures. Either arrow key by itself adjusts the
output slowly. Holding the Ctrl key and pressing the arrow key adjust
the output in larger steps.
The travel transducer reading is also displayed during this test, so its
calibration can also be checked. If the wrong transducer is dis-
played, pressing AltT will toggle to the other possible models with
each press. While the calibration can be adjusted to match a known
displacement, the most accurate calibration is the default value for
each transducer.
Since you have live control over the output; and can read all pressur-
es and the travel, this routine can be used to calibrate a valve and
accessories. The same control exists in the Test program before
starting a test sequence.The calibration records can be recalled from
the View/Print menu and shown on screen or printed to a printer.
96
11.5 Appendix E: Connectors for Diagnostic Testing
This section describes quick connectors which are now available
from Fisher Controls to support diagnostic testing of process control
valve packages. Process control valve packages include a control
valve, actuator, positioner, and accessories.
D The connectors are for use with any actuator, positioner, vol-
ume booster, or other product available from Fisher Controls. The
new connectors allow a quick, positive connection between installed
control devices and the FlowScanner Valve Diagnostic System from
Fisher Controls. To support the use of the FlowScanner System,
connectors are recommended for all actuators and positioners avail-
able from Fisher Controls especially as retrofit items for installed
units.
D Only personnel qualified through training or experience should

install the connectors and operate and maintain process control
equipment. If there are any questions concerning these instructions,
contact your Fisher Controls sales representative or sales office be-
fore proceeding.
The connector assembly consists of pipe nipple, pipe tee, and pipe
bushing as necessary to tap pneumatic lines and a connector body
and body protector. With connectors installed, the FlowScanner can
be rapidly configured for testing of a control valve package.
Specifications
Specifications for diagnostic connectors are listed below.
Available Configurations
Pipe nipple, pipe tee, pipe bushing, and connector body. Install for ease of connection
with the FlowScanner System
Recommended Applications
Fisher Controls (instruction manuals):J 377 Series Trip Valves,J Types 546 and
546S ElectroPneumatic Transducers,J Type 646 ElectroPneumatic
Transducer,J Type 2625 Volume Booster,J 3570 Series Pneumatic Valve
Positioners,J 3582 Series Valve Positioners, Type 3582i Valve Positioner, and Type
3583 Valve Stem Position Transmitter,J Types 3590, S, and ST ElectroPneumatic
Valve Positioners,J 3610J and 3620J Series Positioners,J Types 3660 and 3661
Positioners,J Type 3710 Pneumatic Positioner,J 471 Series Actuators,J Type 481
Actuator,J 490 Series Actuators,J Type 513 and 513R Diaphragm
97
Actuators,J Types 585 and 585R Actuators,J Type 657 Diaphragm Actuator,J Type
667 Diaphragm Actuator,J Type 1031 Piston Rotary Actuators,J Type 1032
RackandPinion Rotary Actuators,J Types 1051 and 1052 Diaphragm Rotary
Actuators,J Type 1061 Piston Rotary Actuators,J Types 1066 and 1066SR Piston
Rotary Actuators,J Types 1250 and 1250R Actuators
Other Manufacturers:J PMV Positioners,J Moore 61H Booster Relay,J Bailey
P8821 Positioner when these products are installed on valve/actuator packages by
Fisher Controls
Connector
J stainless steel orJ brass
Connector Body: 1/8 inch NPT male with female quick-connect receptacle. 1.83
inches (46.5 mm) overall length. Internal poppet valve
Body Protector: Male component (solid plug). 1.75 inches (44.5 mm) overall length.
Inserted into connector body to protect internal body components against damage or
plugging caused by foreign contamination
Stem: 1/8 inch NPT female, for gauge, with male component (open connection). 2.02
inches (51.3 mm) overall length. Stem does not contain internal valve
The FlowScanner System comes equipped with flexible tubing and stems to mate with
installed connector bodies for diagnostic testing
Maximum Temperature Limit

250_F (70_C)
Maximum Safe Working Pressure

When coupling/uncoupling body/stem: 250 psi
When body/stem are coupled
SST: 3000 psi
Brass: 2000 psi
Installation
Connector Mounting Orientation

Assemble the pipe nipple, pipe tee, pipe bushing, and connector ac-
cording to the orientations shown. Refer to the appropriate assembly
drawing for the installation points for diagnostic testing. Rotate the
connector body for ease of connection with the FlowScanner Sys-
tem.
98
Piping
Warning
To avoid personal injury or property damage resulting
from the sudden release of pressure, do not install any
system component, including piping, where service
conditions could exceed the limits given in this manual,
in product manuals, or on product nameplates. Use
pressurerelieving devices as required by government
or accepted industry codes and good engineering
practices.
Warning
If a flammable, toxic, corrosive, or reactive gas is to be
used as the supply pressure medium, personal injury or
property damage could result from fire or explosion of
accumulated gas or from contact with toxic, corrosive,
or reactive gas. Follow appropriate safety practices and
instructions given in product instruction manuals when
installing connectors in piping carrying flammable, toxic,
corrosive, or reactive gas.
Refer to the appropriate assembly drawing in this manual and figures

in the product instruction manual for the location of all input and out-
put connections where connectors will be installed. Use the correct
size and type of tubing or piping for all connections. Always follow
accepted engineering, installation, and safety practices to insure the
safe and accurate transmission of pneumatic signals and process
pressures. Install shutoff valves, vents, drains, or seal systems as
required by accepted practices.
99
Supply Pressure
Warning
Personal injury or property damage may occur from an
uncontrolled process if the supply medium is not clean,
dry, oilfree, or noncorrosive gas. Industry instrument
air quality standards describe acceptable dirt, oil, and
moisture content.
Due to the variability in nature of the problems these

influences can have on pneumatic equipment, Fisher
Controls has no technical basis to recommend the level
of filtration equipment required to prevent performance
degradation of pneumatic equipment. A filter or filter
regulator capable of removing particles 40 microns in
diameter will suffice for most applications. Use of
suitable filtration equipment and the establishment of a
maintenance cycle to monitor its operation is
recommended.
Supply pressure must be clean, dry air or noncorrosive gas. Follow

instructions given for specific products when installing process con-
trol valve packages with connectors.
Principle of Operation
The connector body contains an internal poppet valve. The poppet
valve provides positive shutoff to minimize pressure loss when re-
moving the stem or body protector.
Inserting the stem or body protector into the body does not open the
poppet valve until the stem or body protector is seated in the body.
When removing the stem, the poppet valve seals before the stem or
body protector leaves the body.
To Couple: Align stem with body. Push stem into body until stem
and body lock together.
100
To Uncouple: Pull knurled sleeve on body toward stem until stem
and body unlock. Remove the stem from the body.
Maintenance
Warning
If maintenance procedures require taking process
control devices out of service, avoid personal injury and
property damage caused by uncontrolled process
pressure. Provide some temporary means of control for
the process before taking any control device out of
service.
Before performing any maintenance operations:
Disconnect any operating lines providing supply air

pressure, a process input signal, or other pressure
source to an actuator, positioner, or controller.
Shut off the supply pressure to the positioner or

controller.
Follow all procedures given the product instruction

manuals.
Connectors are subject to normal wear. Inspect and replace parts as

necessary. Inspection and maintenance frequency depends on the
severity of service conditions.
Because of the care Fisher Controls takes in meeting all manufactur-
ing requirements (heat treating, dimensional tolerances, materials of
construction, and other product characteristics specified by Fisher
Controls), use only replacement parts manufactured or furnished by
Fisher Controls.
Select the appropriate maintenance procedure and perform the num-
bered steps. Shut off the supply pressure and process pressure be-
fore beginning maintenance.
101
Parts
Part Ordering
Parts Ordering Whenever corresponding with your Fisher Controls
sales office or representative about process control equipment, al-
ways mention the serial number of each component. When ordering
replacement parts, refer to the 11character part number of each
required part as found in the following parts list
Connector/Hardware, for diagnostic testing

(FlowScanner System hook-up)
Part numbers listed here are for complete FlowScanner System
hookup assemblies. Each assembly includes the connector body,
body protector, gauge stem, and hardware such as pipe tees, bush-
ings, and nipples. Contact your Fisher Controls sales office or repre-
sentative for assistance in ordering individual parts.
Positioners
For Type 546 Transducers
If The Type 546 Transducer Is Used In A Valve Assembly With A
Positioner, No Hookup For Diagnostic Testing Is Required For The
Type 546. The Hookup For Diagnostic Testing Should Be Installed
At The Positioner.
Key Description Part Number Qty
FOR UNITS W/GAUGES
SST FITTINGS 12B8041X012 1
BRASS FITTINGS 12B8041X022 1
FOR UNITS W/OUT GAUGES
FOR TYPE 646 TRANSDUCERS
IF THE TYPE 646 TRANSDUCER IS USED IN A VALVE
ASSEMBLY WITH A POSITIONER, NO HOOKUP FOR
DIAGNOSTIC TESTING IS REQUIRED FOR THE TYPE
646. THE HOOKUP FOR DIAGNOSTIC TESTING
SHOULD BE INSTALLED AT THE POSITIONER.
FRONT OUTPUT
FOR UNITS W/GAUGES
SST FITTINGS 12B804X0X012 1
102
SIDE OUTPUT
FOR UNITS W/GAUGES
FOR TYPE 2625 VOLUME BOOSTER
FOR UNIT USED W/DIAPHRAGM ACTUATOR
FOR UNIT USED W/PISTON ACTUATOR
FOR 3570 SERIES POSITIONERS W/TYPE 377 VALVE
FOR UNITS W/GAUGES
FOR 3582 SERIES VALVE POSITIONERS
FOR UNITS W/GAUGES

FOR TYPE 3582i VALVE POSITIONER
FOR UNITS W/GAUGES

FOR TYPE 3590 POSITIONERS
FOR UNITS W/GAUGES

103
FOR TYPE 3610J POSITIONERS
FOR UNITS W/GAUGES

FOR TYPE 3610JP POSITIONERS
FOR UNITS W/GAUGES

FOR TYPE 3620J POSITIONERS
FOR UNITS W/GAUGES

FOR TYPE 3620JP POSITIONERS
FOR UNITS W/GAUGES

FOR TYPE 3660 POSITIONER
FOR UNITS W/SUPPLY GAUGE

FOR UNITS W/OUT SUPPLY GAUGE
FOR TYPE 3661 POSITIONER
FOR UNITS W/SUPPLY GAUGE

FOR UNITS W/OUT SUPPLY GAUGE
104
FOR TYPE 3710 PNEUMATIC POSITIONER
SINGLEACTION UNITS
FOR UNITS W/GAUGES
DOUBLEACTION UNITS
FOR UNITS W/GAUGES
FOR BAILEY P8821 POSITIONER
SINGLEACTION
FOR UNITS W/GAUGES
DOUBLEACTION
FOR UNITS W/GAUGES
FOR MOORE 61H BOOSTER RELAY
USED W/SPRING/DIAPHRAGM ACTUATOR

USED W/PISTON ACTUATOR
FOR PMV P1200 SERIES POSITIONER
FOR UNITS W/GAUGES

105
FOR UNITS W/GAUGES

FOR UNITS W/GAUGES

Actuators
FOR TYPE 471 ACTUATOR, SIZES 30 130


FOR TYPE 490 ACTUATOR, ALL SIZES

FOR TYPE 513 ACTUATOR, SIZES 20, 32

FOR TYPE 513R ACTUATOR, SIZES 20, 32
FOR TYPES 585, 585R ACTUATOR, SIZES 25, 50, 100

FOR TYPE 657 ACTUATOR, SIZES 30 87, W/ or W/O
TOPMTD HANDJACK

106
FOR TYPE 667 ACTUATOR, SIZES 30 34, 40

FOR TYPE 667 ACTUATOR, SIZES 46, 60, 70, 87



FOR TYPE 1031 FAILCLOSE ACTUATOR, MODELS 33082,
33102, 33122, 45102, 45122, 45171, 45211

FOR TYPE 1031 FAILCLOSE ACTUATOR, MODEL 33072

FOR TYPE 1031 DOUBLEACTING ACTUATOR, MODELS
45102, 45121, 45171, 45211

FOR TYPE 1031 FAILOPEN ACTUATOR, MODELS 33082,
33102, 33122

FOR TYPE 1031 FAILOPEN ACTUATOR, MODEL 33072

FOR TYPE 1032 DOUBLEACTING ACTUATOR, ALL SIZES

FOR TYPE 1032 SPRING RETURN ACTUATOR, ALL SIZES

107
FOR TYPES 1051, 1052 ACTUATOR, SIZES 30 70, W/

or W/O TOPMTD HANDJACK


FOR TYPES 1066, 1066SR ACTUATOR, SIZES 20 75

FOR TYPE 1250 ACTUATOR, SIZES 225, 450, 675

FOR TYPE 1250R ACTUATOR, SIZES 225, 450, 675

A6071
Standard Application Arrangements
108
Figure XX.
12B8042-B
A6074
Type 2625 Volume Booster with Diaphragm Actuator
12B8042-B
A6075
Type 2625 Volume Booster with Piston Actuator
109
12B8047-A
A6079
Type 3590 Positioner
12B8052-A
A6084
Type 3660 Positioner
110
12B8053-A
A6085 Type 3661 Positioner
12B8054-A
A6086
Type 3710 Pneumatic Positioner, Single-Action
111
12B8055-A
A6087
Type 3710 Pneumatic Positioner, Double-Action
12B8062-A
A6119
Bailey P88-21 Positioner, Single-Action

need A6119
112
12B8056-A
A6120
Bailey P88-21 Positioner, Double-Action
12B8058-B
A6121
Moore 61H Booster Relay, Used w/Spring/Diaphragm Actuator
113
12B8057-8
A6122
Moore 61H Booster Relay, Used w/Piston Actuator
12B8059-A
A6116
PMV P-1200 Series Positioner
12B8060-A
A6117
12B8061-A
A6118
114
13B8718-A
A6089
13B8717-A
A6088
Type 481 Actuator
Type 471 Actuator
13B8721-A
A6090
Type 490 Actuator
13B8720-A
A6091
Types 513, 513R Diaphragm Actuators
115
13B8721-A
A6090
Types 585, 585R Actuators
12B8097-A
A6093
Types 657, 1051, 1052 Diaphragm Actuators
12B8098-A
A6094
Type 667 Diaphragm Actuator (Sizes 3087)
116
12B8099-A
A6095
Type 667 Diaphragm Actuator (Sizes 80, 100)
13B8728-A
A6096
Type 1031 Piston Rotary Actuator (Fail Open, Model 33072
117
13B8727-A
A6097
Type 1031 Piston Rotary Actuator

(Fail Open, Models 33082, 33102, 33122)
13B8725-A
A6098

(Fail Closed, Model 33072)
118
13B8724-A
A6099

(Fail Closed, Models 33082, 33102,
33122, 45102, 45122, 45171, 45211)
13B8726
A6100

(Double-Action, Models 45102, 45121, 45171, 45211)
119
11.6 Appendix F: Tech Support
Technical support is available through all of the following:
Local Fisher Representative or the Fisher Direct Sales Office
Local Fisher Service Companies
MRO Field Support Group: Marshalltown, Iowa,

(515) 754-2227
MRO Headquarters: McKinney, Texas, (214) 548-3145
120
11.7 Appendix G: Related Products
FlowScanner Diagnostic System Support Package
With the FlowScanner diagnostic systemsupport package, available
to all FlowScanner system owners, you can extend your diagnostic
capability by taking advantage of a vast array of control valve diag-
nostic services, including technical support from the factory support
group; Flowscanner system factory test repair and recalibration; ac-
cess to an online bulletin board that provides technical assistance
and diagnostic data interpretation; FlowScanner system software
and instruction manual updates. The support package also extends
the warranty on your FlowScanner system.
RatRace Desktop Analysis Software

RatRace desktop analysis software is used with a desktop personal
computer for fast and detailed display and analysis of FlowScanner
diagnostic system test data. The RatRace software adds the ability
to overlay graphs from up to ten tests. The overlayed data sets plot
in different colors and all the displayed tests are listed on the menu
page helpsection in the same order and color in which they are
plotted to aid in review. The software includes tools that allow draw-
ing lines and circles and adding text notes to annotate graphs. All
graphs may be zoomed multiple times in both directions.
Because of the extensive use of colors and hard disk, this package
is sold for use on desktop computers for FlowScanner diagnostic
system analysis support. However, the same installation disk allows
installation on FlowScanner systems, if desired.
FlowStor Data Archive Software

This Windows compatible software program permits copying and
compressing data collected with the FlowScanner Diagnostic System
for long-term storage. The program also combines functions that let
you access and manage the stored data.
You can review summary information for the archived data, or use
the built-in link to RatRace desktop analysis software to view and
analyze the data. You can easily determine valve performance deg-
radation by comparing recently collected data to data that was col-
lected and archived when the valve was new.
The FlowStor software allows you to search and sort data and con-
vert the data for use with popular database programs.
121
Control Valve Diagnostics: Course 1425
This three-day course uses class lectures and hands-on workshops
to teach the student to make a detailed diagnosis of a control valve
assembly using the FlowScanner Diagnostic System. Students who
complete this course will be able to:
properly setup and operate the FlowScanner Diagnostic
System
perform diagnostic testing on sliding stem and rotary valve,

both single and double-acting
understand basic diagnostic data interpretation and analysis

concepts as related to valve setup and performance
Control Valve DiagnosticsData Interpretation

Seminar: Course 1426
This three-day seminar is designed to teach the advanced diagnostic
enginner/technician how to interpret and analyze diagnostic data.
Students are encouraged to bring three to five signatures for class
review. Students who complete this course will be able to:
understand advanced diagnostic data interpretation and analy-
sis concepts as applied to real world problems
understand advanced testing techniques needed to diagnose

non-standard valve applications
use the various elements of the Fisher valve diagnostics pro-

gram, including the bulletin board system, FlowScanner Users Net-
work and data archive system
122
12 Glossary
Actuator
Control Valve
Assembly
Bonnet
Valve Body
A1550
Relationship of Major Components
Accessory Kit
Kit supplied with the FlowScanner containing travel transducers,
pneumatic tubing, various brackets and miscellaneous hand tools.
Actuator
A piston or spring and diaphragm assembly for positioning the actua-
tor stem in relation to the operating pressure(s).
Actuator Return
In a piston actuator, the pressure opposing the stroke pressure.
Actuator Stroke
In a piston actuator, the pressure opposing the return pressure. In a
spring and diaphragm actuator, the pressure opposing the spring.
123
AutoZero Function (az)
A function on the test screen that automatically zeroes the travel
reading at test start.
Automatic Zero of Travel
See autozero function.
Auxiliary Input Data Channels
Input ports on the FlowScanner for recording auxiliary input such as
transmitters or strain gages.
Loading Pressure
Connection
Diaphragm
Casings
Diaphragm Plate
Diaphragm
Actuator Spring
Actuator Stem
Spring Adjuster Spring Seat
Stem Connector
Travel Indicator
Indicator Scale
Valve Plug Stem

Yoke
W0363
Direct-Acting Actuator
124
BBS System
Electronic Bulletin Board System.
Bench Set
The pressure range required to move the actuator from its upper
stop to its rated travel without any body frictional forces present.
Commanded Current
The output current signal commanded by the test and displayed on
the test screen.
Control Signal
The voltage or current signal provided by the FlowScanner to control
the valve during testing.
Dead Band
The range through which an input can be varied without initiating ob-
servable response.
Displayed Travel Units
The unit of measure for travel display, selected from the Options
screen.
Displayed Force Units
The unit of force measure for display, selected from the Options
screen.
DOS
Disk Operating System.
Dynamic Error Band (DEB)
For any given signal level, the difference between upstroke and
downstroke position, expressed as a percentage of total travel.
Dynamic Scan Test
A test in which the control signal is ramped from a preset starting to
a preset ending point at a specific rate.
FlowAux
The FlowScanner operating software.
FlowScanner
A portable, selfcontained test device for analyzing valve condition
and performance.
Hold Signal at Test End
An option (Other) on the test screen that will hold the current at the
minimum preset value at the test end or at its current value if the test
is aborted rather than dropping to zero.
125
Hysteresis
That property of an element evidenced by the dependence of the
value of the output, for a given excursion of the input, upon the histo-
ry of prior excursions and the direction of the current traverse.
Valve Plug Stem
Packing Flange
Actuator Yoke Locknut
Packing
Bonnet Packing Box
Valve Plug
Cage
Seat Ring
W0989
Push-Down-To-Close Valve Body Assembly
Hysteretic Error
Hysteretic error is usually determined by subtracting the value of the
dead band from the maximum measured separation between ups-
cale going and downscale going indications of the measured variable
I/P Plot
A graph that plots input current versus I/P output and provides per-
formance and calibration data for the I/P.
126
I/P Resistance
The input resistance value of the I/P necessary for current calcula-
tion when using the monitor function.
Leak Class
The classification of the valve performance based on the quantity of
fluid passing through an assembled valve when the valve is in the
closed position under stated closure forces, with pressure differential
and pressure as specified.
Linearity
An inherent flow characteristic which can be represented ideally by a
straight line on a rectangular plot of flow versus percent travel.
Main Menu
The menu of FlowAux programs used to run the FlowScanner Diag-
nostic tests.
MAINFS.EXE
The executable file of the FlowAux sliding-stem valve application.
MAINROT.EXE
The executable file of the FlowAux rotary valve application.
Measured Current
The output signal from the Flowscanner as measured by a measure-
ment loop and displayed on the test screen.
Monitor Mode
A function of the FlowScanner in which it records data while the
valve is controlled by the control room.
Net Actuator Pressure
In a piston actuator, the difference between the pressures in the up-
per and lower piston cylinders.
Net Pressure Plot
A graph that plots actuator net pressure versus travel and provides
analysis of travel, friction, spring rate, bench set and seat load.
Operating Defaults
The default settings for the FlowAux application
Password
A character string that identifies the access privileges of the user.
PKUNZIP.EXE
A decompression utility used to inflate files compressed using
PKZIP.EXE.
127
PKZIP.EXE
A data compression utility that allows large amounts of data to be
stored using minimal disk space.
Positioner Plot
A graph that plots I/P output (positioner input) versus travel and pro-
vides analysis of position calibration and performance.
Prepare for System Shut Down
A menu option from the Main Menu that takes the FlowScanner
through a programmed shut down process.
Quick Report
A report providing comparison of specified values from the nametag
and measured values from the test and analysis.
RAM Disk
A temporary storage device that uses a portion of random access
memory to store currently active data files.
Required Seat Load
The required contact force between the seat and the valve plug.
Resolution
The least interval between two adjacent discrete details which can
be distinguished one from the other.
Response Time
A test format used to measure the time required for a valve to re-
pond to a given signal change.
ROTAUX.BAT
The batch file used to start the FlowAux rotary valve application.
Seat Load
The contact force between the seat and the valve plug.
SLIDAUX.BAT
The batch file used to start the FlowAux sliding-stem valve applica-
tion.
Spring Rate
Force change per unit change in rate
Stroking Time
The rate of travel of the actuator
Static End Points
Total Valve Plot
128
Valve Friction
Valve Stroke
129
13 Index
1APP directory, 12, 82, 123

AC power, 8, 123
accessory kit, 8, 11, 31, 32, 33, 37, 86, 123
actuator, 7, 13, 14, 20, 23, 26, 29, 31, 33, 34, 35, 36, 37, 41, 43, 45, 58, 64, 65, 66, 68,
76, 97, 98, 101, 106, 123
approximate weight, 10
ASCII format, 74, 124
auto print graphs, 21, 125
auto save data, 21, 125
AUTOEXEC.BAT file, 16, 18, 125
automatic zero of travel, 47, 56, 125
AutoZero function, 48, 56, 126
auxiliary channels, 8
auxiliary input data channel, 11, 126

balanced construction, 25, 126
battery charging time, 8
BBS system, 74, 126
bearing friction, 7, 14, 126
bench set, 7, 26, 63, 64, 66, 88, 126

C25 DRC travel transducer, 11, 32, 33, 93, 126
130
calibrating current, 126
calibrating pressure, 93, 126
calibrating voltage, 93, 126
calibration, 7, 17, 47, 51, 52, 55, 56, 57, 63, 65, 76, 87, 89-96, 126, 128
Celesco transducer, 11, 29, 31, 34, 47, 48, 49, 50, 56, 87, 126
color monitor, 8
command mode, 41, 127
commanded current, 127
comments field, 24, 127
computer outputs, 8
CONFIG.SYS file, 16, 18, 86, 127
connector arm, 8, 9, 14, 26, 34, 35, 36, 41, 46, 49, 50, 51, 52, 59, 63, 65, 70, 72, 73, 91,
127
control mode, 4, 7, 14, 47, 49, 52
control signal, 127
control signal output, 8
control signal output accuracy, 9
critical valve parameters
bearing friction, 7
bench set, 7
packing, 7
seat load, 7
valve stroke, 7
crossover pressure, 68, 127

data acquisition, 11, 13, 83, 84, 85
DC power, 8, 10, 86, 127
dead band, 44, 63, 127, 128
diagnostic, 7, 97, 102, 121
131
displayed force units, 22, 127
displayed travel units, 22, 127
DOS, 8, 18, 27, 75, 82, 127
DRC transducer, 29, 32, 35, 127
Drive G, 16, 17, 27, 28, 127
dynamic error band, 14, 63, 127
dynamic scan test, 43, 51, 52, 65, 66, 67, 68, 73, 87, 128
E
elapsed time display, 69, 71, 72, 73, 128
F
Fisher Controls, 7, 83, 97, 98, 100, 101, 102
floppy disk, 13, 17, 27, 28, 79, 80, 81, 82, 86, 93, 128
floppy drive capacity, 8
FlowAux, 11, 16, 17, 46, 52, 53, 57, 58, 89, 128, 129
full calibration procedure, 128
H
Haliburton metal case, 9
hard disk, 11, 19, 75, 79, 81, 82, 85, 86, 90, 95, 121, 128
hard disk capacity, 8
hard drive. See hard disk
hardware, 8
hazardous area classification, 9
housing construction, 9
hysteresis, 44, 63, 72, 73, 128
132
hysteretic error, 51, 128
I
I/P, 7
I/P plot, 65, 128
I/P resistance, 26, 128
I/P transducer, 41, 48, 58, 66, 76, 129
Impedance, 48, 128
input channels, 8
INSTALL.EXE, 82, 128
internal battery, 8
K
keyboard, 8
L
LCD assembly, 86, 129
leak class, 25, 129
linear transducer, 29, 31, 129
linearity, 63, 88, 89, 129
M
main menu, 12-14, 17, 19, 20, 22, 27, 28, 46, 55, 58, 60, 74, 76, 79, 93, 95, 129
MAINFS.EXE, 17, 18, 82, 129
MAINROT.EXE, 18, 82, 129
measured column, 76, 129
measured current, 48, 49, 87, 129
133
measuring travel, 28-37
microprocessor, 7
monitor control signal, 8
monitor mode, 7, 14, 41, 43, 55, 129
N
nametag program, 13, 19, 21, 22-28
net actuator pressure, 66, 130
net pressure plot, 66, 130
O
operating defaults, 13, 17, 19, 20, 21, 23, 27, 79, 80, 81, 87, 130
options, 10
output pressure, 37, 45, 51, 52, 65, 70, 130
P
packing, 7
packing friction, 14, 130
Parker Prestolok fittings, 10, 37, 38, 40, 130
password, 90, 91, 130
permanent fittings, 10
PKUNZIP.EXE, 75, 130
PKZIP.EXE, 75, 130
pneumatic, 7, 8
pneumatic input channel accuracy, 9
pneumatic valve assembly, 7, 130
pointing device, 8
134
positioner, 7, 14, 19, 26, 31, 32, 33, 34, 35, 36, 37, 38, 39, 41, 45, 50, 58, 63, 64, 65, 66,
68, 70, 76, 88, 97-134
power supply, 8
pressure connections, 10
process variable, 45, 72, 73, 130
Q
quick report, 20, 51, 73, 76, 77, 79, 87, 131
R
RAM, 8
RAM disk, 16, 17, 18, 20, 21, 54, 75, 82, 86, 131
random access memory, 8
RatRace desktop analysis software, 20, 121, 131
removable fittings, 10
required seat load. See seat load
resolution, 9, 29, 30, 31, 32, 44, 45, 47, 48, 56, 67, 92, 131
response time, 71, 131
rotary valve, 8
ROTAUX.BAT, 12, 16, 18, 82, 131
RS232 serial port, 8
RUNTEST file, 19, 46, 79, 87, 131
S
seat condition, 67, 131
seat load, 7, 14, 25, 26, 43, 49, 63, 66, 67, 88, 131
seat load calculation, 67, 131
serial number, 21, 24, 26, 27, 28, 75, 79, 90, 102, 131
135
service conditions, 66, 99, 101, 131
setup, 7, 11, 13, 14, 17, 19, 28, 42, 46
slewing (dynamic) error, 63, 131
SLIDAUX.BAT, 12, 16, 17, 18, 82, 132
sliding stem valve, 8
software description, 11
specifications, 8-11
operating system, 8
spring rate, 14, 63, 66, 132
static end points, 51, 52, 76, 132
static point test, 44, 70, 132
step change test, 44, 69, 71, 132
step study test, 45, 59, 73, 132
stepped ramp test, 44, 72, 132
stroking speed. See response time
stroking time, 14, 53, 68, 69, 132
system hardware, 8

tag number, 19, 21, 24, 26, 27, 28, 75, 132
TEMPR directory, 82, 132
theory of operation, 13
tool kit, 11, 29, 132
total valve plot, 66, 132
TRAMR directory, 82, 133
TRAMS directory, 82, 133
transducer, 7, 11, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 47, 48, 50, 55, 56, 93, 94,
96, 102, 133
transducers, 28-37
136
travel, 8, 28, 29, 30, 31, 32, 33, 34, 36, 43, 44, 46, 47, 48, 50, 51, 52, 53
travel indicator scale, 66
travel input accuracy, 9
travel transducer, 11, 19, 20, 31, 33, 47, 48, 55, 56, 87, 91, 96, 126
tubing, 10
U
unbalanced construction, 25, 126
V
valve friction, 133
valve stroke, 7, 14, 63, 133
VGA, 8
video mode, 22, 133
volume booster, 7, 37, 97, 133
W
Windows for Workgroups, 8
Y
Yaxis scale, 68, 133
137

FlowScanner User Guide

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FlowScanner User Guide

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FlowScanner Valve Diagnostic

System User Guide

FlowScanner, FlowStor, RatRace, Fisher, Fisher-Rosemount, and

Fisher Controls International, Inc. 1/97;

4 FlowScanner Startup and Shutdown

5 Setting Up for a Test

8 Displaying and Analyzing Test Results

1.1 Scope of Manual

2 FlowScanner Valve Diagnostic System

2.1 Hardware Description

Operating System Software

Control Signal Output

Travel Input Accuracy

Pneumatic Input Channel Accuracy

Hazardous Area Classification

25-inch Celesco travel transducer (sliding stem valves)

C25 DRC travel transducer (rotary valves)

Travel transducer mounting brackets (4)

Adjustable jaw vice-grip (Bessi Clamp)

Std. 10-inch vice-grip (travel feedback arm)

SPI Fisso Support Arm

Double stick tape

1/8-inch pressure tubing

2.2 FlowAux Software Description

A main menu starts when either the SLIDAUX.BAT or ROTAUX.BAT

2.2.1 The Main Menu

FlowAux Main menu

The main menu screen selects the various FlowScanner programs:

FlowScanner Diagnostic System Test Connection Schematics

4.1 Background Information

4.2 Startup Procedures

4.3 Shutdown Procedures

4.4 Wonder Plus (1 Dir +)

5.1 Quick Reference

5.2 Setting Defaults

Operating Defaults Screen

The program drive is set automatically when the program is started.

5.3 Defining Nametags

Sliding Stem Valve Nametag Screen

Rotary Valve Nametag Screen

5.3.1 Filling in a New Nametag

F1 Help Screen for Body Style Field

Sliding Stem Body Type Pop-Up Menu

Sliding Stem Leak Class Help Screen

5.3.2 Saving and Printing Nametags

5.3.3 Retrieving a Nametag File

5.3.4 Using the Drive G for Nametag Storage

5.3.5 Exiting the Nametag Screen

5.4 Making Physical Connections

Complete Family of Transducers for the FlowScanner

Celesco Cable Transducers

The rotary transducer measures 360 of rotation and has 0.0075

5.4.1.3 Travel Feedback Connection

5.4.2 Measuring Pneumatic Pressure

The pneumatic pressure transducers are located in the Flowscanner

5.4.2.1 Installing Test Connectors

5.4.2.1.2 Permanent Installations

Permanent connections are used to provide a way to quickly connect

New valves purchased from Fisher can have permanent connections

5.4.3.1 Command Mode

5.4.3.2 Monitor Mode

5.5 Setting Up Test Parameters