Emerson TopWorx Maintenance Manual

TopWorx™ D-ESD: Partial Stroke & Emergency Shutdown

Installation, Operation & Maintenance Manual

Credible Solutions

Table of Contents

Page 4	ESD Theory of Operation
Page 5	Installation on Actuator
Page 6	Pneumatic Hookup Procedures
Page 8	ESD Conventional Instruction & Operation-Fail Closed Valves Partial
Page 10	Stroke Tolerance Range Selection/Partial Stroke Test ESD
Page 11	Calibration-Fail Closed Valves
Page 12	ESD Conventional Instruction & Operation-Fail Open Valves Partial
Page 13	Stroke Tolerance Range Selection/Partial Stroke Test ESD
Page 15	Calibration/PST Flow Chart-Fail Open Close
Page 18	Dimensions and Materials: TopWorx™ DXP
Page 19	Dimensions and Materials: TopWorx™ DXP - Flameproof Ex d IIC
Page 20	Dimensions and Materials: TopWorx™ DXS
Page 21	Interior & Indicator Assembly
Page 22	Certifications & Approvals
Page 25	Safe Use

ESD Theory of Operation:

The purpose of the TopWorx™ Emergency Shut-Down (ESD) model is to partially stroke a valve that maintains a full open or full closed position for an extended period of time while offering an ESD function. A partial stroke test (PST) verifies functionality of critical valves that must be in their fail position during an emergency. Increasing the frequency of partial stroke testing (i.e. reducing the proof test interval) improves the SIL (Safety Integrity Level) that the system can achieve through a reduction in the PFD avg (Average Probability of Failure On Demand). These partial stroke tests can be performed without shutting down or disrupting the process. In an emergency, the ESD function overrides partial stroke testing and the valve moves to its fail position.

This ESD unit incorporates a sensor communication module (SCM-ESD) to perform the partial stroke test, verify its status, and output that status back to the user. In combination with the SCM, the ESD unit uses either the optional TopWorx™ pilot and spool valve or a

customersupplied solenoid valve to drive the actuator during both normal operation and partial stroke testing. A TopWorx™ GO™ Switch is included for partial stroke confirmation and two (2) limit switches built into the SCM confirm open and close position.

Once the unit is installed, the SCM-ESD must be calibrated for that specific valve, actuator, and solenoid exhaust settings. During calibration, the unit records the time to partially stroke the valve. All future PST times are compared to this original value for determining the test status. To pass a PST, the time must be within +/-20%, 30%, or 40% of the stored calibration value. This PST time tolerance can be changed prior to calibration.

The partial stroke test is initiated via an optional partial stroke test button with a lockable cover, the calibration button on the top of the SCM, or a simulated closed dry contact from the PLC or DCS. Upon issuing a PST command, the SMC-ESD begins a timer while switching a relay to de-energize the pilot/ solenoid. The valve moves from its normal position toward its fail position until the GO™ Switch is made. Once made, the SCM energizes the pilot/solenoid and the valve moves to its normal position while outputting the PST status.

Option ES: SCM

PST

SWITCH

POSITION 1 INDICATION (OPEN)

POSITION 2 INDICATION (CLOSED)

CAL/ALARM
TopWorxTM ESD
POSITION 2	POSITION 1
LED (RED)	LED (GREEN)
ALARM	COM	PSI
CAL SW

PST / CAL

ACTIVATION

PARTIAL STROKE MODULE POWER

PILOT VALVE

CONTROL

PILOT VALVE

CONTROL

DIAGNOSTIC

	PARTIAL
COM	STROKE TEST

Figure 1: Input/Output Diagram

Electrical Ratings

	Current/Voltage

Open/Closed Indication	0.25A@24VDC w/5V drop
	0.25A@120VAC w/5V drop
Dry Contact Rating	Minimum Current Through Switch
	Contacts: 5 mA
Module Voltage	18-28VDC

Module Current	50mA (MAX)

Pilot Current (Standard)	20mA

PST Feedback Relays	800mA@24VDC MAX
	250mA@125VAC MAX
Solenoid Pilot/SOV	800mA@24VDC MAX
Maximum PowerRating	250mA@125VAC MAX

Installation on Actuator

Orientations, Normal and Reverse Acting

Normal acting is full clockwise when the process valve is closed and counterclockwise when the process valve is open. Reverse acting is full clockwise when the process valve is open and counterclockwise when the process valve is closed.

90° indicator dome assemblies are designed 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 TopWorx™ 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 unless otherwise specified, your unit will be factory set to operate in this fashion.

The image to the right shows a TopWorx™ 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.

Mounting

TopWorx™ has numerous mounting bracket kits, both rotary and linear, available to meet your specific application. Consult your local distributor or factory representative for ordering information. The illustration below shows a direct NAMUR mount on a quarter turn valve.

Refer to your mounting kit documentation for specific mounting instructions.

Storage

Until conduit, conduit covers, and any applicable spool valve port connections are properly installed, the TopWorx™ 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 -40°F (-40°C) to 160°F (71°C). Once properly installed, the temperature range listed on the nameplate will supersede this storage temperature range.

Mounting Assembly

Installation Notes

Use caution not to allow undue axial (thrust) load on the shaft.

1.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. Please refer to the Proof Testing section for proper safety function setup.

2.Always use sound mechanical practices when applying torque to any hardware or making pneumatic connections. Refer to the Integrated Pneumatic Control Valves section for detailed information.

3.This product comes shipped with conduit covers 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 or installed outdoors.

4.It is the responsibility of the installer, or end user, to install this product in accordance with the NationalElectricalCode(NFPA70)oranyothernationalorregionalcodedefiningproper practices.

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:

PORT TO OPEN

PORT TO CLOSE

PORT TO OPEN/CLOSE

PLUG

SUPPLY	SUPPLY
ALWAYS INSTALL VENTS	ALWAYS INSTALL VENTS
DOUBLE ACTING ACTUATORS	SPRING RETURN ACTUATORS

PORT TO	PORT TO
ACTUATOR OPEN	ACTUATOR CLOSE

EXHAUST OF PORT 4	EXHAUST OF PORT 2
(WHEN ACTUATOR CLOSES)	(WHEN ACTUATOR OPENS)
	SUPPLY

FAIL CLOSED

Spool Valve Assembly

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.

	VALVE SPECIFICATION
ITEM	PERFORMANCE
Media	Air
Media temperature	Min: -40°C (-40°F); Max: 60°C (140°F)
Operational ambient	Min: -40°C (-40°F); Max: 60°C (140°F)
temperature
Inlet/system pressure	Min: 45 PSI (3.1 bar); Max: 150 PSI (10.3 bar)
Operational pressure	Min: 45 PSI (3.1 bar); Max: 150 PSI (10.3 bar)
differential
Safe working pressure	150 PSI (10.3 bar)
Flow / Cv (Kv)	Cv = 0.86 (Kv = 0.74)
Body port connections	1/4” NPT
Allowable leakage	External: 2 sccm
	Internal: 10 cc/min max for -15°C to 60°C.
	3300 cc/min max for -40°C to -15°C
Optimal design life	500,000 cycles
Material in contact with	Body: Aluminium (black anodized) and
fluid	Stainless Steel 316L
	Internal: Stainless Steel, LT, nitrile, PTFE, Acetal

*Refer to the wiring diagram on the inside lid of your product to determine actual pin out location

FLAME ARRESTORS & ORINGS (X5)

O-RINGS (X2)

M5 X 30MM

SCHS (X3)(4MM

HEX WRENCH)

ADAPTER PLATE

M5 X 12MM SCHS (X4) (4MMHEX WRENCH)

ASCO™ VALVE WITHOUT

MANUAL OVERIDE

Spool Valves and Pilots

SINGLE PILOT ASSEMBLY

M3 X 18 CHEESE HEAD SCREW

TORQUE TO 20 IN-OZ

4-40 X .25” SEM SCREW TORQUE TO 100 IN-OZ

BRACKET

PILOT

ASCO™ 302

MINI PIEZO

AMISCO 110 VAC

AMISCO 220 VAC

SEAL AND PLATE

(NOT USED WITH MINI PIEZO)

MANIFOLD

10-32 METAL BARB FITTING TORQUE TO 60 IN-OZ

10-32 METAL PLUG

RED URRETHANE

TUBING (SUPPLY)

10-32 METAL BARB FITTING TORQUE TO 60 IN-OZ

YELLOW URETHANE	ORIFICE TO BE USED IN
TUBING (WORK)	EXPLOSION PROOF APPLICATIONS

ESD CONVENTIONAL INSTRUCTION AND OPERATION—Fail Closed Valves

Operation: Before operation, the ESD must be calibrated (see Calibration below). After calibration, a Partial Stroke Test (PST) may be performed (see Partial Stroke Test below). The partial stroke time tolerance range can be selected as 20%, 30% or 40% (see Partial Stroke Time Tolerance Range Selection below). A single switch (on board and external) is used to perform the calibration, the partial stroke test and the tolerance range selection. These operations can be initiated from the control room with no need to shut down the entire plant. Nonvolatile memory stores the calibration value and the selected tolerance range value allowing for retention, even in the event of loss of power. The LED, both onboard and in the control room, flashes unique visual indicators to signal pass/fail of tests and possible maintenance issues (please see

ESD Conventional Flow Chart and Message Table for ESD Conventional for more details).

*Note that the following instructions assume the valve is FAIL CLOSED and the direction of travel from CLOSED to OPEN is CCW.

Fail Closed

BLUE

GO™ Switch connection (Prewired)

Black

Valve Pos 1 (Open) switch NO contact. During bench testing only, add a 2500 Ohm, 1/2 W resistor for path back to DC supply via terminal 6.

Valve Pos 1 NC Contact

Valve Position 1 (Open). COM. Tie it to Valve Position 1 COM 24VDC+

Valve Pos 2 (Closed) switch NO contact. During bench testing only, add a 2500 Ohm, 1/2 W resistor for path back to DC supply via terminal 6.

Valve Pos 2 NC Contact

Valve Position 2(Closed) switch COM contact, wire it back to Terminal 5 24VDC+

Calibration Switch

Figure 2: Suggested Test Bench Setup for Fail Closed Applications

CALIBRATION

LED (AMBER)

TopWorx™ ESD

POSITION 2	POSITION 1
LED (RED)	LED (GREEN)
ALARM COM	PSI
CAL SW

External PST button (Prewired)

Power for electronics module 24VDC-

Power for electronics module 24VDC+

Solenoid Pilot or SOV Output (-)

BLACK (-)

To Solenoid Pilot or SOV

RED (+)

Solenoid Pilot or SOV Output (+) 800mA@24VDC MAX 250mA@125VAC MAX

Optional external diagnostic signal. If wired, will pass pulses out the same as the LED flashes for the calibration diagnostic (pg. #16)

Optional external signal COMMON.

Tie it to the Valve Pos 1 and 2 COM

Optional external alarm signal.

If wired, will close if PST calibration if passes.

Wiring Connections:

1.Terminals 1 and 4: External power source for switching the solenoid valve. Type and voltage level must match type of solenoid selected. Typical is 24VDC.

2.Terminals 2 and 3: Output to solenoid pilot or SOV.

3.Terminals 5 and 6: Power for electronics module. 5 MUST be +24VDC and 6 MUST be –24VDC.You can jumper the power from terminals 1 and 4 ifthe Solenoid is rated for 24VDC where a separate 24VDC supply is not available.

4.Terminals 7 and 8: Connection to external calibration and partial stroke test button (if installed). Can be used to remotely trigger PST and Calibration from aDCS.

5.Terminals 9 and 11: Switch common and normally open connections for valve position 2 limit switch. Typically connected to DCS for limit switch sensing. Forbench calibration or use in applications where alternate means of sensing valve position are used, these 2 terminals must still be provided withsource and return. The source and return for the electronics module power can be used, but a 2500 Ohm, 1/2W resistor MUST be installed betweenterminals 6 and 11 to prevent damage to the limit switch contacts from excess current.

6.Terminals 10 & 13: N/C side of Position 1 and 2 limit switch. Make sure current through switch is limited below maximum rating. If the system this unit is implemented on is monitoring the N/C side of the switches, a 2500 ohm, 1/2W resistor will need to wired between terminals 10 and 6, as well terminal 13 and 6 for visual indication. If the system is monitoring the N/O side, neither of these terminals are used.

7.Terminals 12 and 14: Switch common and normally open connections 1 limit switch. Typically connected to DCS for limit switch sensing. For benchcalibration or use in applications where alternate means of sensing valve position are used, these 2 terminals must still be provided with source andreturn. The source and return for the electronics module power can be used, but a 2500 Ohm, 1/2W resistor MUST be installed between terminals 6and 14 to prevent damage to the limit switch contacts from excess current.

8.Terminals 15 and 16: Prewired to the GO™ Switch. Do not change these connections.

9.Terminals 17, 18 and 19: External PST status signals:

A.Terminal 17: PST status signal. In combination with terminal 18, it forms a dry contact that closes if the PST passes.

B.Terminal 18: 24VDC source terminal for diagnostics and status output signal. Wire this to DCS 24VDC output.

C.Terminal 19: PST diagnostic signal. When wired to a DCS DC I/O input, will deliver a pulse train after PST completes to report any

diagnostic information.

Partial Stroke Time Tolerance Range Selection:

1.The default partial stroke time tolerance range is set to 20%. This value can be selected as 20%, 30% or 40% anytime.The value will be recorded in the EEPROM (memory) of the micro controller.

2.Press and hold the push button for ten to fifteen seconds to set the partial stroke time tolerance range to 20%.If the value is saved to memory successfully, the LED and diagnostic relay will flash message code 5-1.

3.Press and hold the push button for within fifteen to twenty seconds to set the partial stroke time tolerance range to 30%.If the value is saved to memory successfully, the LED and diagnostic relay will flash message code 5-2.

4.Press and hold the push button for more than twenty seconds to set the partial stroke time tolerance range to 40%.If the value is saved to memory successfully, the LED and diagnostic relay will flash message code 5-3.

5.If there is a writing value to memory failure, the LED and diagnostic relay will flash message code 6-6. The Pass/Fail relay willbe turned OFF.

Figure 3

HardwareConfiguration:

1.Ensure that the valve is in the OPEN position (the green position 1 LED should be illuminated.)

2.Refer to Fig. 3 which shows the correct orientation of the GO™ Switch target and sensor camsfor FAIL CLOSED valves.

3.If the unit conforms to this configuration, you may proceed to calibration. If not, completeHardware Configuration steps 4-7.

4.Lift the target wheel and rotate it such that the magnet is counterclockwise from the GO™ Switch.

5.Loosen and slide the magnet in the target wheel so as to position it approximately one inch from theedge of the GO™ Switch. Tighten to 20 in-oz.

6.Lift up on the upper cam and rotate it such that it is squarely aligned to the front of the electronicsmodule. The green light on the module should come on.

7.Press down on the lower cam and rotate it such that it is 90º counter clockwise from the electronics module.

Calibration:

1.Before performing calibration, make certain the valve is fully open (the green position 1 LED should be illuminated,) and the target button is set to the properpartial position.

*NOTE:Ifthevalveisnotfullyopen,thetestwillabortandtheLEDanddiagnosticrelaywillflashmessagecode7-7indicating thatthe valve is not fully open. The Pass/Fail relay will be turned OFF.

2.Press and hold the calibration button on board for five to ten seconds.

3.The activation relay will be turned ON to initiate valve closing.

4.The valve will move until the GO™ Switch detects the partial stroke position.

5.The GO™ Switch will send feedback indicating that the predetermined position is reached.

6.The time required to move the valve from the “fully open position” to the “partially open position” is the partial stroke time of the valve.

The acceptable timeranges are from fifty milliseconds to thirty seconds. This “partial stroke calibration time” will be recorded in the

EEPROM (memory) of the micro controller.EEPROM will retain the value until your next calibration.

7.If the calibration is successful, the Pass/Fail relay will be turned ON and both the LED and diagnostic relay will flash message code 3-3.

8.After the LED flashes code for three cycles, both the LED and diagnostic relay will be steady, signifying that the calibration is complete. Reset of the flashingLED and the diagnostic relay may be performed at anytime while the LED is flashing by pressing the calibration button.

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