Topworx Position Switch
Topworx Position Switch
Topworx Position Switch
D-Series
502.969.8000
Table of Contents
Cover Page
Table of Contents
Installation on Actuator.
Mounting & Storage ..
DXP Dimensions and Materials..
DXP-IIC Dimensions and Materials...
DXS Dimensions and Materials..
DXR Dimensions and Materials..
Shaft & Indicator Assembly.
Sensor Options......
Mechanical Switches (M/K/T).... .
P+F/Inductive Sensors (E/V)....
GO Switches( L/Z)...
4-20mA Transmitter (_X)....
4-20mA Transmitter w/ HART (_H)..
FOUNDATION Fieldbus (FF)....
AS-I (AS).........
SCM w/ Reed Switches (R)......
SCM (PN/PS) ..
ESD (ES)......
DeviceNet (DN)..........
Spool Valves & Pilots....
Proof Testing ..
Safe Use....
Special Conditions.
Replacement Parts.......
Warranty......
Certifications & Approvals.....
Operating Temperatures..
1
2
3
3
4
5
6
7
8
9
9
11
15
18
22
27
37
38
39
40
45
48
49
53
54
55
56
57
58
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Installation
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 Valvetop unit mounted parallel to
the process valve in the closed position. The green arrow at the
top shows the normal acting direction of travel to open the valve.
This is the standard orientation and unless otherwise specified,
your unit will be factory set to operate in this fashion.
Mounting
TopWorx has numerous mounting bracket kits, both rotary and linear, available to meet your specific application. Consult your local distributor or
factory representative for ordering information. The illustration below shows a direct NAMUR mount on a quarter turn valve. Refer to your mounting kit documentation for specific mounting instructions.
Storage
Until conduit, conduit covers, and any applicable spool valve port connections are properly installed, the ValveTop unit will not support its IP/
NEMA rating as the unit ships with temporary covers. Ensure that it is stored in a dry environment with a relative humidity range between
10%-95% and a temperature ranging from -40F (-40C) to 160F (71C). Once properly installed, the temperature range listed on the
nameplate will supersede this storage temperature range.
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. Please refer to the Proof Testing section for proper safety function setup.
3.
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.
4.
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.
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.
D-Series
502.969.8000
Enclosure
Fasteners
Shaft
Shaft Bushing
Oilite Bronze
Indicator Dome
Polycarbonate, UV F1 rated
Seals
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Dimensionals
Enclosure
Fasteners
Shaft
Shaft Bushing
Oilite Bronze
Indicator Dome
Polycarbonate, UV F1 rated
Seals
D-Series
502.969.8000
Enclosure
Fasteners
Shaft
Shaft Bushing
N/A
Indicator Dome
Polycarbonate, UV F1 rated
Seals
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Dimensionals
Valox 364
Fasteners
Shaft
Shaft Bushing
Indicator Dome
Polycarbonate, UV F1 rated
Seals
Silicone
D-Series
Indicator Assembly
Indicator Dome,
5 adjustable
Polycarbonate
with keyed mask.
Several rotation and
form options
O-Ring
Available in Buna-N,
Silicone, EPDM, Viton
Cam/Shaft Assemblies
WASHER
1CIRCLIP
SHAFT
10 - 32 Captive screws,
stainless steel (x4)
Color-coded indicator is
available in several
coordinating rotations and
forms for various valve
types, such as 90, 180,
and thru-divert applications
502.969.8000
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Mechanical Switches
PRODUCT SPECIFICATIONS
OPTION M
Switch Type
Mechanical
Sealed
No
Circuitry
SPDT
Termination
Quick Connect
Rating
Conforming to standards
15A@125VAC or 250VAC
UL: 1054
Contact Resistance
15Mmax. (initial)
Insulation Resistance
Switch Type
Mechanical
Sealed
No
Circuitry
SPDT
Termination
Quick Connect
Rating
0.1A@125VAC MAX
Conforming to standards
Switch Type
Step 2: Rotate valve to the OPEN position. Disengage the BOTTOM cam
from the splined Hub and rotate Clockwise until SW1 activates.
Release cam to re-engage the splined Hub.
Sealed
No
Circuitry
DPDT
Termination
Quick Connect
Rating
Contact
Terminals
End or side
Conforming to standards
Repeat Step 3 above.
*When using the (4) and (6) switch options, use the same calibration steps as
above for the switches you determine to indicate OPEN and which indicate
CLOSED.
UL: 1054
OPTION T
Mechanical
**Switches may also be set at midpoint, or any point, of travel for Dribble
Control, or any other logic necessary for the application.
D-Series
502.969.8000
Option T2
Connection
Color Code
Terminal#
NC1
Red
Black
COM1
Black
NO
Blue
NO1
Blue
NC
Red/White
NC2
Red/White
COM
Black/White
COM2
Black/White
NO
Blue/White
NO2
Blue/White
Yellow
Connection
Color Code
Terminal#
NC
Red
COM
Switch#
NC
Yellow
NC1
COM
Brown
COM1
Brown
NO
Orange
NO1
Orange
NC
White/Yellow
10
NC2
White/
Yellow
10
COM
White/Brown
11
White/
Orange
COM2
White/Brown
11
NO
12
NO2
White
13
White/
Orange
12
NC
COM
Gray
14
NO
Violet
15
NC
Pink
16
COM
White/Gray
17
NO
White/Violet
18
NOTE: Refer to the wiring diagram on the inside lid of your product
to determine actual pin out location
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Inductive Sensors
Switch Option E4
Switch Option E6
D-Series
502.969.8000
Wiring Chart
PRODUCT SPECIFICATIONS
General specifications
Switching element function
Rated operating distance
NAMUR NC
sn
Installation
embeddable
Output polarity
NAMUR
sa
SWITCH #
2 mm
0 ... 1.62 mm
0.25
0.2
0.7
Nominal ratings
Nominal voltage
Uo
8V
Switching frequency
0 ... 1000 Hz
Hysteresis
typ. %
Current consumption
Measuring plate not detected
3 mA
1 mA
Standard conformity
EMC in accordance with
Standards
LEAD COLOR
TERMINAL#
BROWN +
BLUE -
BROWN +
BLUE -
BROWN +
BLUE -
BROWN +
BLUE -
BROWN +
BLUE -
10
BROWN +
11
BLUE -
12
IEC / EN 60947-5-2:2004
DIN EN 60947-5-6
(NAMUR)
Ambient conditions
Ambient temperature
Connection type
Core cross-section
0.14 mm2
Housing material
PBT
Sensing face
PBT
Protection degree
IP67
General information
Category
1G; 2G; 1D
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Inductive Sensors
D-Series
502.969.8000
PRODUCT SPECIFICATIONS
General specifications
Switching element function
NAMUR NO
P & F NJ3-18GK-S1N
SWITCH 2
Switching frequency
SWITCH 4
3 mm
Installation
Embed in mild steel
Output polarity
Safety Function
Assured operating distance
0 ... 2.44 mm
Reduction factor rAl
1
Reduction factor rCu
1
Reduction factor rV2A
0
Nominal ratings
Nominal voltage
8V
0 ... 200 Hz
Hysteresis
typ. 0.1%
Current consumption
SWITCH 1
1mA
Calibration Procedure
Never perform switch calibration while an area is known to be
hazardous.
For intrinsically safe models, the unit must be wired in accordance with the
control drawing ES-00210-1.
Connection type
Core cross section
Housing material
Sensing face
Protection degree
Note
2m Silicone cable
0.75mm2
Hostalen PPN, black
Hostalen PPN, black
IP68
Only for non-ferrous metal
General information
Use in the hazardous area
see instruction manuals
Category
1G; 2G; 3G; 1D
When installing a Valvetop product with P&F NAMUR sensors, use of a commercially available switch tester like P&F part# ST0-03 is suggested.
Calibration may be performed using a 24Vdc power supply.
For models mounted in perpendicular orientation, the target disk will have to be rotated to realign the target disk to match the
desired orientation.
Step 1: Grasp the target disk and gently lift until the target disk disengages the orientation pin in the shaft.
Step 2: Rotate the disk as needed to realign the targets.
Step 3: Follow steps 1 through 3 for models mounted in Parallel orientation above.
For reverse acting applications (CCW to close), the switch functions will be transposed. Sw 1 (and Sw 3 if in an V4 model)
become open. Sw 2 (and Sw 4 if in an V4 model) become closed.
The push to set target disk has been designed to accommodate various applications and rotations. If your application is different from
those outlined here, please consult the factory for further information.
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GO Switch
D-Series
502.969.8000
For L2/Z2 models mounted in parallel orientation (see illustration on page 15)
Step 1: With the valve CLOSED position. Push down and slide the target magnet #1 until SW1 activates.
Release the target magnet to lock the position.
Step 2: Rotate the valve to the OPEN position. Push down and slide the target magnet #3 until SW3 activates.
Release the target magnet to lock the position.
Step 3: Cycle the valve CLOSED and OPEN several times to ensure proper calibration.
For L4/Z4 models mounted in parallel orientation (see illustration on page 15)
Step 1: With the valve CLOSED position. Push down and slide the target magnet #1 until SW1 activates.
Release the target magnet to lock the position. Push down and slide the target magnet #3 until SW3 activates.
Release the target magnet to lock the position.
Step 2: Rotate the valve to the OPEN position. Push down and slide the target magnet #2 until SW2 activates.
Release the target magnet to lock the position. Push down and slide the target magnet #4 until SW4 activates.
Release the target magnet to lock the position.
Step 3: Cycle the valve CLOSED and OPEN several times to ensure proper calibration
For models mounted in perpendicular orientation, the target disk will have to be rotated to realign the target disk to
match the desired orientation.
Step 1: Grasp the target disk and gently lift until the target disk disengages the orientation pin in the shaft.
Step 2: Rotate the disk as needed to realign the targets. Use the images provided on the previous page as a reference.
Step 3: Follow steps 1 through 3 for models mounted in Parallel orientation above.
For reverse acting applications (Counterclockwise to close), the switch functions will be transposed. Sw 1 (and Sw 3 if in an
L4/Z4 model) become open. Sw 2 (and Sw 4 if in an L4/Z4 model) become closed.
The push to set target disk has been designed to accommodate various applications and rotations. If your application is different from
those outlined here, please consult the factory for further information.
L2/L4 Specifications
Z2/Z4 Specifications
Repeatability
Repeatability
Response Time
8 milliseconds
Response Time
8 milliseconds
Differential
Differential
Operating
Temperature
Operating
Temperature
Contact Material
Contact Material
Forms
SPDT, Form C
Forms
DPDT, Form CC
Ratings
4A@120VAC / 3A@24VDC
Ratings
Target Material
Ferrous metal
Target Material
Ferrous metal
Sensing Range
Sensing Range
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GO Switch
Ground
COM (Black)
Terminal 2
NO (Blue)
Terminal 3
NC (Red)
Terminal 1
Switch 3
Green to GND
Ground
COM (Black)
Terminal 5
NO (Blue)
Terminal 6
NC (Red)
Terminal 4
Option L4
Switch 1
Switch 2
Green to GND
Ground
Green to GND
Ground
COM (Black)
Terminal 2
COM (Black)
Terminal 5
NO (Blue)
Terminal 3
NO (Blue)
Terminal 6
NC (Red)
Terminal 1
Switch 3
NC (Red)
Terminal 4
Switch 4
Green to GND
Ground
Green to GND
Ground
COM (Black)
Terminal 8
COM (Black)
Terminal 11
NO (Blue)
Terminal 9
NO (Blue)
Terminal 12
NC (Red)
Terminal 7
NC (Red)
Terminal 10
Option Z2
Switch 1
Green to GND
Ground
COM (Black)
Terminal 2
COM (Black/White)
Terminal 5
NO (Blue)
Terminal 3
NO (Blue/White)
Terminal 6
NC (Red)
Terminal 1
NC (Red/White)
Terminal 4
Switch 3
Green to GND
Ground
COM (Black)
Terminal 8
COM (Black/White)
Terminal 11
NO (Blue)
Terminal 9
NO (Blue/White)
Terminal 12
NC (Red)
Terminal 7
NC (Red/White)
Terminal 10
Option Z4
Switch 1
Switch 2
Green to GND
Ground
Green to GND
Ground
Green to GND
Ground
Green to GND
Ground
COM (Black)
Terminal 2
COM (Black/White)
Terminal 5
COM (Black)
Terminal 14
COM (Black/White)
Terminal 17
NO (Blue)
Terminal 3
NO (Blue/White)
Terminal 6
NO (Blue)
Terminal 15
NO (Blue/White)
Terminal 18
NC (Red)
Terminal 1
NC (Red/White)
Terminal 4
NC (Red)
Terminal 13
NC (Red/White)
Terminal 16
Switch 3
Switch 4
Green to GND
Ground
Green to GND
Ground
Green to GND
Ground
Green to GND
Ground
COM (Black)
Terminal 8
COM (Black/White)
Terminal 11
COM (Black)
Terminal 20
COM (Black/White)
Terminal 23
NO (Blue)
Terminal 9
NO (Blue/White)
Terminal 12
NO (Blue)
Terminal 21
NO (Blue/White)
Terminal 24
NC (Red)
Terminal 7
NC (Red/White)
Terminal 10
NC (Red)
Terminal 19
NC (Red/White)
Terminal 22
*The above terminations are typical and may vary depending on your configuration. Refer to the wiring diagram located on the inside top housing for a wiring diagram
specific to your configuration.
D-Series
502.969.8000
Features:
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
Single push button easy calibration eliminates zero/span calibration interaction in both clockwise and counterclockwise actuator/valve
rotation directions.
Non-volatile memory of set points (set points remain after loss of power)
4-20mA power connection is not polarity sensitive
No internal backlash direct shaft position feedback
No gear wear or mechanical binding
Small package size for easier access to limit switch cams. The small packaging allows for additional options that can be mounted in the
valve monitoring enclosure
Position measurement range from 20 to 320. Factory set for 20 to 180 operation in counter clockwise rotation to open and 20 to 90
operation in clockwise rotation to open applications.
Advanced diagnostics includes detection of dead band, out of range indication and detection of internal memory errors
Transmitter PCB is potted and sealed
Included with all valve monitoring switching options, incl. DPDT mechanical
+/- 1% position linearity for the complete device
Selectable +/- 3% over and under travel capability or full linear options set during calibration
Hysteresis: 0.5% of full-scale
Repeatability: 0.3% of full scale
Temperature Range: -40 to 85C
Potentiometer Features
Hollow shaft mounting requires no gears
and has no backlash
Direct shaft position feedback
Capable of 4,000,000 lifetime operations
Better than 0.3 resolution
Conductive plastic Potentiometric sensor
for environmental protection
Temperature Range: -40 to +85C
Electrical Data
-Voltage Input Range: 8.5 - 34 Volts DC
-Standard Output Signal: Two wire 4-20mA
with out of range indication
-Input Polarity: Bi-Directional
Potentiometer Wiring
Blue
Wiper = Black
Red
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4-20mA Transmitter
Is button pressed
and held for at least
0.5 seconds?
NO
YES
Is button released
before 3 seconds?
NO
YES
Is button released
before 5.5 seconds?
Is button released
before 8 seconds?
NO
YES
Calibrate counterclockwise,
device waits for 4ma set point,
LED flashes code 3-1, rotary
NO
YES
Is button
released?
YES
Calibrate counterclockwise,
device waits for 4ma set point,
LED flashes code 5-1, linear
Is button pressed
and released?
NO
YES
Is the set point within
required range?
NO
YES
Device waits for 20ma set point,
LED flashes code 3-3
User moves valve to 20ma position
Is button pressed
and released?
NO
NO
YES
Start position is too high,
LED flashes code 4-4
YES
Is the set point within
required range and has at
least 20 degree of rotation
been detected?
YES
NO
NO
Wrong direction of
rotation occurred, LED
flashes code 4-7
Less than allowed
rotation has occured,
LED flashes code 4-5
NO
Internal error, LED
flashes code 4-1
NO
D-Series
502.969.8000
Probable Cause/Solution
Start and stop positions are less than 20, increase valve
rotation between start and stop positions to greater than 20.
Interpretations
0-0
Calibrated
3-1
3-2
3-3
4-1
Calibration Required
4-3
4-4
4-5
4-6
4-7
5-1
5-2
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4-20mA Transmitter
4)
5)
6)
7)
8)
TRANSMITTER MODULE
BRACKET
ALIGNMENT BOSS
4-20mA POSITION
TRANSMITTER
POTENTIOMETER
1K OR 10K
D-Series
502.969.8000
Option #1: +/- 3% Over and Under Travel at the Set End Points (Rotary):
1)
2)
3)
4)
5)
6)
7)
8)
As the shaft rotates, make sure the potentiometer is not rotating through its deadband area. The red dot located on the potentiometer should
not rotate past the area marked with red during the full rotation of the valve. If it does, reposition the shaft.
Apply power to unit (LED should be continuously on to indicate the unit has been calibrated or flashing the 4-1 code to indicate the unit has
not been calibrated)
Counter-clockwise calibration - Press the button greater than 0.5 seconds and less than 3 seconds if you are going to calibrate using a
counter-clockwise rotation from the 4mA position to the 20mA position. (LED will start flashing a 3-1 code indicating that calibration mode is
active and the unit is waiting to calibrate the 4ma position).
Clockwise calibration - Press the button greater than 3 seconds and less than 5.5 seconds if you are going to calibrate using a clockwise
rotation from the 4mA position to the 20mA position. (LED will start flashing a 3-2 code indicating that calibration mode is active and the unit
is waiting to calibrate the 4mA position).
Rotate valve to the desired position corresponding to 4mA. (This can be the open or closed position)
Press the button to capture the 4mA value (The LED will start flashing a 3-3 code indicating that the unit is waiting to calibrate the 20mA
position)
Rotate valve to the desired position corresponding to 20mA (This will be the position opposite of the position in step 3 or step 4)
Press the button to capture the 20mA value (The LED will turn on continuously)
Option #2: No Under and Over Travel at Set End Points (Full Linear):
1)
2)
3)
4)
5)
6)
7)
8)
As the shaft rotates, make sure the potentiometer is not rotating through its dead band area. The red dot located on the potentiometer should
not rotate past the area marked with red during the full rotation of the valve. If it does, reposition the shaft.
Apply power to unit (LED should be continuously on to indicate the unit has been calibrated or flashing the 4-1 code to indicate the unit has
not been calibrated)
Counter-clockwise calibration - Press the button greater than 5.5 seconds and less than 8 seconds if you are going to calibrate using a
counter-clockwise rotation from the 4mA position to the 20mA position. (LED will start flashing a 5-1 code indicating that calibration mode is
active and the unit is waiting to calibrate the 4mA position).
Clockwise calibration - Press the button greater than 8 seconds if you are going to calibrate using a clockwise rotation from the 4mA
position to the 20mA position. (LED will start flashing a 5-2 code indicating that calibration mode is active and the unit is waiting to calibrate
the 4mA position).
Rotate valve to the desired position corresponding to 4mA. (This can be the open or closed position)
Press the button to capture the 4mA value (The LED will start flashing a 3-3 code indicating that the unit is waiting to calibrate the 20mA
position)
Rotate valve to the desired position corresponding to 20mA (This will be the position opposite of the position in step 3 or step 4)
Press the button to capture the 20mA value (The LED will turn on continuously)
NOTE:**The potentiometer has been factory set for typical valve rotation ranges from 20 to 180 degrees in counter-clockwise rotation applications
from the 4mA position to the 20mA position and from valve rotation ranges from 20 to 90 degrees in clockwise rotation applications from the 4mA
position to the 20mA position. Please contact TopWorx for proper potentiometer set up for ranges greater than specified above.
LED LIGHT
PUSHBUTTON
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HART
Is button pressed
and held for at
least 0.5 seconds?
NO
YES
Is button released
before 3 seconds?
NO
YES
Is button released
before 5.5 seconds?
Is button released
before 8 seconds?
NO
YES
NO
YES
Is button
released?
YES
Calibrate counterclockwise,
device waits for 4ma set point,
LED flashes code 5-1, linear
Is button pressed
and released?
NO
YES
Is the set point within
required range?
NO
YES
Device waits for 20ma set point,
LED flashes code 3-3
User moves valve to 20ma position
Is button pressed
and released?
NO
NO
YES
Start position is too high,
LED flashes code 4-4
YES
Is the set point within
required range and has at
least 20 degree of rotation
been detected?
NO
YES
YES
YES
Is calibration in handheld
device successful?
YES
NO
Wrong direction of
rotation occurred, LED
flashes code 4-7
Less than allowed
rotation has occured,
LED flashes code 4-5
Greater than allowed
rotation has occurred,
LED flashes code 4-6
Calibrated LED on
NO
NO
D-Series
502.969.8000
Make sure that the HART power is not activated before attaching the signal/power wires, wires must be 12 to 24 AWG, to the HART device.
If not already connected, connect the device to the two HART signal/power lines. Pin 1 on the terminal block is the positive input and pin 2 is
the negative input. Pin 1 is the first pin on the left of the module and pin 2 is the middle pin (see picture below). Once connected, activate the
HART power/signal from the control system.
PIN#1
Positive Input
3)
4)
5)
6)
7)
8)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
Connect the Emerson 375 Handheld device to the HART signal lines. Red marked lead to the positive signal
line and the black lead to the negative signal line.
Activate the 375.
Select the HART Application option from the menu selections.
If a warning screen is shown. Disregard and hit CONTINUE.
If the Modification has been made to the configuration screen is shown, hit OK.
ANYTIME the non-zero status code(s) screen is shown, hit YES.
The main menu should now be shown indicating:
- Process Variable
- Device Service
- Review
Select the 2. Device Service option.
Select the 5. Calibrate option.
Select OK when the You are to set the valve operation ranges screen is shown.
Select either the 1. Counter clockwise or 2. Clockwise options depending on the application.
Make sure the potentiometer is not rotating through its deadband area.
Follow the on screen instructions. Select OK when the valve is at the 4mA setpoint (Is the valve fully closed?)
After the first set point is saved, rotate the valve to the 20mA position.
Select OK.
The set points are now calibrated.
If error occurs, the screen will display the error type and abort.
Re-calibrate if an error occurs and again make sure the potentiometer is not rotating through its deadband area.
ScratchPad
Listen For PC
Settings
FOUNDATION Fieldbus
Application
HART Application
1 Offline
2 Online
3 Utility
4 HART Diagnostics
3 Review
2 Device Service
1 Process Variable
1 PV LRV
2 PV URV
3 PV USL
4 PV LSL
5 PV Min span
6 PV Unit
7 Valve mode
8 Calibrated
9 Software rev
10 Hardware rev
1 PV LRV
2 PV URV
3 PV unit
4 PV LSL
5 PV USL
1 Warm reset
2 Factory reset
3 Range values
4 Calibrated
5 Calibrate
6 D/A trim
7 Loop test
8 Valve mode
9 Device info
1 Tag
2 Descriptor
3 Message
4 Date
5 Poll addr
6 Long tag
7 Software rev
8 Hardware rev
3 Status
1 PV
2 PV Loop current
1 Poll address
2 Loop current mode
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HART
D-Series
502.969.8000
Interpretations
0-0
Calibrated
3-1
3-2
3-3
4-1
Calibration Required
4-3
4-4
4-5
4-6
4-7
5-1
5-2
Probable Cause/Solution
Start and stop positions are less than 20, increase valve rotation between start and
stop positions to greater than 20.
Rotation has exceeded the 320 limit. Decrease valve rotation between start and stop
positions to less than 320.
Calibration rotation was in the wrong direction or the potentiometer passed through
the dead-band position.
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FOUNDATION Fieldbus
Foundation Fieldbus
Optional Piezo Pilot Valve
FF Communication Module
Button Board
FF Bus Connection
+ Signal
Shield
- Signal
Ground Strap
Optional Potentiometer Connector
Terminal Board to Optional Valve
Position Switches and Piezo Pilot Valve
FF Communication Module
Target Wheel
Target Magnet
Potentiometer (Optional)
Spool Valve
Fail Closed Spool Valve Replacement Assemblies
PART #
DESCRIPTION
PART #
DESCRIPTION
AV-BFCVA20
AV-BFLPVA20
AV-BFCVS20
AV-BFLPVS20
AV-BFCV620
AV-BFLPV620
D-Series
502.969.8000
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.
Signal
DI
AI
Channel
Unit
None
None
None
None
Instrument temperature
Analog position
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
In closed position
Calibrating closed
position is in process
OPEN
In open position
Calibrating open
position is in process
Closed GO switch is
triggered during calibration
Open GO switch
is triggered during
calibration
on
off
LED=
Flashing
on
off
LED=
Flashing
Time
Function
Reverse valve
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FOUNDATION Fieldbus
Operation (Cont.)
Table 4 Calibration Statuses
Status
Description
Calibration needed
Device is not calibrated or calibration for the other end position is needed.
Running
Timed Out
Both triggered
Range error
In deadband
No sensor detected
Successful
Device is calibrated
D-Series
502.969.8000
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.
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).
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 encountered a power loss.
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.
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FOUNDATION Fieldbus
Operation (Cont.)
d.
e.
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.
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.
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.
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.
D-Series
502.969.8000
Operation (Cont.)
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).
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FOUNDATION Fieldbus
Operation (Cont.)
b.
D-Series
502.969.8000
Operation (Cont.)
Plantweb
Recommended Actions
Failed
Off Spec
Maint.
Check
Failed
Maint.
Check
Calibration Failed
System Temperature
Exceeded
Software Error
Travel Deviation
Shutdown is Set
Buttonboard Failure
Button board is not functioning correctly, replace valve controller when possible.
Advisory
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FOUNDATION Fieldbus
Operation (Cont.)
Table 5 Recommended Actions and Default Setting/Mapping for Alerts (Cont.) (Note that no alert is masked in factory default
settings)
Plantweb
Recommended Actions
Failed
Off Spec
Maint.
Check
Failed
Maint.
NV Memory Failure
Electronics Failure
Advisory
D-Series
502.969.8000
Operation (Cont.)
Restart Methods
You can restart the module via different mechanisms. Depending on which restart option is used; the communication links, static parameters, etc.
may be affected. However, due to the effect that a restart can have on the module, and therefore the process, restarting the module should be used
cautiously.
Restart using bus command
There are several Restart options as described bellow. This can be done via parameter RESTART in the Resource block. The following is
a brief description for each of the restart options:
a. Resource
Performing a Resource-restart resets the dynamic variables in the Function Blocks but has no observable effect on the module.
However, the dynamic variable within the module are reset and this could cause a bump in your process.
b. Defaults
Performing a Restart with Defaults should be done with care. This restart sets the static parameters of the function blocks in the
module to their default state. It also disconnects all links within the module. After performing a Restart with Defaults, a Restart
Processor should be performed.
c. Processor
Performing a Restart Processor has the same effect as removing power from the module and re-applying power. This is typically
used to restart the module if device shutdown is set due to internal communication lost caused by incorrect power application.
d. Valve Controller Processor
Performing a Valve Controller Processor-Restart has the same effect as removing power from the module and re-applying power.
This is typically used to restart the control part of the module.
e. Valve Controller Defaults
Performing a Valve Controller Defaults-restart should be done with care. This restart sets the calibration to default. It will erase the
calibration information. It has the same effect as restart locally using buttons in the following subsection.
f.
Restore Factory Default Blocks
Performing Restore Factory Default Blocks restores default blocks i.e. manufacturer pre-instantiated blocks. It will clear complete
NV memory of device and this will result in NV Memory Failure error. To clear this error in device, a Restart Processor should
be performed.
Restart locally using buttons
To set valve controller to factory default locally using buttons: power off device, push both OPEN and CLOSE buttons, power on device,
release buttons when status LED is on.
Device Options
Enable/disable field diagnostics alerts simulation
This method will enable/disable field diagnostics alerts simulation.
Enable/disable access to the TB base record parameter
This method will enable/disable access to the Transducer Block base record parameter.
DD Version Info
This method will show the build number, date and info for the device description files.
To download more information concerning the Valvetop D-Series Valve Controller with Foundation Fieldbus,
visit us online: http://www.topworx.com/downloads/data.html Or call 502-969-8000 and
reference # ES-02512-1
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FOUNDATION Fieldbus
Calibration
Switch
Calibration
Never perform the switch calibration procedure where area is known
to be hazardous.
Close
Inputs
Outputs
TopWorx
SCM-ASi 2.1
- D3 +
LEDs
Open
Solenoid
Terminals
Once pneumatic hookup and wiring has been completed close the
valve using the SCM-ASI on-board calibration switch. If no AS-i
network connection is available, you may connect a 24VDC power
supply to the ASI terminals as previously described.
- D2 +
AS-i
Terminals
+ASI-
Step 1
AUX Input
Terminals
Note: Internal mount pilot in the DXP/DXS is 0.6W. For any externally mounted,
or customer supplied, solenoid valve 4 watt maximum power consumption is
allowed. A 170 mA max surge current limitation is required to prevent activation
of the short circuit protection.
AS-i Specifications
A
B
Device ID
Device I/O
Free Profile
2 Inputs / 2 Outputs
Inputs
D2 Open Limit Switch
0
D3 Closed Limit Switch 1
Switch Open
Switch Closed
Outputs
D1 Solenoid #1 (Close)
D0 Solenoid #2 (Open)
De-energize Solenoid
Energize Solenoid
0
1
Output Power
Current &
Output Power
Voltage
Step 2
With the valve in the CLOSED position, disengage the BOTTOM cam
from the splined hub and rotate Clockwise until the Red LED lights.
Release the cam to re-engage the splined hub.
Step 3
Open the valve by sliding the calibration switch to the OPEN position.
Step 4
Once the valve is in the OPEN position, disengage the TOP cam from
the splined hub and rotate Counter-clockwise until the Green LED
lights. Release the cam to re-engage the splined hub.
Step 5
Cycle the valve CLOSED and OPEN several times using the
calibration switch to verify both limit switches are maintaining
their set points.
Step 6
Finally, slide the calibration switch to the ASI position. The
AS-i network will now have full control of the valve once the
SCM-ASI has been addressed.
Wiring
Step 1
For internally-mounted or external pilot device(s), wire the + and - leads to the terminals marked D0 (open) and D1 (closed). The internallymounted pilot has an LED indicator for power verification.
Note: For an externally mounted solenoid valve, 4 watt maximum power consumption is allowed. A 160 mA surge current limit is required to
prevent activation of the short circuit protection circuit.
Step 2
Connect the AS-i communication wires to the terminals marked AS-i + and AS-i - .
Note: For calibration of the switches, a 24 VDC power supply may be used instead of an ASI Controller. If an ASI Controller is not
available, wire +24 VDC to ASI+, and GND to ASI-. The calibration switch will still be able to actuate the valve.
Additional Instruction for wiring an external switch input.
For externally mounted auxiliary input limit switches, wire switches to terminals marked -D2+ for open switch and -D3+ for closed limit switch.
NOTE: Refer to the wiring diagram on the inside lid of your product to determine actual pin out location.
D-Series
502.969.8000
Calibration
Never perform limit switch calibration while an area is
known to be hazardous.
Secondary or Dual
Pilot Spool Valve
Terminals
To I/O
Logic
Signal IN
First, be sure you have an air supply connected, and the appropriate spool valve to actuator connections. Set the air supply
between 80 and 100psi.
Step 1
To I/O
Voltage IN for
Pilot Valve Control
To I/O
Logic
Signal IN
To Pilot Valve
To I/O
Step 2
With the valve in the CLOSED position, disengage the lower
cam from the splined Hub and rotate clockwise until the Red
LED lights. Release the cam to re-engage the splined Hub,
making sure it is seated on the splines. This sets the CLOSED
limit switch.
Secondary or Dual
Pilot Spool Valve
Terminals
To I/O
Logic
Signal IN
Step 3
Cycle the valve to the OPEN position using the attached control
equipment.
Step 4
To I/O
Voltage IN for
Pilot Valve Control
To I/O
Logic
Signal IN
To Pilot Valve
Step 5
To I/O
Cycle valve several times to insure limit switches maintain calibration. Check that the target assembly is secure to the actuator pinion, and all air connections are tight.
Electrical Ratings
SCM R2/R4
NOTE: Refer to the wiring diagram on the inside lid of your product
to determine wiring configuration and actual pin out location.
**Install per control drawing #ES-01743-1
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Reed SCM
SCM PS (Shown)
First, be sure you have an air supply connected, and the appropriate
spool valve to actuator connections, as illustrated in the Pneumatic
Hookup section. Set the air supply between 80 and 100psi.
Step 1
For Intrinsically Safe models, unit must be wired according to Control
Drawing S-K087/087A to prevent possible damage to I.S. components,
or for standard explosion-proof units: Using a 24VDC regulated power
supply, connect (+) to COM and (-) to NO terminals. Maximum current
rating for units with LEDs is 0.25A.
Caution: Many power supplies do not have clipping circuits to
dampen surge currents; therefore, ALWAYS use a load resistor
with a value of 200 to 2500 Ohms in series with the COM or NO
legs of the circuit or damage may occur.
A 9V battery may be used as an alternate power source. No load resistors are required.
Voltage Drop
SCM PS w/LEDS
0.25A@24VDC
0.20A@120VAC
5V
SCM PN w/o
LEDS
1.0A@24VDC
0.20A@120VAC
0V
Step 2
With the valve in the CLOSED position, disengage the lower Cam from
the splined Hub and rotate clockwise until the Red LED light illuminates.
Release the Cam to re-engage the splined Hub, making sure it is seated on the splines. This sets the CLOSED limit switch.
Step 3
Cycle the valve to the OPEN position using the attached control equipment.
Step 4
While the valve is in the OPEN position, Disengage the upper Cam from
the splined Hub and rotate the upper Cam counterclockwise until the
Green LED illuminates. Release the Cam to re-engage the splined Hub,
making sure to seat the Cam on the splines. This sets the OPEN limit
switch.
Step 5
Cycle valve several times to insure the limit switches maintain calibration. Check that the target assembly is secure to the actuator pinion,
and all air connections are tight.
When using the SCM-PN module without LEDs, continuity may be
verified using a continuity light or by using an Ohmmeter in series
with NO connection.
D-Series
502.969.8000
Current/Voltage
Open/Closed
Indication
Module Voltage
18-28VDC
Module Current
50mA (MAX)
20mA
CALIBRATION
SWITCH
DIAGNOS-
COM
COM
LOAD
PASS/FAIL
RELAY
ALARM COM
PSI
800mA@24VDC MAX
250mA@125VAC MAX
800mA@24VDC MAX
250mA@125VAC MAX
PARTIAL
STROKE TEST
FEEDBACK
24VDC(-)
NO
200(4W) to
2500(1/4W)Ohms
The diagnostic relay outputs the status flash code as shown in the
Message Table. (see pg.38)
PILOT COIL
1300ms
500ms
500ms
ESD MODULE CONTAINS (2) REED
RELAYS FOR FULL OPEN/CLOSED
INDICATION PLUS ESD TIMER CIRCUIT
The Pulse Train will repeat 3 times. In order to use this diagnostic
relay output, control logic should count the number of positive
transitions in order to get the message number. Clear the count
register in the logic when you see a logic low (open) for more than
one second. The Pulse Train can be reset anytime by activating
the Calibration Switch or the PST/Calibration Activation Input.
Pass/Fail Relay:
The Pass/Fail Relay indicates whether the PST passed or failed.
In this example the relay is closed (high) from the last successful
Partial Stroke Test.
When the PST switch is pressed for less than 5 seconds the test
begins and the Pass/Fail Relay opens (low). The Pass/Fail Relay
closes again once the unit completes and passes the Partial Stroke
Test.
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ESD
Hardware Configuration:
1. Ensure that the valve is in the CLOSED position.
2. Refer to the drawing at right which shows the correct orientation of the
GO Switch target and sensor cams for FAIL CLOSED valves which are
normal acting (see page 3).
3. If the unit conforms to this configuration, you may proceed to calibration.
If not, complete Hardware Configuration steps 4-7
4. Lift the target against the springload and rotate it such that the magnet is
counterclockwise from the GO Switch
5. Slide the magnet in the target wheel so as to position it approximately
one inch from the edge of the GO Switch
6. Press down on the lower cam and rotate it such that it is squarely aligned
to the front of the electronics module. The red light on the module should come on
7. Lift up on the upper cam and rotate it such that it is 90 clockwise from the electronics module.
Calibration:
1. Before performing calibration, make certain the valve is fully open, and the target button is set to the proper partial position. NOTE: If the
valve is not fully open, the test will abort and the LED and diagnostic relay will flash message code 7-7 indicating that the valve
is not fully open. The Pass/Fail relay will be turned OFF.
2. Press and hold the push button on board for five to ten seconds.
3. The activation relay will be turned ON to initiate valve closing.
4. The valve will move until the GO Switch detects the partial stroke position.
5. The GO Switch will send feedback indicating that the pre-determined 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 time ranges are from fifty milliseconds to eight seconds. This partial stroke calibration time will be recorded in the
EEPROM (memory) of the micro controller. EEPROM will retain the value until your next calibration.
7. If the calibration is successful, the Pass/Fail relay will be turned ON and both the LED and diagnostic relay will flash message code 3-3.
8. After the LED flashes code for three times, both the LED and diagnostic relay will be steady, signifying that the calibration is complete.
Reset of the flashing LED and the diagnostic relay may be performed at anytime while the LED is flashing by pressing the calibration
button.
D-Series
502.969.8000
Diagnostic Relay
Message
No action required
1-1
Need to perform the calibration procedure before the partial stroke test
2-2
No action required
3-3
Calibration completed
No action required
4-4
5-1
5-2
5-3
5-5
The valve did not reach the partial stroke position within the allotted time. Possible causes include:
1) The valve is stuck or sluggish
2) The GO Switch target for the partial stroke position is set incorrectly
3) The shaft is broken
6-6
Contact factory
7-7
Unit cannot calibrate or run a partial stroke test without the valve starting in the open position.
Check the following:
1) Air supply to actuator
2) Solenoid is powered
3) If valve is fully open, adjust the open switch cam to indicate the open position
Hardware failure
Contact factory
Solid ON
Continuous
fast
flashing
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ESD
No
Is memory ok?
Yes
No
Is device calibrated?
Yes
No
Is button
released before
5 seconds?
Is button
released before
10 seconds?
No
Is button
released before
15 seconds?
No
Yes
Yes
Is button
released before
20 seconds?
No
No
Is button
released?
Yes
Yes
Yes
No
Yes
No
No
Valve opens
Yes
No
Is device calibrated?
Yes
No
Is stored calibrated
value for partial stroke time
within range?
No
Yes
No
Yes
No
Valve closes
Valve closes
Is maximum
allowed time
(8s)passed?
No
Is partial stroke
position reached?
Is calibrated
time passed?
No
No
No
No
Yes
Is minimum
allowed time (50ms)
passed?
Valve opens
Is writing
tolerance
range value to
memory
successful?
Yes
Valve opens
Valve opens
Yes
Yes
Yes
Yes
Is minimum allowed
time (50ms) passed?
Is partial
stroke position
reached?
Is writing
tolerance
range value to
memory
successful?
No
Is writing
tolerance
range value to
memory
successful?
No
Yes
Yes
Is writing
No
calibrated value
to memory
successful?
Yes
Yes
LED displays
valve is not
calibrated code
1-1 Pass/fail
LED displays
valve closing
time failure code
5-5 Pass/fail
relay state 0
LED displays
partial stroke test
complete code 2-2
for all tolerance range
Pass/fail relay state 1
LED displays
valve has not
moved code
4-4 Pass/fail
relay state 0
LED displays
valve is not
fully open code
7-7 Pass/fail
relay state 0
LED displays
valve closing
time failure code
5-5 Pass/fail
relay state 0
LED displays
calibration
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
D-Series
502.969.8000
T=
3 x PFDave
(1.2 x 10-6 + VALVE + ACTUATOR ) x 2.738 x 10-6
As a guide, the following table gives proof test intervals for the Topworx ESD valve controller together with the selected valve and actuator failure
rates in order to achieve 50% of the total PFDave required for SIL3 (5 x 10-4).
1 x 10-4
2,327
1 x 10-5
6,994
-6
15,780
1 x 10-7
20,528
1 x 10
25000
20000
HOURS
VALVE + ACTUATOR
(per hour)
15000
10000
5000
0
1x10-4
1x10-5
1x10-6
Failure Rate
http://www.topworx.com/downloads/data.html
or call 502-969-8000 and reference # ES-00936-1.
1x10-7
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DeviceNet
Step 4: While the valve is in the OPEN position, disengage the top cam
from the splined Hub and rotate Counterclockwise until the Green LED
lights. Release the cam to re-engage the splined Hub. Be sure the cam
is seated on the Hub.
Step 5: Cycle the valve CLOSED and OPEN a few times using the
calibration switch to verify both limit switches are maintaining their set
points.
Step 6: Finally, slide the calibration switch to the DeviceNet position.
The DeviceNet network will now have full control of the valve once the
SCM-DN has been addressed.
Polled I/O
The client can poll (read) the input and command the output status from the
SCM-DN and can energize or de-energize the discrete outputs on the SCM-DN.
The status LEDs report the actual state of the valve; i.e. the red led is lit when
the valve is closed, and the green led is lit when the valve is open.
Step 3: Set the baud rate and address of the SCM-DN if different from
default (See Baud Rate Selection Table, pg. 42).
The client controls the valve outputs by sending a poll command to the SCMDN. If no data is sent to the SCM-DN during a poll, then the outputs are put into
the idle state and their actions are then governed by the Idle Action and Idle
Value attributes of the Parameter Object (See Configuration Parameters Table,
pg. 42).
Both idle and fault operations are implemented for the valve output points. The
outputs can be set individually to hold last state or to implement user-defined
states upon receipt of an idle command or upon a fault condition. You can
implement these actions via the Parameter Object (See Configuration
Parameters Table, pg. 42).
Step 4: Make sure that there is power on the DeviceNet network and
that it is plugged into a Master device.
Step 6: In fixed baud rate mode, the SCM-DN will undergo its initialization sequence, flashing both LEDs. After approximately 4 seconds, the
Module Status LED (labeled MS) will go on solid green and the
Network LED will flash green.
Step 7: In autobaud mode, the SCM-DN the Module Status LED
will continue to blink until the SCM-DN recognizes valid traffic on
the DeviceNet link and syncs to a specific baud rate.
Step 8: The green Network Status LED (labeled NS) will go on solid
once the Master recognizes the unit on the link and allocates the
connection (commissions it).
Step 9: The SCM-DN is now operating on the network.
Step 1: Once pneumatic hookup and wiring has been completed close the
valve using the SCM-DN on-board calibration switch. If no DeviceNet network
connection is available, you may connect to a 24VDC power supply.
Step 2: Place the calibration switch in the closed position. With the valve in the
CLOSED position, disengage the bottom cam from the splined Hub and rotate
Clockwise until the Red LED lights. Release the cam to re-engage the splined
Hub. Be sure the cam is seated on the Hub.
Step 3: Open the valve by sliding the calibration switch to the OPEN position.
Step 3: If you change the switches, the new selection will not become
effective until the unit is power cycled or a Reset command is received
by the SCM-DN.
Step 4: Switch 6 of SW2 selects the Modbus protocol for ASCII or RTU
as shown in the Modbus Protocol Table, pg 42.
D-Series
502.969.8000
CALIBRATION SW
DEVICENET
MODBUS
SCM-DN
MS/TX NS/RX
ALARM
RESET
CLOSED OPEN
AUX- AUX+
+OUTPUTS
OPEN
AUTO
CLOSE
O
N
ASCII/RTU
MODBUS*
FRAMING
2
V- CANL CANH
ADDRESS
O
N
BAUDRATE
V+
DNET
000
Address Selection
SW 1,1
Node
Address
SW 1,2
SW 2,1
SW 2,2
125k
OFF
OFF
32
16
250k
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
500k
ON
OFF
OFF
OFF
OFF
OFF
OFF
ON
Autobaud
ON
ON
OFF
OFF
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
OFF
ON
OFF
OFF
5
...
OFF
OFF
OFF
ON
OFF
ON
62
ON
ON
ON
ON
ON
OFF
63
ON
ON
ON
ON
ON
ON
DeviceNet Modbus
DeviceNet
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
7,N,2
7,E,1
7,O,1
8,N,1
8,N,2
8,E,1
8,O,1
Modbus Protocol
Modbus Protocol
ASCII
RTU
DIP Sw Position
SW 2,6
OFF
ON
Parameter Name
Values
Default Setting
Default Value
0 to 65535
Disabled
Description
0 to 65535
Disabled
0 to 4294967295
Disabled
0 to 255
Disabled
255
0 to 255
Disabled
0 or 1
0 thru 3
OFF
0 = OFF
1 = Open
2 = Close
3 = No change
0 or 1
0 thru 3
OFF
10
Assembly Config
1 to 4
Standard Assembly
bytes
bytes = last Open & Close Times
bytes + Cycle Count
bytes + last Open/Close Times + Cycle Count
www.topworx.com
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.
Exhaust of Port 2
Supply
Exhaust
of Port 4
Exhaust of Port
2
Supply
Exhaust of Port 4
(when actuator closes)
(when
actuator opens)
(when actuator
closes)
(when actuator opens)
1
4
5
Pilot Valve
Internally
Mounted
Pilot Valve
Internally
mounted
4
Port to Close
Min. Operating
Pressure
Max Consumption
Rate
Ambient
Temperature Range
Flow Coefficient
1.2Cv or 3.0Cv
Environment Rating
Port Size
Manual Override
Available in Latching/Non-Latching
Push Type & Palm Actuator Type
Valve Body
Pilot Valve
Valve
Internally
Mounted
Supply
55
Plug
Port to
Close
Port to Open
Dont forget!
Supply
33
11
44
Highly Recommended
Port to Open
Plug
Port to
to Open
Open /Close
Port
1
4
22
DOUBLE
SPRING ACTING
RETURNACTUATORS
ACTUATORS
Seals
BOTTOM VIEW
Max Operating
Pressure
Port to
Actuator Open
Port to
Port to
Actuator
Actuator
OpenClose
Port to
Actuator Close
Supply
Medium
TOP VIEW
TOP VIEW
Pilot Valve
Internally
mounted
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
2
2
4
wrap on the second thread from
the 4leading thread of the fitting.
This will
FAIL CLOSED
FAIL CLOSED
prevent tape shreds from contaminating the spool valve seals.
3
A flow control may be used in Port 3, but should NEVER BE USED in Port
5. Any blockage or restriction may cause an internal pressure build-up in2
2
4
4
side the enclosure and pose a safety issue.
BLOCK CENTER
BLOCK CENTER
D-Series
502.969.8000
Pilot
Assembly
Manifold
YELLOW Urethane
Tubing (Work)
4- 40 x .25"
SEM screw
TORQUE
100 IN-OZ
10-32 Metal
Barb Fitting
TORQUE 60 IN-OZ
Bracket
RED
Urethane
Tubing
(Supply)
4-40x.25 (x2)
Bracket
10-32 Metal
Barb Fitting
RED
Urethane
Tubing
(Supply)
10-32 Metal
Barb Fitting
TORQUE 60 IN-OZ
ORIFICE TO BE USED
IN EXPLOSION PROOF
APPLICATIONS ONLY
Orifice
Assem-
F7
F9
F18
F21
F17
F16
4- 40 x .25"
SEM screw
TORQUE
100 IN-OZ
Coil 1
Pilot
Assembly
YELLOW Urethane
Tubing (Work)
RED Urethane
Tubing (Supply)
YELLOW Urethane
Tubing (Work)
Bracket
Coil 2
4- 40 x .25"
SEM screw
TORQUE
100 IN-OZ
10-32 Metal
Barb Fitting
I.S. Pilot
Assembly
RED
Urethane
Tubing
(Supply)
RED Urethane
Tubing (Supply)
YELLOW Urethane
Tubing (Work)
10-32 Metal
Barb Fitting
TORQUE 60 IN-OZ
4- 40 x .25"
SEM screw
TORQUE
100 IN-OZ
Bracket
10-32 Metal Plug
Barbed
Y Fitting
Bracket
Barbed
Y Fitting
Spool Valve
Without Manual Override
ORIFICE TO
BE USED IN
EXPLOSION
PROOF
APPLICATIONS
ONLY
Orifice
Assembly
www.topworx.com
D-Series
502.969.8000
www.topworx.com
D-Series
502.969.8000
http://www.topworx.com/downloads/data.html
Or call 502-969-8000
www.topworx.com
Safe Use
User instructions (in compliance with ATEX 94/9/EC Directive, Annex II, 1.0.6)
Instructions for safe selection, installation, use, maintenance and repair
1)
2)
3)
4)
5)
6)
7)
8)
The IIC enclosures are excluded from use in carbon disulphide atmospheres.
The air pressure to the valve block, when fitted, shall not exceed 10.0 bar.
For ambient temperatures above 110C, the degrees of ingress protection IP66 and IP67 are not endorsed.
The slotted hexagonal head cover screws are not of standard form; they shall only be replaced with identical screws
sourced from the equipment manufacturer.
The hexagonal head cover screws are to be replaced only with stainless steel 304, grade A2-70 or A4-80 screws to
ISO 35061.
Cover fasteners are to be tightened to a torque valve of 10.85Nm (8 ft/lbs) minimum.
D-Series
502.969.8000
Description
PTB 01ATEX2191
LCIE 02ATEX6122X
Sira 12ATEX2192U
The installer shall confirm which certified sub-assemblies are contained within the equipment and ensure compliance
with the appropriate certificate (with particular reference to input parameters)
1. The 4-20 mA loop circuit and the various additional sub-assemblies (switches, sensors and valves) shall be treated as separate intrinsically safe circuits.
2. The DXR (resin) enclosure shall only be installed where there is a low risk of mechanical damage.
3. The switchbox may contain simple switches, which shall have a maximum input power (Pi) of 1.3 W for T4 or 0.7
W for T6 from an intrinsically safe supply.
4. For a T4 temperature class, the switchbox may contain simple switch and resistor arrangements, which shall
have a maximum input power (Pi) of 0.7 W from an intrinsically safe supply. These are not permitted for a T6 temperature class.
5. For a T6 temperature class, the input parameters to sensors covered by PTB 99ATEX2219X, PTB 00ATEX2032X, PTB 00ATEX2048X or PTB 00ATEX2049X shall be limited to Ui = 16V, Ii = 25mA, Pi = 64mW.
6. For a T6 temperature class, the Turck proximity sensors listed in certificates KEMA 02ATEX1090X shall have the
maximum input parameters as follows:
Type AX & GX: Ui = 15V, Ii = 20mA, Pi = 200mW
All other sensors: Ui = 15V, Ii = 60mA, Pi = 130W
7. When the equipment incorporates a 4-20 mA Transmitter Module (Sira 12ATEX2192U), the manufacturer may apply the marking II 1G or II 2 D or II 2 GD. A T6 temperature class is not permitted with this Module fitted. The ambient temperature is limited to a maximum range of -40C to +53C, but this range may be reduced, depending on the
enclosure and gasket type, as well as the internal sub-assemblies fitted. Additionally, the output from the 4-20mA
Transmitter Module shall only be connected to a Novotechnic WAL305 potentiometer
Preventative Maintenance
The TopWorx Valvetop is designed to operate for one million cycles without servicing. Call TopWorx when you are approaching
this milestone for a preventative maintenance kit and instructions.
www.topworx.com
Warranty
35-13319M
AV-S24VPMRK
35-83358M
AV-S110VPMRK
AV-SP20PMRK
SCM-FF
SCM-AS
AS-Interface module
SCM-DN
DeviceNet module
AV-MSW1
AV-E1
AV-TSW1
AV-420TMRK
AV-BFLPVA20
AV-BFLPVS20
AV-GB002
AV-BFLPV620
AV-YB002
AV-BB002
AV-4B002
Standard shaft
Buna-N O-Rings & (2) cam Assembly w/ Hardware
AV-NSB201
NAMUR Shaft
Buna-N O-Rings & (2) cam Assembly w/ Hardware
Standard shaft
Buna-N O-Rings & (2) Target Assembly w/ Hardware
AV-SNB205
NAMUR shaft
Buna-N O-Rings & (2) Target Assembly w/ Hardware
NAMUR Shaft
Buna-N O-Rings & (2) cam Assembly w/ Hardware
AV-SSB202
Standard Shaft
Buna-N O-Rings & (2) cam Assembly w/ Hardware
AV-BFCVA20
AV-BFCVS20
AV-BFCV620
AV-BBCVA20
AV-BBCVS20
AV-BBCV620
Consult Factory
To order replacement parts or for information
concerning parts or spool valve options not listed call
TopWorx at 502-969-8000
D-Series
Warranty
502.969.8000
www.topworx.com
D-Series
Switch Description
Mechanical switch - SPDT
-40C to +80C
-20C to +60C
35 GO Switch SPDT
-60C to +80C
-20C to +60C
35 GO Switch DPDT
-60C to +80C
-20C to +60C
-40C to +80C
-20C to +60C
-40C to +80C
-20C to +60C
-40C to +80C
-20C to +60C
PS
-40C to +80C
-20C to +60C
PN
-40C to +80C
-20C to +60C
AS
Asi
-40C to +80C
-20C to +60C
DN
DeviceNet
-40C to +80C
-20C to +60C
FF
Foundation Fieldbus
-40C to +80C
-20C to +60C
MB
Mod Bus
-40C to +80C
-20C to +60C
_X
4-20mA Transmitter
-40C to +80C
-20C to +60C
_H
-40C to +80C
-20C to +60C
0A
1k potentiometer
-40C to +80C
-20C to +60C
0B
10k potentiometer
-40C to +80C
-20C to +60C
NJ2-V3-N
-25C to +80C
-20C to +60C
NJ2-12GK-N
-25C to +80C
-20C to +60C
NJ2-12GK-SN
-40C to +80C
-20C to +60C
NJ2-11-N
-25C to +80C
-20C to +60C
NJ2-11-SN
-40C to +80C
-20C to +60C
NJ2-12GM40-E2
-25C to +70C
-20C to +60C
NJ3-18GK-S1N
-25C to +80C
-20C to +60C
NJ5-30GK-S1N
-25C to +80C
-20C to +60C
NCB5-18GM40-NO-V1
-25C to +80C
-20C to +60C
<N002>
NJ4-12GM-N
-25C to +80C
-20C to +60C
<N003>
SJ3.5-N
-25C to +80C
-20C to +60C
<N004>
SJ3.5-SN
-40C to +80C
-20C to +60C
<N005>
NCN4-12GM35-NO
-25C to +80C
-20C to +60C
<N006>
NJ2-12GK-SN
-40C to +80C
-20C to +60C
<N007>
SJ3.5-S1N
-25C to +80C
-20C to +60C
<N008>
NJ5-18GK-SN
-40C to +80C
-20C to +60C
<N009>
NJ4-12GK-SN
-40C to +80C
-20C to +60C
<N010>
NJ5-11-N-G
-25C to +80C
-20C to +60C
<N011>
NJ2-11-N-G
-25C to +80C
-20C to +60C
<N012>
NJ3-18GK-S1N
-25C to +80C
-20C to +60C
<N013>
NJ5-18GK-N
-25C to +80C
-20C to +60C
<N014>
SC3.5G-N0
-25C to +80C
-20C to +60C
<N015>
NJ2-12GM-N
-25C to +80C
-20C to +60C
<N016>
NJ5-18GM-N
-25C to +80C
-20C to +60C
<N017>
NJ2-12GK-N
-25C to +80C
-20C to +60C
<N018>
NCB5-18GM40-NO
-25C to +80C
-20C to +60C
<N019>
NJ2-12GM40-E2
-25C to +80C
-20C to +60C
<N020>
NCB2-12GM35-N0
-25C to +80C
-20C to +60C
<N021>
SJ3.5-N-BU
-25C to +80C
-20C to +60C
<N022>
NBN4-12GM40-Z0
-25C to +80C
-20C to +60C
<N023>
NJ2-11-SN-G
-40C to +80C
-20C to +60C
<N024>
NBB5-18GM40-Z0
-25C to +70C
-20C to +60C
<N025>
NCB2-12GM40-Z0
-25C to +70C
-20C to +60C
<N026>
NJ4-12GK-N
-25C to +80C
-20C to +60C
502.969.8000
www.topworx.com
DXP/DXS
Valvetop w/o Solenoid
Valvetop w/Solenoid
-40C to +55C
-10C to +50C
-40C to +55C
-10C to +50C
35 GO Switch SPDT
35 GO Switch DPDT
Reed Switch SPDT
Mechanical switch DPDT
Mechanical switch DPDT
DXR
Valvetop w/o Solenoid
Valvetop w/Solenoid
-20C to +53C
-10C to +50C
-20C to +53C
-10C to +50C
-60C to +55C
-10C to +50C
-20C to +53C
-10C to +50C
-60C to +55C
-30C to +55C
not available
-10C to +50C
-10C to +50C
not available
-20C to +53C
-20C to +53C
not available
-10C to +50C
-10C to +50C
not available
-20C to +50C
-10C to +50C
-20C to +53C
-10C to +50C
not available
not available
not available
not available
-30C to +55C
-10C to +50C
not available
not available
not available
not available
not available
not available
not available
not available
not available
not available
-40C to +80C
-20C to +80C
-20C to +80C
-20C to +80C
not available
PS
PN
AS
DN
Asi
DeviceNet
FF
Foundation Fieldbus
MB
Mod Bus
not available
not available
not available
_X
_H
4-20mA Transmitter
4-20 Xmitter with HART
not available
not available
not available
not available
-40C to +55C
-10C to +50C
-40C to +55C
-10C to +50C
0A
0B
1k potentiometer
10k potentiometer
-40C to +55C
-10C to +50C
not available
not available
-40C to +55C
-10C to +50C
not available
not available
-25C to +55C
-25C to +55C
-40C to +55C
-25C to +55C
-40C to +55C
-25C to +55C
-25C to +55C
-25C to +55C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-25C to +40C
-25C to +40C
-25C to +60C
-50C to +40C
-25C to +40C
-25C to +40C
-25C to +40C
-40C to +40C
-50C to +40C
-25C to +40C
-25C to +40C
-25C to +40C
-25C to +40C
-25C to +60C
-25C to +40C
-25C to +40C
-25C to +40C
-25C to +40C
not available
-25C to +40C
-25C to +60C
not available
-40C to +40C
not available
not available
-25C to +40C
-10C to +40C
-10C to +40C
-10C to +60C
-10C to +40C
-10C to +40C
-10C to +40C
-10C to +40C
-10C to +40C
-10C to +40C
-10C to +40C
-10C to +40C
-10C to +40C
-10C to +40C
-10C to +60C
-10C to +40C
-10C to +40C
-10C to +40C
-10C to +40C
not available
-10C to +40C
-10C to +60C
not available
-10C to +40C
not available
not available
-10C to +40C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
-20C to +53C
not available
-20C to +53C
-20C to +53C
not available
-20C to +53C
not available
not available
-20C to +53C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
-10C to +50C
not available
-10C to +50C
-10C to +50C
not available
-10C to +50C
not available
not available
-10C to +50C
NJ2-V3-N
NJ2-12GK-N
NJ2-12GK-SN
NJ2-11-N
NJ2-11-SN
NJ2-12GM40-E2
NJ3-18GK-S1N
NJ5-30GK-S1N
NCB5-18GM40-NO-V1
NJ4-12GM-N
SJ3.5-N
SJ3.5-SN
NCN4-12GM35-NO
NJ2-12GK-SN
SJ3.5-S1N
NJ5-18GK-SN
NJ4-12GK-SN
NJ5-11-N-G
NJ2-11-N-G
NJ3-18GK-S1N
NJ5-18GK-N
SC3.5G-N0
NJ2-12GM-N
NJ5-18GM-N
NJ2-12GK-N
NCB5-18GM40-NO
NJ2-12GM40-E2
NCB2-12GM35-N0
SJ3.5-N-BU
NBN4-12GM40-Z0
NJ2-11-SN-G
NBB5-18GM40-Z0
NCB2-12GM40-Z0
NJ4-12GK-N
www.topworx.com
Middle East
P.O. Box 17033
Jebel Ali Free Zone
Dubai 17033
United Arab Emirates
+971 4 811 8283
[email protected]
Europe
Horsfield Way
Bredbury Industrial Estate
Stockport
SK6 2SU UK
+44 0161 406 5155
[email protected]
Africa
24 Angus Crescent
Longmeadow Business Estate East
Modderfontein
Gauteng
South Africa
+27 11 451 3700
[email protected]
The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2014 Emerson Electric Co.
2014 TopWorx, All rights reserved. TopWorx, Valvetop, GO Switch, and Leverless Limit Switch are all trademarks
of TopWorx. All other marks are the property of their respective owners. Information herein including product
specifications is subject to change without notice.
ES-01857-1 R15