topworx回讯器说明书

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Valvetop D-Series Valve Controllers

®

Master Installation, Operation & Maintenance Manual

®

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D-Series

Master Installation, Operation & Maintenance

502.969.8000

Table of Contents

Cover Page………………………………………………………………………………………… 1 Table of Contents………………………………………………………………………………… 2 Installation on Actuator…………………………………………………………………………. 3 DXP Dimensions and Materials……………………………………………………………….. 4 DXP-IIC Dimensions and Materials…..………………………………………………………. 5 DXS Dimensions and Materials……………………………………………………………….. 6 DXR Dimensions and Materials……………………………………………………………….. 7 Shaft & Indicator Assembly……………………………………………………………………. 8 Sensor Options…..……………………………………………………..……………………….. Mechanical Switches……………………………………………..…………………….. P+F/Inductive Sensors……………………………………………..……………………. 11 GO Switches………………………..………………………………….…………………. 4-20mA Transmitter ………………..…………………………………………..………… 4-20mA Transmitter w/ HART...………………………………………………..……….. FOUNDATION Fieldbus...………………………………………………..…………………. 27 AS-I…………………….…………...……………………………………………..….…… SCM w/ Reed Switches…………...………………………………………………….… ESD…………………….…………...……………………………………………..……… DeviceNet…………………......………………………………………………..…………. Spool Valves & Pilots…………………………………………………………………...………. 43 Safe use…………………………….…………………………………………………….……….. Replacement Parts…...………….…………………………………….……………………….. Warranty…...…………………………………………………………………….……………….. Certifications & Approvals..………………………………………………….……………….. Contact Information……………………………………………………………………..……… 60

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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.

The image to the right shows a Valvetop mounted perpendicular to the process valve in the closed position. The green arrow at the top shows the “normal acting” direction of travel to open the valve. Notice that the indicator dome has been rotated 90° compared to the unit above.

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 mount-ing kit documentation for specific mounting instructions.

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 connections. 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.

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D-Series

Master Installation, Operation & Maintenance

502.969.8000

Dimensions and Materials: Valvetop DXP

MATERIALS OF CONSTRUCTION

Enclosure

Cast A360 aluminum with dichro-mate conversion coating inside & out, epoxy coated exterior rated for 250 hrs salt spray per ASTM B117 304 Stainless Steel standard 316 Stainless Steel optional 304 Stainless Steel standard 316 Stainless Steel optional Oilite Bronze

Polycarbonate, UV F1 rated O-ring seals available in: Buna, Silicone, EPDM & Viton

Fasteners Shaft Shaft Bushing Indicator Dome Seals

Maximum Fastener Torque Specifications

Enclosure Housing Bolts Indicator Dome Screws Bottom Mounting Holes

8 ft-lbs [10.8 N·m] 320 in-oz [2.3 N·m] 10 ft-lbs [13.6 N·m]

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Dimensionals

Dimensions and Materials: Valvetop DXP - IIC

MATERIALS OF CONSTRUCTION

Cast A360 aluminum with dichro-mate conversion coating inside & out, epoxy coated exterior rated for 250 hrs salt spray per ASTM B117 304 Stainless Steel standard 316 Stainless Steel optional 304 Stainless Steel standard 316 Stainless Steel optional Oilite Bronze

Polycarbonate, UV F1 rated O-ring seals available in: Buna, Silicone, EPDM & Viton

Enclosure

Fasteners Shaft

Shaft Bushing Indicator Dome Seals

Maximum Fastener Torque Specifications

Enclosure Housing Bolts Indicator Dome Screws Bottom Mounting Holes

8 ft-lbs [10.8 N·m] 320 in-oz [2.3 N·m] 10 ft-lbs [13.6 N·m]

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D-Series

Master Installation, Operation & Maintenance

502.969.8000

Dimensions and Materials: Valvetop DXS

MATERIALS OF CONSTRUCTION

Enclosure Cast 316 Stainless Steel

Fasteners Shaft

Shaft Bushing Indicator Dome Seals

304 Stainless Steel standard 316 Stainless Steel optional 304 Stainless Steel standard 316 Stainless Steel optional N/A

Polycarbonate, UV F1 rated O-ring seals available in: Buna, Silicone, EPDM & Viton

Maximum Fastener Torque Specifications

Enclosure Housing Bolts Indicator Dome Screws Bottom Mounting Holes

8 ft-lbs [10.8 N·m] 320 in-oz [2.3 N·m] 10 ft-lbs [13.6 N·m]

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Dimensionals

Dimensions and Materials: Valvetop DXR

MATERIALS OF CONSTRUCTION

Enclosure Fasteners Shaft

Shaft Bushing Indicator Dome Seals

Valox® 364 Polybutylene

Terephthalate (PBT) 304 Stainless Steel standard 316 Stainless Steel optional 304 Stainless Steel standard 316 Stainless Steel optional Delrin® 500P white

Polycarbonate, UV F1 rated Silicone

20 in-lbs [2.3 N·m] 20 in-oz [2.3 N·m] 8 ft-lbs [10.8 N·m]

Maximum Fastener Torque Specifications

Enclosure Housing Bolts Indicator Dome Screws Bottom Mounting Holes

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D-Series

Master Installation, Operation & Maintenance

502.969.8000

Indicator Assembly

Indicator Dome,

+5

O

10-32 Captive screws,Stainless (x4)

0, 1800

Cam/Shaft Assemblies

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Mechanical Switches

Mechanical Switches: Options M2/M4/M6/K2/K4/T2

Calibration Procedure

perform switch calibration while an area is known to be hazardous. Calibration procedures for DPDT switches are the same as those for SPDT switches.

Calibration may be performed using a Volt-Ohm meter by using the Ohm setting across COM and NO. When the switch is active, the meter will read <0.5 Ohms, or the Diode setting may be used to indicate continuity.

If a 120Vac source is used, an appropriately sized resistor must be used in series to limit current to a maximum of 15 Amperes when circuit rating is unknown, or permanent damage may occur.

Step 1: With valve in the CLOSED position, disengage the BOTTOM cam from the splined Hub and rotate Clockwise until SW1 activates. Release cam to re-engage splined Hub.

Step 2: Rotate valve to the OPEN position. Disengage the TOP cam from the splined Hub and rotate Counter-clockwise until SW2 activates. Release cam to re-engage the splined Hub.

Step 3: Cycle valve CLOSED and OPEN several times to insure switches will maintain calibration.

For Reverse Acting actuators:

Step 1: With valve in the CLOSED position, disengage the TOP cam from the splined Hub and rotate Counter-clockwise until SW2 activates. Release cam to re-engage the splined Hub.

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.

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.

**Switches may also be set at midpoint, or any point, of travel for Dribble Control, or any other logic necessary for the application.

PRODUCT SPECIFICATIONS

OPTION M

Switch Type Mechanical Sealed Circuitry Termination

Rating

Conforming to standards Contact Resistance Insulation Resistance Switch Type Sealed Circuitry Termination Rating

Conforming to standards Switch Type Sealed Circuitry Termination Rating

Conforming to standards Contact Terminals

No SPDT Quick Connect

10A@125VAC or 250VAC UL: 1054

15M max. (initial) 100M min. (at 500V DC) OPTION K

Mechanical No SPDT Quick Connect 0.1A@125VAC MAX UL: 1054 OPTION TMechanical

No DPDT Quick Connect

8A 125V AC or 250V AC UL recognized and CSA certified, meets MIL-S-8805 Gold or silver End or side

Mechanical Switch Assembly

Switch Option M2/K2/T2

Switch Option M4/K4/T4

Switch Option M6/K6/T6

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D-Series

Master Installation, Operation & Maintenance

502.969.8000

Mechanical Switches: Options M2/M4/M6/K2/K4/T2

Wiring Diagrams and Charts

Option M/K

Color 1

2

3

4

NO

White/

Orange

12

5

6

10

Option T2

1

5 2 NC2

White/

Yellow

10

11

NO2

White/Orange

12

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

Inductive Sensors: Options E2/E4

Calibration Procedure

perform switch calibration while an area is known to be hazardous. 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.

Step 1: With valve in the CLOSED position, disengage the BOTTOM cam from the splined hub and rotate clockwise until SW1 activates. Release cam to re-engage splined hub.

Step 2: Rotate valve to the OPEN position. Disengage the TOP cam from the splined hub and rotate counter-clockwise until SW2 activates. Release cam to re-engage the splined hub.

Step 3: Cycle valve CLOSED and OPEN several times to insure switches will maintain calibration.

For Reverse Acting actuators:

Step 1: With valve in the CLOSED position, disengage the TOP cam from the splined hub and rotate counter-clockwise until SW2 activates. Release cam to re-engage the splined hub.

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.

Repeat Step 3 above.

*When using the (4) and (6) switch options, determine which switches are to indicate OPEN and which indicate CLOSED and then use the same calibration steps as above.

**Switches may also be set at midpoint, or any point, of travel for Dribble Control, or any other logic necessary for the application.

P & F NJ2-V3-N Switch Assembly

Switch Option E2

Switch Option E4

Switch Option E6

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D-Series

Master Installation, Operation & Maintenance

502.969.8000

Inductive Sensors: Options E2/E4

Product Specifications PRODUCT SPECIFICATIONS

General specificationsSwitching element function NAMUR NCRated operating distancesn

2 mmInstallation

embeddableOutput polarity NAMURAssured operating distancesa0 ... 1.62 mmReduction factor rAl

0.25Reduction factor rCu

0.2 Reduction factor rV2A

0.7 Nominal ratings Nominal voltage Uo 8 V

Switching frequencyf0 ... 1000 Hz Hysteresis

H

typ. %

Current consumption

Measuring plate not detected

≥3 mAMeasuring plate detected≤1 mA

Standard conformityEMC in accordance with

IEC / EN 60947-5-2:2004 Standards DIN EN 60947-5-6

(NAMUR)

Ambient conditionsAmbient temperature

-25 ... 100 °C (248 ... 373 K)Mechanical specificationsConnection type Core cross-section 130 mm, PVC cable 0.14 mm2

Housing material

PBTSensing face

PBTProtection degree

IP67General informationUse in the hazardous area

see instruction manualsCategory

1G; 2G; 1D12

LEAD WIRE TERMINATIONS CHART SWITCH #

LEAD COLOR TERMINAL#

1

BROWN + 1 BLUE - 2 2

BROWN + 3 BLUE - 4 3

BROWN + 5 BLUE - 6 4

BROWN + 7 BLUE - 8 5

BROWN + 9 BLUE - 10 6

BROWN +

11

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

Inductive Sensors : Options V2/V4

Target Arrangement

All Valvetop products are factory set for 90° rotation normal acting on parallel orientation with switch 1 (full clockwise) for the process valve closed position

When changing orientation the target disk will have to be relocated for your application. All target disks are supplied with 4 slots on 90° increments allowing the Valvetop unit to be rotated 90°, 180°, or 270° from standard.

TYPICAL V2 TARGET ARRANGEMENT

MINIMUM USABLE ROTATION 45° MAXIMUM USABLE ROTATION 125°

TYPICAL V4 TARGET ARRANGEMENT

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D-Series

Master Installation, Operation & Maintenance

502.969.8000

Inductive Sensors: Options V2/V4

P & F NJ3-18GK-S1N

SWITCH 2

PRODUCT SPECIFICATIONS

General specifications

Switching element function NAMUR NO

Rated operating distance

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 8 V Switching frequency Hysteresis

0 ... 200 Hz typ. 0.1%

TORQUE TO

7 IN-LBS

SWITCH 3

SWITCH 4

SWITCH 1

Current consumption

Measuring plate not detected Max 1mA

Measuring plate detected ≥3 mA

Ambient conditions Ambient temperature Connection type Core cross section Housing material Sensing face

Protection degree Note

-25 ... 100 °C

Mechanical specifications

2m Silicone cable 0.75mm 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

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 and ES-00210-1 A.

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 V2 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 V4 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. (see illustration on page 15)

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 page 15 as a reference. 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

GO Switch: Options L2/L4/Z2/Z4

Target Arrangement

All Valvetop products are factory set for 90° rotation normal acting on parallel orientation with switch 1 (full clockwise) for the process valve closed position. When changing orientation the target disk will have to be relocated for your application. All target disks are supplied with 4 slots on 90° increments allowing the Valvetop unit to be rotated 90°, 180°, or 270° from standard.

TYPICAL L2/Z2 TARGET ARRANGEMENT

MINIMUM USABLE ROTATION 45° MAXIMUM USABLE ROTATION 125°

TYPICAL L4/Z4 TARGET ARRANGEMENT

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D-Series

Master Installation, Operation & Maintenance

502.969.8000

GO Switch: Options L2/L4/Z2/Z4

Calibration Procedure

Never perform switch calibration while an area is known to be hazardous.

For intrinsically safe models with L2/L4, the unit must be wired in accordance with the control drawing S-K127 and S-K127A.

For intrinsically safe models with Z2/Z4, the unit must be wired in accordance with the control drawing ES01179-1.

GO Switch calibration may be performed using a Volt-Ohm meter with the Ohm setting across COM and NO. When the switch is active, the meter will read ≤0.5 Ohms, or the Diode setting may be used simply to indicate continuity. If a 120VAC source is used, an appropriately sized resistor must be used in series to limit current to a maximum of 1.5 Amperes when circuit rating is unknown or permanent damage may occur.

For L2/Z2 models mounted in parallel orientation (see illustration on page 18)

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 18)

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. (see illustration on page 18)

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.

Repeatability .002" (.05 mm)

Response TimeDifferential

Operating Temperature Contact Material Forms Ratings Target Material Sensing Range

Sensing Range with Target Magnet

Approx. 5/32" (4 mm) -40° to 221°F (-40° to 105°C) Silver cadmium oxide, gold flashed SPDT, Form C

4A@120VAC / 3A@24VDC Ferrous metal

Approx. 1/10" (2.5 mm) 3 5/8" (92mm) (max)

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GO Switch: Options L2/L4/Z2/Z4

Electrical Connections & Wiring

Option L2/Z2

Switch 1

Green to GND 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/Z4

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

NC (Red)

Terminal 4

Switch 3

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

**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.

GO Switch

Terminal Strip Assembly

40 IN-OZ

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

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D-Series

Master Installation, Operation & Maintenance

502.969.8000

4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X

The 2-wire 4-20mA transmitter will generate a nominal 4 – 20mA output for full-range actuation of the valve. The transmitter is capable of generating signals below 4mA and above 20mA if the position sensor indicates an out of range value.

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 20º to 320º. Factory set for 20º to 180º operation in counter clockwise rotation to open and 20º to 90º 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: -40º to 85ºC

Potentiometer Only Shaft Position Monitoring Description

The potentiometer only version (without the 4-20mA Position Transmitter Module) will generate a ratio metric voltage output based on the excitation voltage and the position of the valve. Standard potentiometer options include 0-1k ohm and 0-10k ohm.

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: -40º to +85ºC

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 Electrical Data

-Voltage Input Range: 0-35 Volts

-Actual Electrical Travel 340° (dead band of 20°) -Current Maximum: 3mA

-Recommended operating wiper current is less than or equal to 1 micro amp (recommend using the wiper voltage to drive an operational amplifier working as a voltage follower in which a very small load is applied to the wiper)

-Independent Linearity ±2%

-Resistance Tolerance ±20%

Potentiometer Wiring

NOTE: Refer to the wiring diagram on the inside lid of your product

to determine actual pin out location

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4-20mA Transmitter

4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X

Calibration Flow Chart

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D-Series

Troubleshooting

Master Installation, Operation & Maintenance

502.969.8000

4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X

Error Code and Problem Table

Problem Probable Cause/Solution

Transmitter Module has no current output

If the LED on the Transmitter Module is not lit

- Loose or shorted signal connection (fix connection)

- Controller Board not responding (Replace Transmitter Module)

If the LED on the Circuit Board is lit

- Potentiometer is disengaged from shaft (must be returned for repair) - Defective controller board (Replace Transmitter Module)

Transmitter does not output 4 or 20mA (+/-1%) Unit not calibrated (calibrate)

at desired end of travel Unit is calibrated (recalibrate - if still fails, replace board) Output is not linear or does not track valve position or rotation Error Code 4-3 Error Code 4-4 Error Code 4-5 Error Code 4-6 Error Code 4-7 Error Code 4-1

Input signal is not linear

- Linkage or drive mechanism is introducing non-linearity - Unit is not calibrated (calibrate) Start position is too low or in the dead-band position. Start Position is too high

Start and stop positions are less than 20º, increase valve rotation between start and stop positions to greater than 20º. Rotation has exceeded the 320º limit. Decrease valve rotation between start and stop positions to less than 320º. Calibration rotation was in the wrong direction or the potentiometer passed through the dead-band position.

Internal Error has occurred. Recalibrate, if error continues, replace module.

Operation of the 4-20mA Current Position Transmitter

During run mode, the 4-20mA position transmitter will output 4-20mA for valve positions between and including the set points. The module has an optional over or under travel correction if the valve position exceeds the high or low set point by +/-3%. In other words, the output will be 4mA for +/-3% over and under travel on the low end and 20mA for +/-3% over and under travel on the high end. If the valve position exceeds 3% of over travel then values below 4mA or above 20mA will be output. The user selectable other option is to calibrate the device without the over and under travel capability. See the calibration procedure in this document for additional information.

Operation of the Stand Alone Potentiometer

The potentiometer only version will generate a ratio metric voltage output based on the excitation voltage and the position of the valve. Standard potentiometer options include 0-1k ohm and 0-10k ohm.

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4-20mA Transmitter

4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X

D-Series Upgrade Procedure: 4-20mA Position Transmitter

(Use the following installation procedure to upgrade an existing D-Series in the field)

Typically the 4-20mA Position Transmitter module and potentiometer options are already installed in TopWorx valve controller products. Use the following installation directions only if you are replacing or upgrading an existing unit:

1) First remove the valve monitor enclosure from the valve/actuator

2) Install the 4-20mA position transmitter using the supplied or existing mounting bolts (See illustration below)

3) Remove the existing shaft and replace with the new shaft and position sensor kit assembly (See illustration below)

a) Remove circlip and washer from shaft on bottom of enclosure (outside) b) Pull shaft out gently from top side of enclosure

c) Install lube (from packet) on new shaft just below potentiometer and spread around o-ring seals on shaft

4) The alignment boss on the bracket (indicated in Illustration 10) should hold one of the mounting ears of the

sensor in place. Once mounted, verify that no rotary movement of the potentiometer housing is possible 5) If applicable, plug the position sensor cable into the 4-20mA position transmitter keyed header connector 6) Connect the three output wires to the indicated terminal block positions if you are using the potentiometer

only option.

7) The module is now ready for calibration/operation

8) Before mounting the DXP to an actuator, make sure the potentiometer alignment marks are aligned as shown in the illustration below with

the valve in the closed position.

The potentiometer has been factory set for typical valve rotation ranges from 2º to 180º in counter-clockwise rotation applications from the 4mA position to the 20mA position and from valve rotation ranges from 2º to 90º 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.

Module and Bracket

Potentiometer Shaft Assembly

21

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