Valvetop™ D-Series with FF Option FOUNDATION ™Fieldbus Installation, Operation & Maintenance Manual

Table of Contents 2 2 4 4 5 6 8 10 16 18 20 21 26 27 29 31 35

Introduction Quick Installation Guide Installation Storage Pneumatic Connection Electrical Connection FF Operation Troubleshooting and Maintenance Appendix A: FF Technology Appendix B: Resource Block Resource Block DD Menu Structure Appendix C: Transducer Block Transducer Block DD Menu Structure Appendix D: Discrete Output (DO) Block Appendix E: Discrete Input (DI) Block Appendix F: Dimension & Assembly Drawings Appendix G: Specifications & Reference Data

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D-Series with FF Option

Installation, Operation & Maintenance

502.969.8000

Introduction This manual is intended to provide instruction for Installing, Operating and Maintaining the TopWorx Model DXP/DXS-FF Discrete Valve Controller with FOUNDATION™ Fieldbus.

Warnings and Precautions that require special instructions or considerations are noted by this symbol.

DXP Quick Start Installation Guide Step 1 - Mount DXP/DXS-FF (Fig. 1) a) Connect bolts firmly between switchbox and bracket b) Connect bolts loosely between actuator and bracket c) Cycle actuator to limits in both directions 3 times to center shaft d) Tighten the bolts between the actuator and bracket Step 2 - Secure pneumatic connections a) Refer to Figure 2 for details b) Use of Locktite 567 is recommended Step 3 - Make electrical connections a) Attach fieldbus wiring to FF terminals (Fig. 2) b) FOUNDATION Fieldbus wiring is polarity insensitive Step 4 - Calibrate switches a) Move the valve to the CLOSE position, push and rotate lower cam to activate the Red LED b) Move the valve to the OPEN position, push and rotate upper cam to activate the Green LED c) Verify calibration by actuating valve open and closed several times NOTE: Switches can be set using calibration switch without FF connection by using any 9-32VDC power source.

Step 5 - Commission DXP-FF a) Connect single DO to Channel 5 • No DI needed - Readback_D provides the actual valve position b) Set the Mode to AUTO (Automatic) in the Transducer Block Calibration Switch

Sim

OPEN CLOSE FF

Auxilliary Input Terminals (Dry contacts only)

Mounting - Figure 1

Std Operation Jumper Location

WrtPrt

AUX

SCM-FF Foundation Fieldbus Loop Terminals

2

FF

- V2 +

FLASH RESET

Wiring - Figure 2

- V1 +

Piezo Pilot Terminals Single Pilot Dual Pilot + = Orange - = Black

NOTE: TopWorx has pre-configured modules and faceplates available for DeltaV control systems. Contact TopWorx factory for more information.

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Installation on Actuator Orientations, Normal and Reverse Acting Normal acting is full CW when the process valve is closed and CCW when the process valve is open. Reverse acting is full CW when the process valve is open and CCW when the process valve is closed. 90° indicator dome assemblies are design to accommodate any mounting arrangement and can be adjusted up to 9° off axis if needed. 45° indicator dome assemblies can only accommodate normal acting applications that are mounted parallel ±9°. Consult your local distributor or factory representative for 45° reverse acting or mounted perpendicular applications.

Illustration #1: The image to the left shows a Valvetop unit mounted parallel to the process valve in the closed position. The green arrow at the top shows the “normal acting” direction of travel to open the valve. This is the standard orientation and your unit unless otherwise specified will be factory set to operate in this fashion.

Illustration #2: The image to the right shows a Valvetop mounted perpendicular to the process valve in the closed position. The green arrow at the top shows the “normal acting” direction of travel to open the valve. Notice that the indicator dome has been rotated 90° compared to the unit above.

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D-Series with FF Option

Installation, Operation & Maintenance

502.969.8000

Installation on Actuator (continued) Mounting TopWorx has numerous mounting bracket kits available to meet your specific application, whether rotary or linear. Consult your local distributor or factory representative for ordering information. The illustration shows a direct Namur mount on a quarter turn valve. Refer to your mounting kit documentation for specific mounting instructions.

Storage Until conduit, conduit plugs, and any applicable spool valve port connections are properly installed, the ValveTop unit will not support its IP/NEMA rating as the unit ships with temporary covers. Ensure that it is stored in a dry environment with a relative humidity range between 10%-95% and a temperature ranging from -40ºF (-40ºC) to 160ºF (71ºC). Once properly installed, the temperature range listed on the nameplate will supersede this storage temperature range.

Illustration #3: Mounting Assembly Installation Notes 1. Use caution not to allow undue axial (thrust) load on the shaft. 2. Cycle the valve a couple of times prior to final tightening of the mounting kit hardware. This allows the shaft to self-center in the pinion slot, or coupler. Refer to the dimensions and materials section of this document for appropriate tightening torque. 3. Always use sound mechanical practices when torquing down anyhardware or making pneumatic connections. Refer to the Integrated Pneumatic Control Valves section for detailed information on pneumatic connections. 4. This product comes shipped with conduit covers in the conduit entries in an effort to protect the internal components from debris during shipment and handling. It is the responsibility of the receiving and/or installing personnel to provide appropriate permanent sealing devices to prevent the intrusion of debris, or moisture, when stored outdoors or when installed. It is the responsibility of the installer, or end user, to install this product in accordance with the National Electrical Code (NFPA 70) or any other national or regional code defining proper practices.

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Pneumatic Hookup Procedures Prior to connecting the supply air to the spool valve, flush the system to remove any debris or contaminates. Galvanized pipe can easily flake and contaminate the system and therefore is not recommended. A 40 micron point of use filter at every device is recommended.

4-Way Spool Valves The TopWorx spool valve is a 5 port, 4-way valve driven by an internally mounted pilot. The spool valve supply port and work ports are marked as follows:

Highly Recommended TopWorx highly recommends Locktite 567 brand thread sealant. Do not use a hard setting pipe compound. If Teflon thread seal tape is used, start the wrap on the second thread from the leading thread of the fitting. This will prevent tape shreds from contaminating the spool valve seals. Breathers (AL-M31) should be installed in the exhaust ports to keep debris from falling into the spool valve and damaging the seals. This must be addressed prior to installation, or storage. A flow control may be used in Port 3, but should NEVER BE USED in Port 5. Any blockage or restriction may cause an internal pressure build-up inside the enclosure and pose a safety issue.

Spool Valve Specifications

***Never Plug, Block or Restrict Port 5***

Always install vents or speed controls

Supply

5

3

1 4

2

Always install vents or speed controls

Supply

5

Dried, filtered air (40 micron)

Max Operating Pressure

100psi (0.69 MPa) (6.89Bar)

Min. Operating Pressure

30psi (0.21 MPa) (2.07Bar)

Max Consumption Rate

600 cc/min @ 80psi

Ambient Temperature Range

Refer to Product Nameplate Marking

Flow Coefficient

1.2Cv or 3.0Cv

Environment Rating

Type 4, 4X, IP67

Port Size

1/2” NPT for 3.0Cv valve 1/4" NPT for 1.2Cv valve

Manual Override

Available in Latching/Non-Latching Push Type & Palm Actuator Type

Valve Body

Available in Hardcoat Anodized Aluminum, 304, or 316 Stainless Steel

3

1 4

Medium

2

Valve Seals Port to Close

Port to Open

DOUBLE ACTING ACTUATORS

Plug

Port to Open /Close

Spool Seals: Buna-N Valve Body Seals available in Buna-N, Silicone, EPDM & Viton.

SPRING RETURN ACTUATORS

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D-Series with FF Option

Installation, Operation & Maintenance

502.969.8000

Electrical / FF Connections The FOUNDATION Fieldbus Sensor Communications Module (SCM-FF) combines integral switch relays for position sensing with FOUNDATION Fieldbus communications and pilot valve output drivers.

Pilot Valve Wiring Single Pilot Valve · ·

The Orange (or Red) lead is terminated on V1+. (+ = Orange) The Black lead is terminated on V1-. (- = Black)

Dual Pilot Valve · ·

The open valve wiring to the V1 terminal (+ = Orange) The close valve wiring to the V2 terminal (- = Black)

FOUNDATION Fieldbus Wiring The Fieldbus Segment Wiring is connected to the FF Terminals on the SCM. These terminals are NOT polarity sensitive. It is strongly recommended that FF wiring leads are not daisy-chained together and each drop provides short-circuit protection.

Auxiliary Dry Contact Attach dry contact wiring to the AUX terminals.

Calibration Switch

Std Operation Jumper Location Sim

OPEN CLOSE FF

Auxilliary Input Terminals (Dry contacts only)

WrtPrt

AUX

SCM-FF Foundation Fieldbus Loop Terminals

FF

- V2 +

FLASH RESET

- V1 +

Piezo Pilot Terminals Single Pilot Dual Pilot + = Orange - = Black

Illustration #4: Mounting Assembly

Flash Reset Button When there is an active device alarm, the LEDs will blink. The Flash Reset Button will stop the flashing indications. For testing of the pneumatics and calibration of the target assembly, a 9 to 32 VDC power supply can be used with the calibration switch to open and close the valve without a fieldbus loop attached.

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Calibration of Target / Feedback Calibration of the FOUNDATION Fieldbus SCM-FF Never perform calibration procedure unless area is known to be safe. · ·

For Intrinsically Safe models, unit must be wired in accordance with Control Drawing S-K088A, or I.S. components may be damaged. For standard explosion-proof models: The OPEN and CLOSED limit switches encapsulated within the SCM-FF may be calibrated using a DC power supply set between 9-32V, or calibrated once connected to the Fieldbus network.

Step 1 Connect the power supply, or Fieldbus wires, to the FF terminals. The terminals are not polarity sensitive. With power applied to the FF terminals, the valve may be manually stroked using the Calibration Switch on the SCM-FF.

Step 2 Place calibration switch to the CLOSE position. Valve should move to CLOSE position. If it does not, consult troubleshooting section of page 11.

Step 3 Disengage the bottom Cam from the splined hub and rotate the bottom Cam clockwise until the Red LED lights. Release the Cam to re-engage the splined hub.

Step 4 Slide the calibration switch to the OPEN position. Valve should move to OPEN position. If it does not, consult troubleshooting section on page 11.

Step 5 Disengage the top Cam from the splined hub and rotate the top Cam counter-clockwise until the Green LED lights. Release the Cam to re-engage the splined hub.

Step 6 Cycle the valve CLOSED and OPEN a few times using the calibration switch to verify both limit switches are maintaining their set points.

Step 7 Place calibration switch in the FF position. If using a power supply to calibrate, disconnect leads to the supply, and connect the Fieldbus loop when ready to put into service.

Step 8 Manipulate the transducer parameters via the control system as necessary for desired mode of operation. NOTE: If using a reverse acting actuator, re-calibrate switches using Steps 3-6, but rotate counter-clockwise for close and clockwise for open. Reverse Action must be set in the Transducer Block (see “Transducer Block Initialization, Single-Dual Action”).

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D-Series with FF Option

Installation, Operation & Maintenance

502.969.8000

Section 2: Operation This section of the manual provides operational information for configuring the SCM-FF device on the FOUNDATION Fieldbus Host Control System. This section includes both required Control Configuration and optional Monitoring Configuration information.

Control Configuration (Required) The TopWorx FOUNDATION Fieldbus products should be configured for operation using a single Discrete Output (DO) Function Block with Channel Parameter assignment of 5. This module configuration will provide a multi-value DO Block that will fully control a single or a dual output device. The Readback_D parameter will provide actual valve position based on the Open / Closed Limit Switches in the device. Discrete Input (DI) Blocks are neither required nor desired for feedback function. The values of these parameters are as follows:

DO DO Channel

Assignment 5

Figure 4

Definition

Readback_D Valves

Open/Close/Stop 0 - Closed Outputs 1 - Open 2 - Stopped 3 - Opening 4 - Closing

Control Method Single Block, Dual Action

NOTE: TopWorx has pre-configured modules and faceplates available for DeltaV control systems. Contact the TopWorx factory or www.topworx.com for more information.

The Transducer Block is shipped from the factory in the OOS (Out of Service) Mode to allow field installation/testing using the SCM calibration switch. Once the installation and the configuration above are complete, The Transducer Block must be placed in the AUTO (Automatic) Mode for device operation. The complete device control algorithm should be as depicted below:

Readback_D Parameter

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Discrete Control Function Block

Discrete Output (DO) Function Block

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Alarm Configuration (Optional) Discrete Input (DI) Block may be configured for monitoring internal Device Alarms within the Control Strategy of the Host System. The Internal Device Alarms can be monitored using a Discrete Input (DI) Block with the Channel Parameter assignment of 13. All alarms that are activated (checked in the Transducer Block) can be read by this single DI block in a masked fashion. See Appendix C for Transducer Block parameter settings.

DI Channel Assignment

Definition

OUT_D Values

13

Device Alarms

0x00 - No Alarm 0x01 - Cycle Count 0x02 - Time to Open 0x04 - Time to Close 0x08 - Time Board Temp Hi 0x10 - Board Temp Lo

Multiple active alarms are depicted by a HEX value representing the sum of all active alarms OUT_D Values. For example, a device with a Cycle Count Alarm and a Time to Close Alarm both active would have an OUT_D Value of 0x05.

Auxiliary Input Configuration (Optional) The AUX Input terminal may be monitored using a Discrete Input (DI) Block with the Channel Parameter assignment of 9.

DI Channel Assignment

Definition

9

Aux Input

OUT_D Values 0 - Aux Dry Contact Closed 1 - Aux Dry Contact Open

9

D-Series with FF Option

Installation, Operation & Maintenance

502.969.8000

Section 3: Maintenance This Section provides information on Troubleshooting and Component Replacement for the DXP-FF.

Troubleshooting Description of Problem

Possible Cause

Possible Solution

Red or green LED does not illuminate when the valve is either in closed or open position

Target not calibrated properly

Use calibration procedure on page 7

LED's do not operate, regardless of valve position

Power not connected to FF terminals

Make sure at least 9 VDC connected to FF terminals

LED's not enabled

Transducer block parameter "LED_ENABLE" set to ENABLE

Transducer Block in incorrect mode

Set transducer block actual model to "Out of Service"

Power not connected to FF terminals

Make sure at least 9VDC connected to FF terminals

Piezo and spool valve is not pressurized

Verify proper air pressure. Reference mechanical troubleshooting chart

LEDs flash from red to green after valve has shifted

Time to open/close alarm has triggered

Target not calibrated properly. Recalibrate using the procedure on page 7

LEDs flash from red to green as soon as unit starts moving during a setpoint change

Operational setpoints do not match limit switch positions (i.e. the closed switch is made when the unit has an open setpoint)

Set Transducer Block Action_Element setting according to chart

Module goes "unattached" from the segment

Power dropped below 9V

Check voltage to ensure that it is consistently above 9V Check for loose wire connections

Calibration switch will not operate

Verify that the segment has a terminating resistor at each end Excessive noise on the segment

Valve will not shift

Using a Fieldbus Monitor, verify that peak and average noise levels are