TopWorx™ D2-FF: FOUNDATION™ Fieldbus
Installation, Operation & Maintenance Manual
2
D2-FF Installation, Operation & Maintenance 502.969.8000
Table of Contents
Cover Page………………………………………………………………………………………………………………………………………………….. 1
Table of Contents………………………………………………………………………………………………………………………………………….. 2
1. Description &Specification………………………………………………………..………….………………………………………………………. 3
1.1 Storage ………………………………………………………………………………………………………………………………………3
2. Installation ….…………..………………………………………………………………….…...………………………………………………………. 3
2.1. Orientations, Normal and Reverse Acting Actuators…..……………………..…..…………………….. ………..…….……………. 3
2.2. Mounting.…………..…………………………………………..……………………..…………………………..……........................... 4
2.3. Wiring……………….…………………………………………..……………………..……………………………………….………….. 4
2.4. Dimensions and Materials……..………………………………………………………………………………………………………… 5
2.5. Spool Valves & Pilots…………………………………………..…………………………………………………………………………. 9
2.6. Component Replacement………………………………………..………………………………………………….……………………. 10
3. Operation…..……………………………………………………..…………………………..……………..…………………….………………..…... 11
3.1. Operation Mode and Function Block Assignments…..……………………..…..………………………..………..………...………... 11
3.2. Device Calibration (Required Configuration)…..……………………..…..…………………………………………..…….…...…….. 12
3.3. End Position Deadband Adjustment …..……………………..…..…………………………………………………...…….…...…….. 13
3.4. Reverse Valve Position…..……………………..…..…………………………………………………………………..…….…...…….. 13
3.5. Flash LED…..……………………..…..………………………………………………………………………………….…….……...….. 13
3.6. Shutdown Configuration …..……………………..…..………………………………………………………………...….……….…….. 13
3.7. Button board Enable…..……………………..…..……………………………………………………………………..………….…….. 14
3.8. Valve Position Indication…..……………………..…..………………………………………………………………...….………...…... 14
3.9. Position Sensor Type Indication…..……………………..…..………………………………………………………..….……...……... 14
3.10. Temperature Indication…..……………………..…..………………………………………………………………...….……...……... 14
3.11. Device Cycle Count, Adjustment and Control…..……………………..…..………………………………………..………..……... 14
3.12. Timers…..……………………..…..…………………………………………………………………………………….………..……... 14
3.13. Field Diagnostic Alerts/Plantweb Alerts…..……………………..…..……………………………………………….………..……... 15
3.14. Restart Methods…..……………………..…..………………………………………………………………………….………...…….. 19
3.15. Device Options…..……………………..…..…………………………………………………………………………...………...…….. 19
3.16. Base Record Methods…..……………………..…..…………………………………………………………………..………..……... 19
3.17. DD Version Info…..……………………..…..………………………………………………………………………….………..……… 19
3.18. Menu structure for handheld devices and host systems that support DD menus…..……………………..…………..……….... 20
3.19. Troubleshooting…..……………………..…..………………………………………………………………………….………..……... 24
Appendix A: Resource Block Parameters…………………………………………………………………………………………………………….. 29
Appendix B: Transducer Block Parameters………………………………………………………………………………………………………….. 36
Appendix C: AI Function Block Parameters………………………………………………………………………………………………………….. 39
Appendix D: DI Function Block Parameters………………………………………………………………………………………………………….. 44
Appendix E: DO Function Block Parameters………………………………………………………………………………………………………… 45
Appendix F: PID Function Block Parameters………………………………………………………………………………………………………… 47
Appendix G: Specifications and Reference Data………………………………………………………………………………………………….... 52
Certifications & Approvals..…………………………………….………………..…………………………………………………………………….. 53
Recommended Operating Temperatures…...…………………………………………………………………….………………..………………… 54
Replacement Parts ……………………………………………………………………………………………………………………………………… 54
Notes…...…………………………………………………………………….………………..…..……………………………………………………….. 55
Contact Information……………………………………………………………………..………………………………………………………………. 56
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1. Description & Specification
The TopWorx™ D2-FF Discrete Valve Controller combines position sensing and monitoring
with FOUNDATION Fieldbus communications and pilot valve output drivers. It incorporates
the following features:
FOUNDATION Fieldbus digital communication:
• Link active scheduler capability/Link Master (LAS)
• Pre-instantiated** blocks include Resource Block (RB), Transducer Block (TB),
Analog Input (AI) Function Block, Discrete Output (DO) Function Block, 2 Discrete
Input (DI) Function Block, Proportional, Integral, and Derivative (PID) Function Block
• Function block instantiation, live download, auto commission/replacement
• Fast function block execution time: DI: 15ms, AI: 15ms, DO: 20ms, PID: 20ms
• Easy integration into AMS and DeltaV systems
• Device Dashboards powered by enhanced Electronic Device Description
Language (EDDL)
Position sensing/monitoring
• Optional GO switches for open/close status
• Optional potentiometer for position percentage indication,
can be used for any rotation range between 20 and
320 degrees. End position offsets are adjustable.
Control and monitor inputs and outputs
• Supports single/double and
normal/reverse acting actuators
• Local LEDs for visual indication
• Local push buttons for calibration
• Remote configuration from control
system or field communicator
• Stroke valve method
• Cycle count monitoring
• Open/close time monitoring
• Temperature monitoring
• Open/short circuit protection
• Integrated field diagnostics
• Embedded NAMUR NE 107 diagnostics
**Pre-instantiated blocks are the pre-installed factory default function blocks. Instantiation is the capability to add blocks to and delete blocks from FF devices on the link.
Up to 15 additional copies of each function block can be added to a device (except the transducer and resource blocks). Not an available feature in some DSC systems.
Additional information is provided in FF-103.
1.1 Storage
Until conduit, conduit plugs, 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 -40ºF (-40ºC) to 160ºF (71ºC). Once properly installed, the temperature range listed on the nameplate will supersede this
storage temperature range.
2. Installation
This section provides instruction for installing the TopWorx D2-FF Discrete Valve Controller including mounting, tubing and wiring connections.
2.1. Orientations, Normal and Reverse Acting Actuators
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.
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 perpendicu-
lar 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 TopWorx™ has been rotated 90° compared
to the unit on the left.
Intrinsically Safe Input Parameters:
Bus Connector pins 1 to 3
I.S. Parameters FISCO Parameters
Ui 30V Ui 17.5V
Ii 380mA Ii 380mA
Pi 1.5W Pi 5.32W
Ci 5nF Ci 5nF
Li 10μH Li 10μH
Electrical Specifications
Current Consumption 17.65mA nominal
Max. Applied Voltage 35VDC
Operating Voltage 9-32VDC
Fieldbus Specifications
Topology Point to Point
Bus with Spurs
Daisy Chain
Tree
Cable Twisted Pair
Bus Length 1900m (max)
Transmission Speed 31.25 kbit/s
Intrinsically Safe Yes
Function Block
Execution Times
DI 15ms
AI 15ms
DO 20ms
PID 20ms
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D2-FF Installation, Operation & Maintenance 502.969.8000
2.2. 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.
2.2.1. 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 applying torque to any hardware or making pneumatic connec-
tions. Refer to the Integrated Pneumatic Control Valves section for detailed information.
4. This product comes shipped with plastic plugs 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 or installed outdoors.
5. 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.
2.3. Wiring
NOTE: TopWorx has pre-configured modules and faceplates available for DeltaV control
systems. Contact TopWorx factory for more information.
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2.4. Dimensions and Materials
Cast aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.
2.4.1. TopWorx™ DXP
Fastener Torque Specifications
Enclosure
Housing Bolts
8 ft.-lbs [10.8 N·m] +/-10%
Indicator
Dome Screws
320 in-oz. [2.3 N·m] +/-10%
Bottom
Mounting Holes
10 ft.-lbs [13.6 N·m] +/-10%
MATERIALS OF CONSTRUCTION
Enclosure
Cast A360 aluminum with
dichromate conversion coating
inside & out, epoxy coated
exterior rated for 250 hrs. salt
spray per ASTM B117
Fasteners
304 Stainless Steel standard
316 Stainless Steel optional
Shaft
304 Stainless Steel standard
316 Stainless Steel optional
Shaft Bushing Oilite Bronze
Indicator Dome Polycarbonate, UV F1 rated
Seals
O-ring seals available in: Buna,
& Silicone
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D2-FF Installation, Operation & Maintenance 502.969.8000
2.4. Dimensions and Materials (Continued)
Cast aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.
2.4.2. TopWorx™ DXS
Fastener Torque Specifications
Enclosure
Housing Bolts
8 ft.-lbs [10.8 N·m] +/-10%
Indicator
Dome Screws
320 in-oz. [2.3 N·m] +/-10%
Bottom
Mounting Holes
10 ft.-lbs [13.6 N·m] +/-10%
MATERIALS OF CONSTRUCTION
Enclosure Cast 316 Stainless Steel
Fasteners
304 Stainless Steel standard
316 Stainless Steel optional
Shaft
304 Stainless Steel standard
316 Stainless Steel optional
Shaft Bushing N/A
Indicator Dome Polycarbonate, UV F1 rated
Seals
O-ring seals available in: Buna
& Silicone,
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2.4. Dimensions and Materials (Continued)
Cast aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.
2.4.3. TopWorx™ DXR
Fastener Torque Specifications
Enclosure
Housing Bolts
20 in-lbs [2.3 N·m] +/-10%
Indicator Dome
Screws
20 in-oz. [2.3 N·m] +/-10%
Bottom
Mounting Holes
8 ft.-lbs [10.8 N·m] +/-10%
MATERIALS OF CONSTRUCTION
Enclosure Valox™ 364
Fasteners
304 Stainless Steel standard
316 Stainless Steel optional
Shaft
304 Stainless Steel standard
316 Stainless Steel optional
Shaft Bushing Delrin™ 500P white
Indicator Dome Polycarbonate, UV F1 rated
Seals Silicone
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D2-FF Installation, Operation & Maintenance 502.969.8000
2.4. Dimensions and Materials (Continued)
2.4.4. Indicator Assembly
2.4.5. Cam/Shaft Assembly
Indicator Dome
±5° adjustable
Polycarbonate
with keyed mask.
Several rotation and
form options
10 - 32 Captive
screws
Stainless steel
(x4)
O-Ring
Available in Buna-N
& Silicone
Color-coded indicator
Available in several
coordinating rotations
and forms for various
valve types, such as 90°,
180°, and thru-divert
applications
Optional Potentiometer
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2.5. Spool Valves and Pilots
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 installation, or storage.
Spool Valve Assembly
ASCO VALVE WITH
MANUAL OVERIDE
ASCO VALVE WITHOUT
MANUAL OVERIDE
M5 X 12mm SHCS (x4)
(4mm hex wrench)
ADAPTER PLATE
Flame Arrestor O-ring (x4)
M5 X 30mm SHCS (x4)
(4mm hex wrench)
* For Explosionproof “1” approval, TopWorx recommends
80 PSI Max Operating Pressure.
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D2-FF Installation, Operation & Maintenance 502.969.8000
2.6. Component Replacement
Optional Piezo Pilot Valve
Button Board
Terminations for Optional Valve
Position Switches and Piezo Pilot Valve
FF Bus Connection
Ground Strap
Optional Potentiometer Connector
+ Signal
Shield
- Signal
FF Communication Module
D2-FF Assembly: “Inside the Box”
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LED Label Off On Blink Flash
STATUS
No power
Device is calibrated
and full functioning
Reversing valve is
in process
Calibration is required
or error has occurred
CLOSE
Not in closed position In closed position
Calibrating closed
position is in process
Closed GO switch is
triggered during calibration
OPEN
Not in open position In open position
Calibrating open
position is in process
Open GO switch
is triggered during
calibration
NOTE: LED duty cycle is shown on the right.
Flashing: LED is on for 5% of every second.
Blinking: LED is on for 50% of every second.
Function Block Signal Channel Unit
DO
Command to open or close 1 None
DI
Output command readback 2 None
Open indicator input 3 None
Close indicator input 4 None
AI
Instrument temperature 5 ºC
Analog position 6 %
3. Operation
This section of the manual provides operational information for configuring, control and monitoring the device locally or remotely through the
FOUNDATION Fieldbus Host Control System.
3.1 Operation Mode and Function Block Assignments
Automatic (Auto) and Out of Service (OOS) mode are available for all the function blocks in FOUNDATION Fieldbus Host Control System.
To operate device using function block, first set the required Function Block mode to OOS, then set the required channel number according to
Table 1. After downloading the Function Block to system, set the Function Block mode to AUTO.
Note: For DI block, if “Open Indicator Input” is chosen, FIELD_VAL_D parameter will indicate Open/Close status. If “Close Indicator Input” is chosen, FIELD_VAL_D parameter will indicate reversed Open/Close status.
Table 1 Function Block Assignments
Table 2 LED Functionality
Table 3 Button Board Functionality
Activity Function
REVERSE button pressed Reverse valve
OPEN button pressed once Start to calibrate open position
OPEN button pressed again Confirm current position as open position
CLOSE button pressed once Start to calibrate closed position
CLOSE button pressed again Confirm current position as closed position
(Section 3 Continued on next page)
on
off
on
off
LED=
Flashing
LED=
Blinking
Time
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D2-FF Installation, Operation & Maintenance 502.969.8000
Status Description
Calibration needed Device is not calibrated or calibration for the other end position is needed.
Running Device calibration is in process
Timed Out Device calibration timed out (maximum 5 minutes)
Both triggered Both Go switches are triggered simultaneously
Range error Less than minimum allowed rotation range (minimum 20 degrees)
In deadband End position is too high/low or in deadband
No sensor detected No sensor is detected during calibration
Successful Device is calibrated
3. Operation
(Cont.)
Table 4 Calibration Statuses
3.2. Device Calibration (Required Configuration)
Device can be calibrated either locally using buttons (see section 3.2.1) or remotely using bus command (see section 3.2.2). A summary for LED
and button board functionalities is provided in Table 2 and 3.
3.2.1. Calibrating End Positions Locally
3.2.1.1. Perform Calibration
a. This operation is only available if Transducer Block is in OOS mode and the button board is active. If Transducer Block is in Auto
mode, change the mode to OOS. If the button board is disabled, set “Buttonboard Enable” parameter to “Active in OOS”.
b. STATUS LED will flash if device is not calibrated. To start calibration procedure, identify the current shaft position by sight, press
(greater than 50ms and less than 5min) either the CLOSE or OPEN button according to the position to start the calibration.
c. If CLOSE button is pressed, CLOSE LED will blink to indicate that calibration is in process, perform the following according to sensor
type to calibrate the closed end position (note that either CLOSE or OPEN position can be calibrated first):
Option #1: GO switch only case: Move magnet to trigger the closed switch (the
GO switch labeled as closed position switch). CLOSE LED will flash to indicate the
switch is triggered.
Option #2: Potentiometer only case: Make sure the potentiometer is not in deadband
(the red dot should not fall into the red line area).
Option #3: Both GO switch and potentiometer case: Move magnet to trigger the closed
switch (the GO switch labeled as closed position switch). CLOSE LED will flash to indicate
the switch is triggered. Make sure the potentiometer is not in deadband (the red dot should
not fall into the red line area).
* Press the CLOSE button AGAIN to confirm the position. CLOSE LED will become solid on.
d. Press the REVERSE button (greater than 50ms and less than 5min) to move valve to the other position. If there is a potentiometer, as
the shaft rotates, make sure the potentiometer is not rotating through its deadband area. STATUS LED will blink for 3 seconds to indicate the reverse action. Note: The REVERSE button is not operational in units without integral pilot valves supplied by TopWorx. For
those applications, the valve will have to be moved manually or with existing controls.
e. Press the OPEN button and perform the following according to sensor type to calibrate the open end position (note that these steps
are similar to the calibration for the closed end position):
Option #1: GO switch only case: Move magnet to trigger the open switch (the GO switch labeled as open position switch).
OPEN LED will flash to indicate the switch is triggered.
Option #2: Potentiometer only case: Make sure the potentiometer is not in deadband.
Option #3: Both GO switch and potentiometer case: Move magnet to trigger the open switch (the GO Switch labeled as
open position switch). OPEN LED will flash to indicate the switch is triggered. Make sure the potentiometer is not in deadband.
* Press the OPEN button AGAIN to confirm the position. OPEN LED will become solid on.
f. STATUS LED will become solid on if the calibration procedure is successful. It will flash if the calibration is failed. The calibration sta-
tus will be shown in “Calibration Status”. Please see Table 4 for the list of calibration statuses.
Note that either end position can be re-calibrated/re-adjusted if the other end position is already calibrated. That is, after initial calibration, either
position can be recalibrated individually without calibrating the other position.
3.2.2. Calibrating End Positions Remotely
Calibration remotely using bus command can be done through guided method (For example, from AMS or Handheld screens, see section 3.2.2.1)
or manual setup (see section 3.2.2.2).
3.2.2.1. Perform Guided Calibration through Method (Recommended)
Click the method “Device Setup” or “Calibrate” on screen and follow the instructions for calibration.
3.2.2.2. Perform Calibration by Setting Parameters
a. This operation is only available if the Transducer Block is in OOS mode. If Transducer Block is in Auto mode, change the
mode to OOS.
(Section 3 Continued on next page)
Deadband
Indication
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3. Operation
(Cont.)
b. STATUS LED will flash if device is not calibrated. To start calibration procedure, select the “Set to current position” from either the
“Open End Position” or the “Close End Position” parameter. The corresponding OPEN or CLOSE LED will blink to indicate that calibration is in process.
c. For calibrating the “Close End Position”, perform the following according to sensor type to calibrate the closed end position (note that
either the “Open End Position” or the “Close End Position” can be calibrated first):
Option #1: GO switch only case: Move magnet to trigger the closed switch (the GO switch labeled as closed position switch).
CLOSE LED will flash to indicate the switch is triggered.
Option #2: Potentiometer only case: Make sure the potentiometer is not in deadband (the red dot should not fall into the red
line area).
Option #3: Both GO switch and potentiometer case: Move magnet to trigger the closed switch (the GO Switch labeled as
closed position switch). CLOSE LED will flash to indicate the switch is triggered. Make sure the potentiometer is not in deadband
(the red dot should not fall into the red line area).
* The status for “Close End Position” will automatically change back to “No Action Required” if the action is performed.
d. Select the “Reverse” from the “Reverse Valve Position” parameter. If there is a potentiometer, as the shaft rotates, make sure the
potentiometer is not rotating through its deadband area. STATUS LED will blink for 3 seconds to indicate the reverse action.
Note: The REVERSE button and "Reverse Valve Position" is not operational in units without integral pilot valves supplied by
TopWorx. For those applications, the valve will have to be moved manually or with existing controls.
e. Select the “Set to current position” from the “Open End Position”. (note that these steps are similar to the calibration for the closed
end position):
Option #1: GO switch only case: Move magnet to trigger the open switch (the GO switch labeled as open position switch).
OPEN LED will flash to indicate the switch is triggered.
Option #2: Potentiometer only case: Make sure the potentiometer is not in deadband.
Option #3: Both GO switch and potentiometer case: Move magnet to trigger the open switch (the GO switch labeled as open
position switch). OPEN LED will flash to indicate the switch is triggered. Make sure the potentiometer is not in deadband.
* The status for “Open End Position” will automatically change back to “No Action Required” if the action is performed.
f. STATUS LED will become solid on if the calibration procedure is successful. It will flash if the calibration failed. The calibration status
will be shown in “Calibration Status”. Please see Table 4 for the list of status.
*Note that either end position can be re-calibrated/re-adjusted if the other end position is already calibrated.
3.3. End Position Deadband Adjustment
If there is a potentiometer, the end position deadband is determined by the value for “Open/Close Stop Offset” parameter. This value is adjustable.
Its default value is 10% and the allowable range is 5% to 40%. For example, with the default value, if the open position is at 100 degree and the
closed position is at 50 degree, then if actual value position is within 50±(100-50)×10%=45~55 degree, the “Close State” is “True”, and the “Open
State” is “False”.
3.4. Reverse Valve Position
Valve position can be reversed locally by pressing the REVERSE button on the button board if it is enabled. It can also be done remotely by selecting the “Reverse” from the “Reverse Valve” parameter when device is in OOS mode. The value for “Reverse Valve” will automatically change back to
“No action” (default value) if the action is performed. STATUS LED will blink for 3 seconds to indicate the reverse action. Note: The REVERSE
button is not operational in units without integral pilot valves supplied by TopWorx. For applications, the valve will have to be moved manually or with
existing controls.
3.5. Flash LED
To identify a device in the plant, put Transducer Block into OOS mode and select the “Flash LED” for the “Flash LED” parameter. Status LED on the
unit will blink for 5 minutes. After 5 minutes, status for “Flash LED” will automatically change back to “Finished” (default value).
3.6. Shutdown Configuration
Shutdown configuration controls the behavior of the valve in case of an internal communications failure in the electrical module. This is independent
of the FF communication on the bus line. The “shutdown action” parameter is also re-used as the default position (initial status) for a device encoun-
tered a power loss.
3.6.1. Parameters and functions
a. Shutdown enable (SHUTD_ENABLE parameter):
Enable, auto recovery: If there is an internal failure, valve will move to certain position according to the setting of parameter
SHUTDOWN_ACTION. When the internal failure is solved, the valve will automatically go to its current setpoint position.
Enable, manual recovery: If there is an internal failure, valve will move to certain position according to the setting of parameter
SHUTDOWN_ACTION. When the internal failure is solved, the valve will NOT automatically go to its current setpoint position unless
SHUTD_RESET parameter is manually selected as “reset”.
Disable: Shutdown functionality is not operational; the valve will stay in its last position after an internal failure.
b. Shutdown action (SHUTD_ACTION parameter):
Open: When performing shutdown operation or starting up after a power loss, valve will go to open position.
Close: When performing shutdown operation or starting up after a power loss, valve will go to close position.
Hold: When performing shutdown operation or starting up after a power loss, valve will stay in original position.
Note: The shutdown action is not operational in units without integral pilot valves supplied by TopWorx. For those applications, the
valve will have to be moved manually or with existing controls.
c. Shutdown delay (SHUTD_DELAY_TIME parameter):
The time waited to perform shutdown operation after the internal failure occurs. The default value is 5 seconds. The allowable range
is from 2 to 255 seconds.
(Section 3 Continued on next page)
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D2-FF Installation, Operation & Maintenance 502.969.8000
3. Operation
(Cont.)
d. Shutdown reset (SHUTD_RESET parameter):
Inactive: Shutdown reset function is not active. If “manual recovery” is selected for SHUTD_ENABLE parameter and there is an
internal error, after the internal failure is solved, the valve will NOT automatically go to its current setpoint position. Device stays in
shutdown status.
Reset: Shutdown reset function is active. If “manual recovery” is selected for SHUTD_ENABLE parameter and there is an internal
error, after the internal failure is solved, shutdown status will be reset, and the valve will automatically go to its current setpoint
position. When this reset is completed, the SHUTD_STATUS parameter will be “Device is operational” and the SHUTD_RESET
parameter will return to “inactive”.
e. Shutdown status (SHUTD_STATUS parameter):
Device operational: there is no internal error.
Device shutdown: there is internal error.
3.6.2. Examples
a. For internal communications failure
The factory default shutdown configuration settings are as following:
Shutdown enable: Enable, Manual Recovery
Shutdown action: Close
Shutdown delay: 5 seconds
Shutdown reset: Inactive
If there is an internal failure, after 5 seconds, valve will move to close position according to the setting of parameter
SHUTDOWN_ACTION. When the internal failure is solved, the valve will NOT automatically go to its current setpoint position
unless SHUTD_RESET parameter is manually selected as “reset”.
b. For power lose
If the “shutdown action” is “Open”, when power is re-applied to device after a power loss, before valve receives the bus command
(for example, the SP_D from DO function block), valve will go to open position.
If the “shutdown action” is “Hold”, when power is re-applied to device after a power loss, before valve receives the bus command
(for example, the SP_D from DO function block), valve will stay in the previous position, that is, the position that power is off.
3.7. Buttonboard Enable
Local operation through push buttons is only available when the button board is active. The factory default value for “Buttonboard Enable” parameter
is “Active in OOS”. When device is in OOS mode, the button board can be enabled by setting the “Buttonboard Enable” parameter to “Active in
OOS” or disabled by setting it to “Never active”.
3.8. Valve Position Indication
The “Analog position” parameter will indicate current valve position in percentage (the display range for AI block: -200% to +199%, the display range
for TB block: 0%~100%) if there is a potentiometer and the calibration is successful, otherwise, the value is 0. The percentage is calculated as the
distance in degrees from current position to close position versus the full open to close distance in degrees. The “Final Discrete Position” parameter
will indicate current valve position as “Closed”, “Open”, “Opening” or “Closing”. Device will indicate “Closed” or “Open” according to the discrete
position. The assigned position from DO block is indicated by “DO Command” parameter as “Close” or “Open”.
3.9. Position Sensor Type Indication
The “Position Sensor Type” parameter will indicate the sensor type detected by the device during calibration. This parameter will indicate “GO switch
only”, “Potentiometer only”, or “Both GO switch and potentiometer” if sensor type is detected. Otherwise, it will indicate “Not assigned” (default value).
3.10. Temperature Indication
Temperature is measured every 100 millisecond by the sensor on the circuit board and indicated as degree C by “Temperature” parameter. The
allowed temperature range is -25 to +65 degree C. An alarm will be triggered if temperature is out of range (Please see the Alert section for more
details). The maximum/minimum measured temperature is recorded in the device. It can be viewed through the command in base record.
3.11. Device Cycle Count, Adjustment and Control
The parameter “Cycle Count” (this parameter is read only) indicates the total end position cycles. The parameter “Adjusted Count” indicates the end
position cycles after adjustment. If valve position changes from close to open and back to close, the value for both parameters will be increased by
one. Users can set “Adjusted Count” to any non-negative value and the adjusted cycle count will start to increase based on this set value. Users
can set a limit for them using the “Cycle Count Limit” and “Adjusted Count Limit” parameters. The default limit is 1000000 cycles. The allowed input
value for “Cycle Count Limit” must be greater than the current cycle count and less than 4294967296. The allowed input value for “Adjusted Count
Limit” must be greater than the current adjusted cycle count and less than 4294967296. An alarm will be triggered if the count is out of range limit
(Please see the Alert section for more details).
3.12 Timers
There are 3 timers available in this device:
Time in position: the time in seconds that device is in current position since the last movement. It is automatically reset to zero when the power is
switched off.
Open travel time: the time between when pilot valve position is changed due to request and when the open end position is reached. It is indicated
in seconds with accuracy in 10 milliseconds.
Close travel time: the time between when pilot valve position is changed due to request and when the close end position is reached. It is indicated
in seconds with accuracy in 10 milliseconds.
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3. Operation
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These values are important in determining abnormal events that recently occurred. For example, a temporary drop in pressure or a sticky process
valve (valve that has been left in the same position for a long time without cycling) will affect the performance of the last operation of the valve, but
does not necessarily mean the mechanical device is worn out. The average open/close travel time (in seconds) of the last 30 strokes is calculated
and indicated in parameter “Average Time”. Process valve/actuators typically wear out at a constant steadily pace. A good indication of wear will be
the average travel times since the change is slow, but constant. Users can set an upper limit for “Time in position” using the “Time in Position Hi
Limit” parameter. The default value is 864000 seconds (10 days). The allowed input value must be less than 4294967296. Users can also set the
low/high limits for the open/close travel time and the average open/close travel time using their “Travel Lo Limit” and “Travel Hi Limit” parameters.
The default value is 0 for the low limit and 300 seconds for the high limit. The allowed input value must be less than 65536. An alarm will be triggered if any time value is out of range limit (Please see the Alert section for more details).
3.13 Field Diagnostic Alerts/Plantweb Alerts
3.13.1. List of Alerts
Check: The Check condition is true if any transducer block has a normal mode other than Out of Service and the actual mode is
not AUTO.
Calibration Failed: Device has not been calibrated or the calibration has failed. Please refer to Table 4 Calibration Statuses for
the reason of failure.
Bad Temperature Sensor: Temperature sensor is malfunctioning. Temperature value is not reliable.
System Temperature Exceeded: Maximum/minimum temperature exceeds the value set in the limit.
Software Error: Controller card memory error occurs.
Travel Deviation:
a. Valve/actuator moves to an undesired position. For example, the device energizes an output to OPEN a spring return
actuator. The position feedback indicates the device has reached the OPEN position. Afterwards, air pressure is lost and the
actuator moves back to the CLOSED position (spring-return). The position feedback sensor will indicate the actuator is in the
CLOSED position although a command to CLOSE the actuator has never been issued. In this situation a Travel Deviation
alert will be generated indicating the actuator was in a desired position, but moved to an undesired position.
b. Valve/actuator doesn’t move to a desired position. For example, the device energizes an output to OPEN a spring return
actuator. But the air pressure is lost so the actuator doesn’t move. After 5 minutes, the position feedback indicates the
device still has not reached the OPEN position. Travel Deviation alert will be generated indicating the actuator can not move
to a desired position.
Shutdown is Set: Device shutdown is operating due to an internal communications failure in the electrical module.
Buttonboard Failure: Button board is malfunctioning.
Open/Short Circuit: There is an open circuit for the main Piezo or there is a short circuit for any Piezos. If there is an open circuit
or the main Piezo, only this alert is triggered. Device will automatically operate as normal once there is no open circuit for the
main Piezo. If there is a short circuit for any Piezos, device will power off both Piezos. Device will return to normal Piezo operation
only if no short circuit is detected after a power cycle.
Adjusted Cycle Count Exceeded: Adjusted cycle count has exceeded the value set in the limit.
Control Module Life Cycle Exceeded: Cycle count has exceeded the value set in the limit.
Time in Position Limit Exceeded: Time value has exceeded the value set in the limit.
Open Travel Time Limit Exceeded: Time value has exceeded the value set in the limit.
Close Travel Time Limit Exceeded: Time value has exceeded the value set in the limit.
Internal I/O Failure: Internal communications are lost; device will act according to shutdown configuration.
NV Memory Failure: Non-volatile EEPROM data corruption was detected on the Fieldbus electronics board. Default values were
loaded into the faulty block. If the failure reoccurs it may indicate a faulty EEPROM memory chip.
Electronics Failure: The device has detected a fault with an electrical component on the Fieldbus electronics module assembly.
Note: The Travel Deviation and Open/Short Circuit Alerts are not monitored in units without integral pilot valves supplied by
TopWorx. For those applications, the valve will have to be moved manually or with existing controls.
3.13.2. Alert handling
Both field diagnostics and PlantWeb alerts are supported in this device. Although these alerts have default settings (see table
5), these can be changed by the customer to match their requirements.
For field diagnostic alerts, there are four levels of alerts available:
a. Failed Alerts
A Failure Alert indicates a failure within a device that will make the device or some part of the device non-operational. This
implies that the device is in need of repair and must be fixed immediately.
This alert has the following five parameters:
FD_FAIL_MAP: Enables or disables conditions to be detected as active for this alarm category. Thus the same condition
may be active in all, some, or none of the alarm categories.
FD_FAIL_MASK: allows the user to suppress any single or multiple conditions that are active, in this category, from being
broadcast to the host through the alarm parameter.
FD_FAIL_PRI: Designates the priority.
FD_FAIL_ACTIVE: Reflects the error conditions that are being detected as active as selected for this category. Multiple
conditions may be shown.
FD_FAIL_ALM: To report the particular failed condition to the host system.
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b. Off Spec Alerts
An Off Spec Alert indicates a condition within a device that is out of the range of the specification. The alert is used to notify
the host that the device has detected a condition within the device that is not critical, will not cause a failure if left unattended but should be reported to the host for awareness and possible action.
This alert has the following five parameters:
FD_OFFSPEC_MAP: Enables or disables conditions to be detected as active for this alarm category. Thus the same condition may be active in all, some, or none of the alarm categories.
FD_OFFSPEC_MASK: allows the user to suppress any single or multiple conditions that are active, in this category, from
being broadcast to the host through the alarm parameter.
FD_OFFSPEC_PRI: Designates the priority.
FD_OFFSPEC_ACTIVE: Reflects the error conditions that are being detected as active as selected for this category. Multiple
conditions may be shown.
FD_OFFSPEC_ALM: To report the particular failed condition to the host system.
c. Maintenance Alerts
A Maintenance Alert indicates a condition within a device that, if not attended to in the near future (the type of alert defines
the time period for “Near Future”) will make the device or some part of the device non-operational. This implies that the de-
vice is in need of repair and must be fixed as soon as possible.
This alert has the following five parameters:
FD_MAINT_MAP: Enables or disables conditions to be detected as active for this alarm category. Thus the same condition
may be active in all, some, or none of the alarm categories.
FD_MAINT_MASK: allows the user to suppress any single or multiple conditions that are active, in this category, from being
broadcast to the host through the alarm parameter.
FD_MAINT_PRI: Designates the priority.
FD_MAINT_ACTIVE: Reflects the error conditions that are being detected as active as selected for this category. Multiple
conditions may be shown.
FD_MAINT_ALM: To report the particular failed condition to the host system.
d. Check Alerts
A Check Alert indicates output signal temporarily invalid (e.g. frozen) due to on-going work on the device. This alert has
the following five parameters:
FD_CHECK_MAP: Enables or disables conditions to be detected as active for this alarm category.
Thus the same condition may be active in all, some, or none of the alarm categories.
FD_CHECK_MASK: allows the user to suppress any single or multiple conditions that are active, in this category, from being
broadcast to the host through the alarm parameter.
FD_CHECK_PRI: Designates the priority.
FD_CHECK_ACTIVE: Reflects the error conditions that are being detected as active as selected for this category. Multiple
conditions may be shown.
FD_CHECK_ALM: To report the particular failed condition to the host system.
For Plantweb alerts, there are three levels of alerts available:
a. Failed Alerts
A Failure Alert indicates a failure within a device that will make the device or some part of the device non-operational. This
implies that the device is in need of repair and must be fixed immediately.
This alert has the following five parameters:
FAILED_ENABLE: Enable the indication and reporting.
FAILED_MASK: Suppress reporting.
FAILED_PRI: Designates the priority.
FAILED_ACTIVE: Displays which of the conditions within the alert is active.
FAILED_ALM: To report the particular failed condition to the host system.
b. Maintenance Alerts
A Maintenance Alert indicates a condition within a device that, if not attended to in the near future (the type of alert defines
the time period for “Near Future”) will make the device or some part of the device non-operational. This implies that the de-
vice is in need of repair and must be fixed as soon as possible.
This alert has the following five parameters:
MAINT_ENABLE: Enable the indication and reporting.
MAINT_MASK: Suppress reporting.
MAINT_PRI: Designates the priority.
MAINT_ACTIVE: Displays which of the conditions within the alert is active.
MAINT_ALM: To report the particular failed condition to the host system.
c. Advisory Alerts
An Advisory Alert indicates a condition within a device that is informational in nature. The alert is used to notify the host that
the device has detected a condition within the device that is not critical, will not cause a failure if left unattended but
should be reported to the host for awareness and possible action.
This alert has the following five parameters:
ADVISE_ENABLE:Enable the indication and reporting.
ADVISE_MASK: Suppress reporting.
ADVISE_PRI: Designates the priority.
ADVISE_ACTIVE: Displays which of the conditions within the alert is active.
ADVISE_ALM: To report the particular failed condition to the host system.
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3.13.3. Alert parameter description
a. Alerts – Enable/Map
These parameters are used to enable the indication and reporting of each corresponding alert. When an alert is disabled, the device
shall not detect that particular alert; it shall not be indicated in the xxxx_ACTIVE parameters or be reported via respectively alerts. If
an alert enable parameter is changed to “disabled” while the alert is active, it shall clear the alert and re-evaluate the alert.
b. Alerts - Mask
These parameters will mask any of the failed conditions listed in respectively alerts.
Setting a bit to true will cause the corresponding alert to be indicated in the xxxx_ACTIVE parameters but not reported to the host
via the alerts. If an alert mask is changed while the alert is active, the alert is cleared and all the conditions are reevaluated.
c. Alerts - Priority
This designates the priority of the alerts. The default is 0 and the recommended value is between 10 and 15. If left as initial value,
no alerts will be delivered to the HOST.
d. Alerts - Active
These parameters display which of the conditions is active. When a device detects a condition has become active, it shall set the
corresponding bit in the xxxx_ACTIVE parameters. If it is not suppressed/masked, it will be reported using the associated alert parameter. These parameters are read only.
e. Alerts - Alarm
These parameters are used to report the particular condition to the host. These parameters are read only.
3.13.4. Recommended Actions and Default Settings for Alerts. Please see the Table 5 below for the recommended actions and default
settings for all alerts. Note: Enabling/disabling and masking for PlantWeb Alerts follow the NAMUR Field Diagnostics alerts
and are not independent. However, the alarm priorities are independent such that it is possible to get "double" or no
alerts.
Table 5 Recommended Actions and Default Setting/Mapping for Alerts (Note that no alert is masked in factory default settings)
Alerts
Recommended Actions
Default Enabled Alert
Field Diagnostic Plantweb
Failed Off Spec Maint. Check Failed Maint. Advisory
Check Check transducer block mode.
✓ ✓
Calibration Failed
Calibration required or failed, check
calibration status for reasons, check air
pressure, check valve system, recalibrate valve controller.
✓ ✓
Bad Temperature Sensor
Temperature sensor is not functioning,
replace valve controller when possible.
✓ ✓
System Temperature
Exceeded
Temperatures too high/low, take corrective actions to bring temperature
within specified range.
✓ ✓
Software Error
Software error detected, cycle power, if
problem persists, replace valve controller when possible.
✓ ✓
Travel Deviation
Lost position, check air pressure, check
shaft assembly and position, check
open/close go switch and/or potentiometer connection if available.
✓ ✓
Shutdown is Set
Internal communications problem,
check shutdown configuration for restart, if problem persists after restart,
replace valve controller when possible.
✓ ✓
Buttonboard Failure
Button board is not functioning correctly, replace valve controller when possible.
✓ ✓
Open or Short Circuit
Output to pilot valve disabled because
of open/short circuit, check pilot valve
connection. Replace malfunctioning
Piezo. When short circuit issue is resolved, device must be power cycled.
✓ ✓
Adjusted Cycle Count
Exceeded
Adjusted cycle counter exceeded limit,
re-assign limit or re-adjust cycle count.
✓ ✓
(Section 3 Continued on next page)
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