Emerson TopWorx Maintenance Manual

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Page 1

TopWorx™ D-ESD: Partial Stroke & Emergency Shutdown

Installation, Operation & Maintenance Manual

Page 2

Credible Solutions

Page 3

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 Certications & Approvals Page 25 Safe Use

Page 4

ESD Theory of Operation:

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) veries 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 conrmation and two (2) limit switches built into the SCM conrm open and close position.

Once the unit is installed, the SCM-ESD must be calibrated for that specic 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

Page 5

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

specied, 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 specic 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 specic 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 dening proper

practices.

Page 6

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 Teon 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)

ADAPTER PLATE

Page 7

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

Page 8

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.

Page 9

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 Conguration:

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 conguration, you may proceed to calibration. If not, completeHardware Conguration 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.

Page 10

Partial Stroke Test:

1. Before performing the Partial Stroke Test (PST), make certain the valve is fully open.

* 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 that the valve isnot fully open. The Pass/Fail relay will be turned OFF.

2. If using the onboard module calibration button, press the button and hold it for more than half a second and less than ve seconds. If using the optional external PST button, push rmly once.

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 time required to move the valve to the partial stroke position will be compared against the “partial stroke calibration time” value stored in EEPROM (memory). The acceptable time ranges from “(1-tolerance range value) x partial stroke calibration time” to”(1+tolerance range value) x partial stroke calibration time”. For example, if the partial stroke calibration time is 6 seconds and the tolerance range value is 20%, the acceptable PST time ranges are from 4.8 to 7.2 seconds.

6. If the time required for moving the valve to the Partial Stroke position is outside the acceptable range of the “partial stroke calibration time”, the test will beaborted, indicating valve failure. The Pass/Fail relay will remain OFF and both the LED and

diagnostic relay will ash message code 5-5 if the valve has moved. If the valve has not moved, the Pass/Fail relay will remain OFF and both the LED and diagnostic relay will ash code 4-4.

CAUTION: Beforerecalibration, make sure any failure codes are addressed (see table pg.#16).

7. If the time required is within the acceptable range, the Pass/Fail relay will be turned ON and both the LED and Diagnostic Relay will

ash message code 2-2 .

8. After the LED ashes code for three times, both the LED and diagnostic relay will be steady, signifying that the Partial Stroke Test is

complete.

* Note: Partial Stroke Time Tolerance Range Selection, Calibration or Partial Stroke Test cannot be performed when the LED is

ashing. Before rerunning the test, please wait for the LED to become steady or clear it by pressing the button.

Page 11

ESD Calibration/PST Flow Chart—Fail Closed Valves

Apply power

Is partial stroke

position reached?

YES

Is minimum allewed

time (50ms) passed?

YES

Valve opens

LED displays

valve is not

calibrated code

1-1 pass/fail

relay state 0

Is memory ok?

Is button

releasedbefore

5 seceonds?

YES

Begin partial stroke test

YES

Is valve fully open? Is valve fully open?

YES YES

Is device calibrated?

YES

Is stored calibrated value

for partial stroke time

within range?

YES

Valve closes

Has valve moved?

LED displays valve closing

time failure code

5-5 pass/fail

relay state 0

NO NO

Valve opens

Is calibrartted

time passed?

Valve opens

YES

LED displays

valve has not

moved code 4-4 pass/fail relay state 0

Write uncalibrated status to momory

Is maximum allowed time (30s) passed?

YES

Valve opens Valve opens

LED displays

valve is not

fully open code

7-7 pass/fail relay state 0

Is device calibrated?

Is button pressed and held

for at least 0.5 seconds?

Is button

released before

10 seceonds?

Begin partial stroke calibration

Writing status value to

memory successful?

Valve closes

LED displays valve closing

time failure code

5-5 pass/fail

relay state 0

YES

stroke position

allowed time (50ms)

calibrated value

Is partial

reached?

YES

Is minimum

passed?

YES

Is writing

to memory successful?

YES

Is button

released before

15 seceonds?

YES

Set partial stroke time

tolerance range to 20%

LED displays writing error code 6-6 pass/fail relay state 0

LED displays memory error

continuous fast ashing

Pass/fail relay state 0

released before

tolerance range to 30%

Is writing tolerance

range value to

memory

successful?

YES

Is writing

tolerance

range value to

memory

successful?

Is button

20 seceonds?

Set partial stroke time

YES YES

error code 6-6 pass/fail

YES

Set partial stroke time

tolerance range to 40%

LED displays writing

relay state 0

range value to

Is button released?

YES

Is writing tolerance

memory

successful?

LED displays

partial stroke test

complete code 2-2

for all tolerance range

pass/fail relay state 1

LED displays

calibrarion

complete code

3-3 pass/fail relay state 1

LED displays range set to

20% complete

code 5-1

LED displays

range set to

30% complete

code 5-2

LED displays

range set to

40% complete

code 5-3

Page 12

ESD CONVENTIONAL INSTRUCTION AND OPERATION—Fail Open Valves

Operation:

For operation, the ESD must be calibrated (see Calibration below). After calibration, a partial stroke test 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 maintenancei ssues (please see ESD Conventional Flow Chart and Message Table for ESD Conventional on pg.#15 for more details).

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

Fail Open

GO™ Switch connection (Prewired)

Valve Pos 1 (Clo sed) switc h NO contact , needs path

(Add a 2500 O hm 1/2W resistor to pa th)

Valve Posi tion 1(Closed) COM . Tie it to Valve P osition 1 COM

Valve Pos 2 (Op en) switch NO con tact, ne eds path back t o DC

Valve Posi tion 2(Open) swi tch COM contac t, wire it ba ck to

Figure 4: Suggested Test Bench Setup for Fail Open Applications

(Add a 2500 O hm 1/2W resistor to pa th)

BLUE

Black

back to DC

Valve Pos 1 NC C ontact

Valve Pos 2 NC C ontact

Terminal 5

CALIBRATION

LED (AMBER)

TopWorx™ ESD

POSITION 2

LED (RED)

CAL SW

Calibration

Switch

POSITION 1

LED (GREEN)

ALARM COM PSI

Exte rnal PST but ton (Prew ired)

Power for electronics module 24VDC-

Power for electronics module 24VDC+

Soleno id Pilot or SOV O utput (-)

BL ACK (-)

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 th e same as

the LED a shes for the ca libration d iagnostic ( 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 if PST calibration 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 if the 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 a DCS.

terminals must still be provided with source and return. The source and return for the electronics module power can be used, but a 2500 Ohm, 1/2W resistor MUST be installed between terminals 6 and 11 to prevent damage to the limit switch contacts from excess current.

7. Terminals 12 and 14: Switch common and normally open connections 1 limit switch. Typically connected to DCS for limit switch sensing.

For bench calibration or use in applications where alternate means of sensing valve position are used, these 2 terminals must still be provided with source and return. The source and return for the electronics module power can be used, but a 2500 Ohm, 1/2W resistor MUST be installed between terminals 6 and 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.

Page 13

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.

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

tomemory 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 will be turned OFF.

Figure 5

Hardware Conguration:

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

2. Refer to Fig. 5 which shows the correct orientation of the GO™ Switch target and sensor cams for FAILOPEN valves.

3. If the unit conforms to this conguration, you may proceed to calibration. If not, complete HardwareConguration 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 the edgeof the GO™ Switch. Tighten to 20in-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 closed (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 closed, the test will abort and the LED and diagnostic relay will ash message code 7-7 indicating

that the valve is not fully closed. 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 closed position” to the “partially closed 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 times, 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.

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