Valvetop D-Series with FF Option
™
FOUNDATION Fieldbus
™
Installation, Operation & Maintenance Manual
Table of Contents
2 Introduction
2 Quick Installation Guide
4 Installation
4 Storage
5 Pneumatic Connection
6 Electrical Connection
8 FF 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) F
OUNDATION 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
FF
CLOSE
Auxilliary Input
Ter mi na ls
(Dry contacts only)
AUX
OPEN
SCM-FF
Foundation
Fieldbus Loop
Ter mi na ls
FF
FLASH RESET
- V2 +
Wiring - Figure 2
2
Std Operation
Jumper Location
Si m
Wrt Prt
- V1 +
Piezo Pilot
Ter mi na ls
Single Pilot
Dual Pilot
+ = Orange
- = Black
Mounting - Figure 1
NOTE: TopWorx has pre-configured
modules and faceplates available for
DeltaV control systems. Contact
TopWorx factory for more
information.
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TM
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.
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.
Illustration #1:
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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 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.
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TM
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 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.
***Never Plug, Block or Restrict Port 5***
Always install vents
1
3
2
Port to OpenPort to Close
or speed controls
5
4
Plug
Supply
5
4
DOUBLE ACTING ACTUATORS SPRING RETURN ACTUATORS
Supply
Supply
1
2
Port to Open
Always i nstall v ents
or speed controls
3
/Close
Spool Valve Specifications
Medium Dried, filtered air (40 micron)
Max Operating
Pressure
Min. Operating
Pressure
Max Consumption Rate 600 cc/min @ 80psi
Ambient
Temperature Range
Flow Coefficient 1.2Cv or 3.0Cv
Environment Rating Type 4, 4X, IP67
Port Size
Manual Override
Valve Body
Valve Seals
100psi (0.69 MPa) (6.89Bar)
30psi (0.21 MPa) (2.07Bar)
Refer to Product Nameplate Marking
1/2” NPT for 3.0Cv valve
1/4" NPT for 1.2Cv valve
Available in Latching/Non-Latching
Push Type & Palm Actuator Type
Available in Hardcoat Anodized
Aluminum, 304, or 316 Stainless Steel
Spool Seals: Buna-N
Valve Body Seals available in
Buna-N, Silicone, EPDM & Viton.
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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 F
Pilot Valve Wiring
Single Pilot Valve
Dual Pilot Valve
FOUNDATION Fieldbus Wiring
The Fieldbus Segment Wiring is connected to the FF Terminals on the SCM. These terminals are NOT polarity
sensitive.
Auxiliary Dry Contact
Attach dry contact wiring to the AUX terminals.
OUNDATION Fieldbus communications and pilot valve output drivers.
· The Orange (or Red) lead is terminated on V1+. (+ = Orange)
· The Black lead is terminated on V1-. (- = Black)
· The open valve wiring to the V1 terminal (+ = Orange)
· The close valve wiring to the V2 terminal (- = Black)
It is strongly recommended that FF wiring leads are not daisy-chained together and each drop provides
short-circuit protection.
Auxilliary Input
Ter mi nal s
(Dry contacts only)
Foundation
Fieldbus Loop
Ter mi nal s
AUX
SCM-FF
FF
Calibration Switch
CLOSE
OPEN
FLASH RESET
FF
- V2 +
Std Operation
Jumper Location
Si m
Wrt Prt
- V1 +
Piezo Pilot
Ter min al s
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.
6
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Calibration of Target / Feedback
Calibration of the F
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 e ncapsulated 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 “Transd ucer
Block Initialization, Single-Dual Action”).
OUNDATION Fieldbus SCM-FF
TM
7
D-Series with FF Option Installation, Operation & Maintenance
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:
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:
TopWorx has pre-configured modules and faceplates available for DeltaV contr ol systems.
DO
DO Channel
Assignment
5 Open/Close/Stop
Contact the TopWorx factory or www.topworx.com for more information.
Definition Readback_D
Valves
0 - Closed
Outputs
1 - Open
2 - Stopped
3 - Opening
4 - Closing
Control Method
Single Block,
Dual Action
502.969.8000
Readback_D
Parameter
8
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 setting s.
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.
DI Channel
Assignment
13 Device Alarms 0x00 - No Alarm
Definition OUT_D Values
Auxiliary Input Configuration (Optional)
The AUX Input terminal may be monitored using a Discrete Input (DI) Block with the Channel Parameter
assignment of 9.
TM
0x01 - Cycle Count
0x02 - Time to Open
0x04 - Time to Close
0x08 - Time Board Temp Hi
0x10 - Board Temp Lo
DI Channel
Definition OUT_D Values
Assignment
9 Aux Input 0 - Aux Dry Contact Closed
1 - Aux Dry Contact Open
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D-Series with FF Option Installation, Operation & Maintenance
Section 3: Maintenance
This Section provides information on Troubleshooting and Component Replacement for the DXP-FF.
Troubleshooting
Description of Problem Possible Cause Possible Solution
502.969.8000
Red or green LED does not illuminate when
the valve is either in closed or open position
LED's do not operate, regardless of valve
position
Calibration switch will not operate Transducer Block in incorrect mode
LEDs flash from red to green after valve has
shifted
LEDs flash from red to green as soon as unit
starts moving during a setpoint change
Module goes "unattached" from the segment Power dropped below 9V
Target not calibrated properly Use calibration procedure on page 7
Power not connected to FF terminals
LED's not enabled
Power not connected to FF terminals
Piezo and spool valve is not pressurized
Time to open/close alarm has triggered Target not calibrated properly. Recalibrate using the
Operational setpoints do not match limit switch positions
(i.e. the closed switch is made when the unit has an open
setpoint)
Excessive noise on the segment
Make sure at least 9 VDC connected to FF terminals
Transducer block parameter "LED_ENABLE" set to ENABLE
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
procedure on page 7
Set Transducer Block Action_Element setting according to
chart
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
Bad Status on FeedBack Signal and/or No
Feedback signal
Transducer Block Out of Service
Configuration/DO Block NOT downloaded
Transducer Block mode is Out of Service Place Transducer Block in Auto Mode
Follow troubleshooting chart, (pg. 11) then continue with
mechanical troubleshooting chart (pg. 12). If problem
persists contact the factory
10
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TM
DO
DO
DO
DO
DO
DO
DO
11
D-Series with FF Option Installation, Operation & Maintenance
502.969.8000
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