Emerson DXP-FF Instruction manual

™

Valvetop D-Series with FF Option

FOUNDATION Fieldbus

Installation, Operation & Maintenance Manual

Table of Contents

2Introduction

2Quick Installation Guide

4Installation

4Storage

5Pneumatic Connection

6Electrical Connection

8FF Operation

10 Troubleshooting and Maintenance

16 Appendix A: FF Technology

18 Appendix B: Resource Block

20 Resource Block DD Menu Structure

21 Appendix C: Transducer Block

26 Transducer Block DD Menu Structure

27 Appendix D: Discrete Output (DO) Block

29 Appendix E: Discrete Input (DI) Block

31 Appendix F: Dimension & Assembly Drawings

35 Appendix G: Specifications & Reference Data

™

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

Mounting - Figure 1

FLASH RESET

AUX

OPEN

- V2 + - V1 +

Wrt Prt

FF Sim

SCM-FF

Calibration Switch

Auxilliary Input

Termi nals

(Dry contacts only)

Foundation

Fieldbus Loop

Termi nals

Piezo Pilot

Terminals

Single Pilot

Dual Pilot

Std Operation

Jumper Location

+ = Orange

- = Black

NOTE: TopWorx has pre-configured

modules and faceplates available for

DeltaV control systems. Contact

TopWorx factory for more

information.

Wiring - Figure 2

www.topworx.com

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.

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 any-

hardware 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.

www.topworx.com

Pneumatic Hookup Procedures

Prior to connecting the supply air to the spool valve, flush the system to remove any debris or contaminates. Galva-

nized 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:

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

Supply

Port to OpenPort to Close

Always install vents

or speed controls Supply

DOUBLE ACTING ACTUATORS SPRING RETURN ACTUATORS

Port to Open

Plug

/Close

Supply

Always install vents

or speed controls

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 pre-

vent 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 instal-

lation, 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

Medium Dried, filtered air (40 micron)

Max Operating

Pressure 100psi (0.69 MPa) (6.89Bar)

Min. Operating

Pressure 30psi (0.21 MPa) (2.07Bar)

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

Valve Seals

Spool Seals: Buna-N

Valve Body Seals available in

Buna-N, Silicone, EPDM & Viton.

Max Consumption Rate 600 cc/min @ 80psi

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.

FLASH RESET

AUX

OPEN

- V2 + - V1 +

Wrt Prt

FF Si m

SCM-FF

Calibration Switch

Auxilliary Input

Terminals

(Dry contacts only)

Foundation

Fieldbus Loop

Terminals

Piezo Pilot

Terminals

Single Pilot

Dual Pilot

Std Operation

Jumper Location

+ = Orange

- = Black

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.

Illustration #4: Mounting Assembly

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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”).

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:

Figure 4

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:

DO Channel

Assignment

Definition Readback_D

Valves

Control Method

5 Open/Close/Stop

Outputs

0 - Closed

1 - Open

2 - Stopped

3 - Opening

4 - Closing

Single Block,

Dual Action

Readback_D

Parameter

Discrete

Control

Function

Block

Discrete

Output (DO)

Function

Block

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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

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.

Multiple active alarms are depicted by a HEX value representing the sum of all active alarms OUT_D Val-

ues. 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 OUT_D Values

9 Aux Input 0 - Aux Dry Contact Closed

1 - Aux Dry Contact Open

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

LED's not enabled

Make sure at least 9 VDC connected to FF terminals

Transducer block parameter "LED_ENABLE" set to ENABLE

Calibration switch will not operate Transducer Block in incorrect mode

Power not connected to FF terminals

Piezo and spool valve is not pressurized

Set transducer block actual model to "Out of Service"

Make sure at least 9VDC connected to FF terminals

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

Excessive noise on the segment

Check voltage to ensure that it is consistently above 9V

Check for loose wire connections

Verify that the segment has a terminating resistor at each

end

Using a Fieldbus Monitor, verify that peak and average

noise levels are <11db

Valve will not shift See mechanical troubleshooting flowchart on page 12

No response from operator interface DO Block and/or DO Channel not correctly assigned

Transducer Block Out of Service

Configuration/DO Block NOT downloaded

Follow troubleshooting chart, (pg. 11) then continue with

mechanical troubleshooting chart (pg. 12). If problem

persists contact the factory

Bad Status on FeedBack Signal and/or No

Feedback signal

Transducer Block mode is Out of Service Place Transducer Block in Auto Mode

This manual suits for next models

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