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 Certications & Approvals
Page 25 Safe Use
ESD Theory of Operation:
R
STROKE TEST
COM
INDI
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) veries 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 conrmation and two (2) limit switches built into the SCM conrm open and close position.
Once the unit is installed, the SCM-ESD must be calibrated for that specic 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
CATION (CLOSED)
CAL/ALARM
TopWorxTM ESD
POSITION 2
LED (RED)
CAL SW
ALARM
POSITION 1
LED (GREEN)
COMPSI
DIAGNOSTIC
Figure 1: Input/Output Diagram
PARTIAL
PST / CAL
ACTIVATION
PARTIAL STROKE
MODULE POWE
PILOT VALV E
CONTROL
TO
PILOT VALV E
PILOT VALV E
CONTROL
Electrical Ratings
Current/Voltage
Open/Closed Indication 0.25A@24VDC w/5V drop
Dry Contact Rating Minimum Current Through Switch
Module Voltage 18-28VDC
Module Current 50mA (MAX)
Pilot Current (Standard) 20mA
PST Feedback Relays 800mA@24VDC MAX
Solenoid Pilot/SOV
Maximum PowerRating
0.25A@120VAC w/5V drop
Contacts: 5 mA
250mA@125VAC MAX
800mA@24VDC MAX
250mA@125VAC MAX
4
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
specied, 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 specic 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 specic 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 nal 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 National Electrical Code (NFPA 70) or any other national or regional code dening proper
practices.
Pneumatic Hookup Procedures
Prior to connecting the supply air to the spool valve, ush the
system to remove any debris or contaminates. Galvanized pipe
can easily ake and contaminate the system and therefore is not
recommended. A 40 micron point of use lter at every device is
recommended.
PORT TO OPEN
PORT TO CLOSE
PORT TO OPEN/CLOSE
PLUG
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
ACTUATOR OPEN
EXHAUST OF PORT 4
(WHEN ACTUATOR CLOSES)
(WHEN ACTUATOR OPENS)
SUPPLY
FAIL CLOSED
PORT TO
ACTUATOR CLOSE
EXHAUST OF PORT 2
Spool Valve Assembly
SUPPLY SUPPLY
DOUBLE ACTING ACTUATORS SPRING RETURN ACTUATORS
ALWAYS INSTALL VENTS ALWAYS INSTALL VENTS
Highly Recommended
TopWorx™ highly recommends Locktite 567 brand thread sealant.
Do not use a hard setting pipe compound. If Teon thread seal tape
is used, start the wrap on the second thread from the leading thread
of the tting. 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
temperature
Inlet/system pressure Min: 45 PSI (3.1 bar); Max: 150 PSI (10.3 bar)
Operational pressure
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
Optimal design life 500,000 cycles
Material in contact with
uid
* Refer to the wiring diagram on the inside lid of your product to determine actual
pin out location
Min: -40°C (-40°F); Max: 60°C (140°F)
Min: 45 PSI (3.1 bar); Max: 150 PSI (10.3 bar)
Internal: 10 cc/min max for -15°C to 60°C.
3300 cc/min max for -40°C to -15°C
Body: Aluminium (black anodized) and
Stainless Steel 316L
Internal: Stainless Steel, LT, nitrile, PTFE, Acetal
M5 X 30MM
SCHS (X3)(4MM
HEX WRENCH)
FLAME ARRESTORS & ORINGS (X5)
O-RINGS (X2)
ASCO™ VALVE WITHOUT
MANUAL OVERIDE
M5 X 12MM SCHS (X4)
(4MMHEX WRENCH)
6
ADAPTER PLATE
Spool Valves and Pilots
M3 X 18 CHEESE HEAD SCREW
TORQUE TO 20 IN-OZ
SINGLE PILOT ASSEMBLY
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
4-40 X .25” SEM SCREW
TORQUE TO 100 IN-OZ
BRACKET
YELLOW URETHANE
TUBING (WORK)
RED URRETHANE
TUBING (SUPPLY)
10-32 METAL BARB FITTING
TORQUE TO 60 IN-OZ
ORIFICE TO BE USED IN
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, ashes 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
GO™ Switch connection (Prewired) Exte rnal PST but ton (Prew ired)
Valve Pos 1 (Op en) switch NO con tact. Du ring bench te sting only, ad d a
2500 Ohm, 1/2 W res istor for pat h back to DC supp ly via termin al 6.
Valve Pos 1 NC C ontact
Valve Posi tion 1 (Open). COM. T ie it to Valve Posi tion 1 COM 24VDC+
Valve Pos 2 (Clo sed) switc h NO contact . During ben ch testing o nly, add a
2500 Ohm, 1/2 W res istor for pat h back to DC supp ly via termin al 6.
Valve Pos 2 NC C ontact
Valve Posi tion 2(Closed) s witch COM con tact,
wire it ba ck to Terminal 5 24VD C+
Figure 2: Suggested Test Bench Setup for Fail Closed Applications
BLUE
Black
Calibration Switch
CALIBRATION
TopWorx™ ESD
POSITION 2
LED (RED)
CAL SW
LED (AMBER)
POSITION 1
LED (GREEN)
ALARM COM PSI
Power for electronics module 24VDC-
Power for electronics module 24VDC+
Soleno id Pilot or SOV O utput (-)
BL ACK (-)
To Solenoid P ilot or SOV
RE D (+)
Soleno id Pilot or SOV O utput (+)
800mA@24VDC MAX
250mA@125VAC MAX
Option al externa l diagnosti c signal. If wi red, will pas s pulses out
the same a s the LED ashe s for the calib ration diag nostic (pg. #16)
Option al externa l signal COMMO N.
Tie it to th e Valve Pos 1 and 2 COM
Optional external alarm signal.
If wired , will close i f PST calibr ation if pass es.
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.
8
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 fteen 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 ash message code 5-1.
3. Press and hold the push button for within fteen 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 ash 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 ash message code 5-3.
5. If there is a writing value to memory failure, the LED and diagnostic relay will ash message code 6-6. The Pass/Fail relay willbe turned OFF.
Figure 3
Hardware Conguration:
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 conguration, you may proceed to calibration. If not,
completeHardware Conguration 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: If the valve is not fully open, the test will abort and the LED and diagnostic relay will ash message code 7- 7 indicating
thatthe valve is not fully open. The Pass/Fail relay will be turned OFF.
2. Press and hold the calibration button on board for ve 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 fty 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 ash message code 3-3.
8. After the LED ashes code for three cycles, both the LED and diagnostic relay will be steady, signifying that the calibration is complete.
Reset of the ashingLED and the diagnostic relay may be performed at anytime while the LED is ashing by pressing the calibration button.
Loading...