Crane WESTLOCK CONTROLS DIGITAL EPIC-2 User manual

Page 1 of 75
To be used in conjunction with the relevant VCIOM-04592 for the D510/520 or VCIOM-04979
for the D530/540/550 short form installation and operating manuals
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
www.westlockcontrols.com
Copyright © Crane Co. All rights reserved.
VCIOM-05044-EN 17/03
TABLE OF CONTENTS
1. Introduction ................................................... 2
1.1 Product overview................................ 2
1.2 Principles of operation....................... 2
2. Definitions...................................................... 3
2.1 Acronyms............................................ 3
2.2 Terms.................................................. 3
2.2.1 Safety .................................................. 3
2.2.2 Functional safety................................ 3
2.2.3 Basic safety ........................................ 3
2.2.4 Safety assessment............................. 3
2.2.5 Fail-safe state .................................... 3
2.2.6 Full-stroke test .................................. 3
2.2.7 Partial-stroke test.............................. 4
2.2.8 Solenoid operated valve test (SOVT) . 4
2.2.9 Signatures .......................................... 4
2.2.10 On-line proof test............................... 4
3. Installation..................................................... 4
3.1 Rotary direct mount........................... 4
3.2 Rotary remote mount......................... 6
3.3 Linear direct mount ........................... 7
3.4 Linear remote mount......................... 8
3.5 Pneumatic connections for units
supplied with esd and pressure
profiling enabled. ............................... 9
4. Field wiring .................................................. 10
4.1 D510/520 models ............................. 10
4.1.1 Direct mount..................................... 10
4.1.2 Remote mount.................................. 11
4.2 D530/540/550 models ...................... 12
4.2.1 Direct mount..................................... 12
4.2.2 Remote mount.................................. 13
5. Safety instrumented functions ................... 14
5.1 References and standards .............. 14
5.2 DEPIC-2 ESD description ................ 14
5.3 Designing a SIF using a
DEPIC-2 ESD.................................... 14
5.3.1 Safety function.................................. 14
5.3.2 Environmental limits........................ 14
5.3.3 Application limits.............................. 14
5.3.4 Design verification............................ 15
5.3.5 SIL Capability.................................... 15
5.3.6 Connecting the DEPIC-2 ESD
to the SIS logic solver ...................... 15
5.3.7 General requirements ..................... 16
5.4 Diagnostics....................................... 16
5.4.1 FST .................................................... 16
5.4.2 PST.................................................... 16
5.4.3 SOVT.................................................. 16
5.4.4 Signatures ........................................ 16
5.4.5 Proof test .......................................... 16
5.5 DEPIC-2 ESD product safety........... 17
5.5.1 General installation, maintenance
or replacement................................. 17
6. Operation ..................................................... 18
6.1 Valve position transmitter ............... 18
6.2 ESD monitor and basic diagnostics 18
6.3 Advanced diagnostics with
pressure profiling............................. 19
7. User interfaces............................................ 21
7.1 Local keypad/LCD............................ 21
7.1.1 Boot-up LCD screen ........................ 21
7.1.2 Idle/main LCD screen...................... 22
7.1.3 Quick setup screen .......................... 24
7.2 HART communications.................... 27
7.2.1 Field device manager (FDM) ........... 27
7.2.2 Device type manager (DTM) ............ 27
7.2.3 Emerson 475 handheld
communicator.................................. 27
7.3 User interface menu system........... 28
7.3.1 Login/logout menu........................... 29
7.3.2 Configuration menus ....................... 29
7.3.3 Calibration menus............................ 42
7.3.4 Diagnostics menus .......................... 48
7.3.5 Device information menus .............. 64
7.3.6 Device status menus........................ 65
8. Additional documentation........................... 72
9. Appendix....................................................... 73
9.1 Field wiring and grounding
schematic ......................................... 73
9.2 Cover lock operation........................ 74
9.3 Non-intrusive feature ...................... 74

VCIOM-05044
Page 2 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
1 INTRODUCTION
1.1 PRODUCT OVERVIEW
Westlock Controls Digital EPIC-2®is a second
generation ARM®Cortex-M3 microcontroller
based intelligent valve position transmitter with
an advanced diagnostics functions designed
especially for safety valves. The key application
of the DEPIC-2 is on emergency shut-down
valves to monitor the valve position in real-
time and perform diagnostics functions like
Partial-Stroke (PST), Full-Stroke Test (FST)
and Solenoid Operated Valve Test (SOVT) to
ensure valve will move to its fail-safe position in
emergency situation.
The DEPIC-2 is powered through the 9-24 V
analog signal from the control system and
provides 4-20 mA position feedback and digital
HART communication on the same signal to the
control system. The safety function is provided
from the 0-24 V digital signal from the safety
system to DEPIC-2 to de-energize the valve
during an emergency shutdown event.
A step by step guided setup wizard on 64x128
graphic LCD and 3 buttons provides an easy
way to configure, calibrate and operate the
device locally. In addition, the remote HART®
DD or FDT®DTM can be used to configure,
calibrate and perform advanced diagnostics
functions on the device.
Under the hood is a powerful industry
leading low power 32 bit ARM®Cortex-M3
microcontroller with one non-contact Hall
Effect position sensor, two pressure sensors
and one temperature sensor. The low power
operation of the microcontroller keeps the
device operating even at 3.8 mA with HART®
communication during an ESD event.
The DEPIC-2 can be easily mounted using
NAMUR compatible mounting kits on linear
or rotary actuator. The completely sealed and
potted electronics are resistant to dirt and
moisture and expanded temperature range of
-40°C to +85°C enhances the reliability of the
device to work in harsh environments.
The state of the art diagnostic functions like
Emergency Shutdown (ESD), Partial Stroke
Testing (PST), Solenoid Operated Valve Testing
(SOVT) and Full Stroke Testing (FST) lowers the
total cost of ownership by suggesting predictive
maintenance of the device under operation
before it fails and interrupt the process. The
artificial intelligence of the underlying alarm
system points to the root cause of the problem
instead of reporting nuisance alarm.
All packaged and integrated in a single housing,
DEPIC-2 offers a unique solution to tackle the
problems faced by plant operation team.
1.2 PRINCIPLES OF OPERATION
As explained in the product overview section,
the DEPIC-2 is a 4-20 mA position transmitter.
The primary function of the device is to
measure the valve position using the Hall
Effect sensor and provide 4-20 mA current
output as a feedback to the control system.
In addition, it has one temperature sensor to
monitor the temperature of the device and two
pressure sensors to monitor the pressure.
It also monitors the safety demand signal
from the safety system as an input voltage to
solenoid and generates an ESD alarm when the
device is in emergency shut-down mode. As a
secondary function, it offers variety of different
diagnostics tests that can be performed on the
valve/actuator package to detect any potential
failures. These tests include Partial Stroke
Test (PST), Full Stroke Test (FST) and Solenoid
Operated Valve Test (SOVT). The DEPIC-2 uses
the data collected from its position, pressure
and temperature sensors during these tests to
generate an alert for less severe condition and
alarm for any potential dangerous condition.
This is particularly important in safety
applications to detect abnormal operation and
notify the user before it becomes a critical
problem, possibly preventing a valve from
going to its safety position when required. More
details about each diagnostic test can be found
in later sections of the document.

VCIOM-05044
Page 3 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
2 DEFINITIONS
2.1 ACRONYMS
The following acronyms are related to the
DEPIC-2 and safety functions used throughout
this document.
• DEPIC2 - Digital EPIC second generation
• DD - Device Description
• DTM - Device Type Manager
• ESD - Emergency Shut-Down
• FDM - Field Device Manager
• FMEDA - Failure Modes, Effects and
Diagnostic Analysis
• FST - Full-Stroke Test. While FST is not
used extensively in SIF applications due to
its interference with the normal process,
it should be used on occasion to verify that
the valve can fully move to its de-energized
position.
• HFT - Hardware Fault Tolerance
• IS - Intrinsically Safe
• PFD - Probability of Failure on Demand
• PFDavg - Average Probability of Failure on
Demand. Each component of an SIF system
has its own PFD. The average is the average
of all components combined. The average is
heavily influenced by the weakest link.
• PST - Partial Stroke Test, a test used to
detect failure modes in the positioner,
actuator, and valve assembly with minimal
disruption to the process.
• SFF - Safe Failure Fraction, the fraction of the
overall failure rate of a device that results in
either a safe fault or a diagnosed unsafe fault.
• SIF - Safety Instrumented Function, a set of
equipment intended to reduce the risk due to
a specific hazard (a safety loop).
• SIL - Safety Integrity Level, discrete level (one
out of a possible four) for specifying the safety
integrity requirements of the safety functions
to be allocated to the E/E/PE safety-related
systems where Safety Integrity Level 4 has
the highest level of safety integrity and Safety
Integrity Level 1 has the lowest.
• SIS - Safety Instrumented System -
Implementation of one or more Safety
Instrumented Functions. A SIS is composed
of any combination of sensor (s), logic solver
(s), and final element (s).
• SOV - Solenoid Operated Valve
• SOVT - Solenoid Operated Valve Test. This
can be an important test in SIF applications
because a solenoid can fail at any time and it
is better to find it before the next PST is done
and fails. This also tests pressure sensor 1 in
safety applications. This should be done more
frequently than a PST.
• TUV - Technischer Überwachungs-Verein
(English - a Technical Inspection Association)
• XP - Explosion Proof
2.2 TERMS
The following terms and abbreviations are
related to the DEPIC-2 device and safety
functions used throughout this document.
2.2.1 Safety
This is defined as the freedom from
unacceptable risk of harm.
2.2.2 Functional safety
This is the ability of a system to carry out the
actions necessary to achieve or to maintain a
defined level of safety for the valve/actuator
assembly under control of the system.
2.2.3 Basic safety
The equipment must be designed and
manufactured such that it protects against
risk of damage to persons by electrical shock
and other hazards and against resulting fire
or explosion. The protection must be effective
under all conditions of the nominal operation
and under single fault condition.
2.2.4 Safety assessment
The investigation to arrive at a judgment, based
on evidence, of the safety achieved by safety-
related systems.
2.2.5 Fail-safe state
State where the DEPIC-2 solenoid is de-
energized and has exhausted Pressure 1 in a
spring-return actuator.
2.2.6 Full-stroke test
Full-Stroke Test (FST) here means a test of full
valve movement from fully closed to fully open
(open movement) or from fully open to fully
closed (close movement). Since it is disruptive
to the process, there is no mechanism
to automatically perform this. It must be
scheduled and performed by field personnel.
In general it should be done at least once per
year if not sooner. Note this feature is only
available on devices that have the Signature
option enabled from Factory and by the user.

VCIOM-05044
Page 4 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
2.2.7 Partial-stroke test
Partial-Stroke Test (PST) refers to a special
test of valve movement used mainly in safety
systems where a valve remains mostly in one
position (open or closed) for long periods of
time. So in order to determine if the valve/
actuator assembly is functioning properly
without disrupting the process, a Partial-Stroke
Test (PST) is performed moving the valve
from the energized position to a configured
position which may be 1-50% of full-stroke
and back again. In general it should be done
at least monthly or weekly depending upon
environment and corrosive process and/or
time-frame needed to achieve SIL3.
2.2.8 Solenoid operated valve test (SOVT)
This is a special function which can test the
operation of the solenoid and pressure sensor
1 with virtually no disruption in process. Since
a solenoid or pressure sensor can fail without
warning at any time, this test is recommended
daily or weekly, generally more often than
a PST (unless PST Duplex is enabled which
does an SOVT as part of PST with redundant
solenoids).
2.2.9 Signatures
A Signature is a plot or graph of data captured
either during a full-stroke or partial-stroke
movement of the valve. All sensors on the
device (position and pressure) are monitored
at a specific interval (based upon valve speed)
to produce a plot showing the characteristic
operation of the valve/actuator in the process.
Note this feature is only available on devices
that have the Signature option enabled from
Factory and by the user.
3 INSTALLATION
3.1 ROTARY DIRECT MOUNT
Step 1. Mount bracket and inner beacon
coupler to actuator. If actuator shaft has a
tapped hole, fasten using proper flat head
screw. If actuator does not have a tapped hole,
fasten using set screws on side of coupler.
(See Figure 1)
Step 2. Press fit the inner beacon to the inner
beacon coupler. The inner beacon needs to
be properly oriented. Use the symbols on the
top of the inner beacon to mount as shown in
Condition 1 or Condition 2. (See Figure 2)
Condition 1 and Condition 2 show the
placement of the inner beacon with respect to
the Transmitter housing while the actuator is
in the fail position.
Step 3. Mount the Transmitter to the bracket.
As stated in Step 2 make sure that the
Transmitter is mounted in a fashion that
properly orients it with respect to the inner
beacon.
FIGURE 1
Bracket / coupler mounting
Flat head screw
Inner beacon
coupler
Bracket
Set screw
Actuator accessory
mounting shaft
2.2.10 On-line proof test
The objective of on-line proof testing is to
detect potentially dangerous failures and
proves the PFDavg for the SIL rating. Increasing
the proof test frequency is directly proportional
to an improvement in lowering the average
PFD, consequently increasing SIL. FST, PST
and SOVT are available proof tests on DEPIC-2.
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 5 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
D510/20 MODELS
D510/20 MODELS
D530/40/50 MODELS
D530/40/50 MODELS
Condition 1: Actuator fails in a clockwise direction.
Condition 2: Actuator fails in a counter clockwise direction.
Tplaced at 6:00
|| placed at 3:00
Tplaced at 9:00
|| placed at 6:00
FIGURE 2
Direct mount beacon orientation
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 6 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
3.2 ROTARY REMOTE MOUNT
Step 1. Mount bracket and inner beacon
coupler to actuator as described in Section 3.1
Step 1.
Step 2. Press fit the inner beacon to the inner
beacon coupler. The inner beacon needs
to be properly oriented. Use the symbols
on the top of the inner beacon to mount
as shown in Condition 1 or Condition 2.
(See Figure 3). Condition 1 and Condition 2
show the placement of the inner beacon with
respect to the position sensor housing while the
actuator is in the fail position.
FIGURE 3
Remote mount beacon orientation
Condition 1: Actuator fails in a clockwise direction.
Condition 2: Actuator fails in a counter clockwise direction.
Tplaced at 6:00
|| placed at 3:00
Tplaced at 9:00
|| placed at 6:00
Step 3. Mount the position sensor to the
bracket. As stated in Step 2 make sure that the
position sensor is mounted in a fashion that
properly orients it with respect to the inner
beacon.
Inner beacon
Inner beacon
Actuator
(in fall position)
Actuator
(in fall position)
Position sensor
Position sensor
Conduit entry
Conduit entry
Copyright © Crane Co. All rights reserved.

VCIOM-05044
1
/
16
Page 7 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
3.3 LINEAR DIRECT MOUNT
Step 1. Mount the magnet assembly to the
stem of the actuator. A coupler block normally
is needed to extend the magnet assembly
outside the yoke area and into the sensing
range of the magnetic pick-up unit.
Step 2. Fasten the mounting bracket to the
actuator.
Step 3. Mount the transmitter to the mounting
bracket. The transmitter should be mounted
so the magnetic pick-up unit of the transmitter
is centered between the limits of the magnetic
assembly’s stroke. After mounting the
transmitter, the magnet assembly should be
within ⅛” from the back of the transmitter
(
1
/
16” is ideal). (See Figure 4).
FIGURE 4
Linear mount
NOTE
For fisher actuators model 657 and 667 sizes
34 thru 70, Westlock Controls can supply a
slotted mounting kit design. This will allow
the user to easily center the transmitter
sensor between the limits of the magnet
assembly’s stroke. Other mounting kits are
available upon request.
Digital EPIC-2
housing assembly
Digital EPIC-2
housing assembly
Centerline of
magnetic pick-up unit
(position sensor)
Centerline of
magnetic pick-up unit
(position sensor)
Actuator
centerline
Magnet
assembly
Magnet assembly
Mounting bracket
SIDE VIEW
TOP VIEW
Full
stroke ½
stroke
½
stroke
Actuator split block
(at lower limit of travel) Actuator split block
(at upper limit of travel)
Actuator yoke
Actuator
split block
Upper limit of travel
Location of center line
Lower limit of travel
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 8 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
FIGURE 5
Linear mount
Magnet assembly at
upper limit of travel
Upper limit of
travel mark
Actuator
Midpoint of
travel mark
Mounting
bracket
Position sensor
Conduit entry
Lower limit of
travel mark
Digital EPIC-2
housing assembly
Magnet assembly at
lower limit of travel
3.4 LINEAR REMOTE MOUNT
Step 1. Mount the magnet and bracket to the
actuator as described in Section 3.3 Step 1.
Step 2. Mount the position sensor housing
so that the conduit entry faces away from
the diaphragm or cylinder. (See Figure 6).
NOTE
For Fisher actuators model 657 and 667
sizes 34 thru 70, Westlock Controls supplies
a slotted mounting kit design, to ease the
mounting process. This will allow the user
to easily center the transmitter sensor
between the limits of the magnet assembly’s
stroke. Other mounting kits are available
upon request.
Step 3. Mount transmitter at a remote location.
For wiring instructions on remote transmitter
see Section 5.
FIGURE 6
Linear remote mount
To center the transmitter
1. Stroke the actuator to its upper limit and
place a mark on the actuator’s yoke that
lines up with the red arrow on the magnet
assembly.
2. Stroke the actuator to its lower limit and
place a mark on the actuator’s yoke that
lines up with the red arrow on the magnet
assembly.
3. Place a third mark on the yoke centered
between the upper and lower limit marks.
4. Lastly, mount the transmitter to the bracket
so that the transmitter sensor (nose) of the
Epic Transmitter lines up with the midpoint
mark. (See Figure 5).
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 9 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
MAXIMUM PARTICLE SIZE AND CONCENTRATION OF SOLID CONTAMINANTS
Class Maximum particle size (microns) Maximum concentration (mg/m3)
3 5 5
MAXIMUM OIL CONTENT
Class Maximum concentration (mg/m3)
3 1
All pneumatic connections are ¼” NPT or BSP.
FIGURE 7
Figure pneumatic connections
D510/20 MODELS D530/40/50 MODELS
Single acting cylinder
P1 port
P2 port
3 way valve
Pneumatic supply
3.5 PNEUMATIC CONNECTIONS FOR UNITS SUPPLIED WITH ESD AND PRESSURE PROFILING
ENABLED
Install a “T” air fitting in the air line from solenoid valve outlet port and pipe to the pressure
sensor port “P1” and to the actuator energize port. Plug port “P2”. See Figure 7.
NOTE
Air supply to the DEPIC-2 must be clean, dry, oil free instrument air per ANSI/ISA-7.0.01-xxx and
ISO 8573-1:xxx.
Copyright © Crane Co. All rights reserved.

VCIOM-05044
3
1
4
5
6
4-20 mA(+)
4-20 mA(-)
(+)
2
(-)
(+)
(-)
Page 10 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
4 FIELD WIRING
• The DEPIC-2 has been certified for use
in hazardous locations to international
standards. Although wiring practices may
vary from region to region it is up to the end
user to ensure that the electrical codes for
installation have been satisfied.
• All unused cable entries must be plugged
with suitably certified plugs that can maintain
an ingress protection level of IP66.
• For ambient temperatures below -10°C
and above +60°C, use field wiring suitable
for both minimum and maximum ambient
temperatures.
• Electromagnetic compatibility (emissions and
susceptibility) is guaranteed only if, the unit
and all cables are shielded and grounded as
illustrated in Appendix.
4.1 D510/520 MODELS
4.1.1 Direct mount
1. Remove cover from enclosure.
2. Locate terminal strip (for EXD option
terminal strip is removable, See illustration
on right).
3. Connect the 4 to 20 mA loop signal to
terminal points marked 1 and 2. The
4-20 mA analog output is of the current
sink type. Typically the 24 VDC supply
required comes from the HOST system
(24 VDC nominal). See Figure 8 for a
wiring schematic.
4. Connect the solenoid coil to terminal points
3 and 4.
See Figure 8 for wiring. Solenoid coil is
24 V with current not to exceed 500 mA.
Power to activate the solenoid comes from
a Safety Instrumented System logic solver
24 V output and is connected to terminals
5 and 6. See Figure 8 for wiring schematic.
The SIS logic solver output must be able
to provide sufficient current to operate the
solenoid.
5. Connect electrical ground wire to green
screw on housing (ground). Do not connect
cable shield to ground. Cable shield at this
end should be isolated using a shrink tubing
or isolation tape.
6. External grounding is required for all zone
installations. All wiring must be done in
accordance with local and national electric
code. See Figure 8 for external ground
connection.
7. After all connections have been made (for
EXD option reconnect the terminal strip)
replace cover.
ATTENTION
Do not over tighten terminal screws.
Max torque 3.5 in·lbs /0.4 Nm.
All unused cable entries must be plugged
with suitably certified plugs that can
maintain an ingress protection level of IP66.
Test point for
HART communicator
EXD enclosure
Test point for
HART communicator
Solenoid
input
Solenoid output
(external solenoid)
Analog
input
FIGURE 8
Field wiring direct mount
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 11 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
4.1.2 Remote mount
1. Remove cover from junction enclosure by
screwing ‘clockwise’ the cover retaining
screw using a 9/64 A/F allen key.
2. Locate terminal board mounting screws
(See Figure 9), remove the two screws
and lift up terminal board. (See Figure 9).
3. Locate J3 and J4 connectors on the
bottom of terminal board and connect the
two part remote cable plugs as shown.
See Figure 10.
4. Replace the terminal strip board, replace
the screws and replace the cover.
NOTE
To maintain the approval compliance,
ensure that the junction enclosure cover
locking screw is used. Screw the cover down
to create a water tight seal, then rotate the
locking screw anti-clockwise until the head
of the screw mates with the underside of the
cover. See Appendix B.
Terminal board
mounting screw
Junction cover
Position sensor
Wiring schematic
Hall
effect
sensor
Shield
Black
Green
Red
White
Remote mount enclosure
Terminal board
Plug two (3)
pin connectors
Terminal board
mounting screw
Terminal board
Yellow
Red
Green
Black
White
Junction enclosure
top view (no cover)
Junction enclosure
ISO view
FIGURE 9
Field wiring remote Mount-1
FIGURE 10
Field wiring remote Mount-2
Connector
orientation mark
5. If necessary, cut the remote cable to
required length.
NOTE
When shortening the cable, ensure to cut
the end opposite female connector.
6. Locate remote transmitter enclosure and
remove cover.
7. Wire the cable from junction enclosure to
remote transmitter. See Figure.
After all connections have been made
replace remote transmitter cover.
Two (3) pin connectors
(to junction enclosure
of positioner)
Copyright © Crane Co. All rights reserved.
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 12 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
4.2 D530/540/550 MODELS
4.2.1 Direct mount
a. Remove cover from enclosure.
b. Connect the 4 to 20 mA loop signal to
terminal points marked 1 and 2. The
4-20 mA analog output is of the current
sink type. Typically the 24 VDC supply
required comes from the HOST system
(24 VDC nominal). See Figure 11 for a
wiring schematic.
c. Connect the solenoid coil to terminal points
3 and 4. See Figure 11 for wiring. Solenoid
coil is 24 V with current not to exceed
500 mA. Power to activate the solenoid
comes from a safety instrumented system
logic solver 24 V output and is connected to
terminals 5 and 6. See Figure 11 for wiring
schematic.
d. The SIS logic solver output must be able
to provide sufficient current to operate the
solenoid.
ATTENTION
Do not over tighten terminal screws.
Max torque 3.5 in·lbs /0.4 Nm.
e. Connect electrical ground wire to Earth
screw inside the housing.
NOTE
Do not connect cable shield to ground. Cable
shield at this end should be isolated using a
shrink tubing or isolation tape.
f. External grounding is required for all zone
installations. All wiring must be done in
accordance with local and national electric
code. See Figure 11 for external ground
connection.
g. All unused cable entries must be plugged
with suitably certified plugs that can
maintain an ingress protection level of IP66.
PST
confirmation
(output)
(D540 /D550 shown)
Product
Earth/Ground
connections
4-20 mA position
measured output
Push button
(PST initation input)
Solenoid
input
Solenoid output
(external solenoid)
FIGURE 11
Direct mount wiring
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 13 of 75
FIGURE 12
Customer remote conntection
FIGURE 13
Customer remote conntection - flying lead version
FIGURE 14
Remote mount enclosure
4.2.2 Remote mount
• Remove the enclosure cover. The remote
cable connections are located under the
terminal strip. See Figure 12 for the standard
configuration and Figure 13 for the flying lead
version.
• The standard length of the remote cable is
50 feet (approx. 15 m). If necessary, cut the
remote cable to the required length.
NOTE
1. When shortening the cable, ensure to
cut the end opposite female connector.
2. For the flying lead version, either end
can be shortened.
ATTENTION
When shortening the cable please
ensure that the following steps are
followed:
a. Remove shrink tubing.
b. Cut cable to length (see note above).
c. Remove outer insulation approx.
2.25 to 2.50” (57 - 63 mm).
White
Black
Red
Green
Yellow
Blank
5 - Yellow
4 - Green
3 - Red
2 - Black
1 - White
Position sensor
Wiring schematic
Hall
effect
sensor
Shield
Black
Green
Red
White
Remote mount enclosure
Two (3) pin connectors
(to junction enclosure
of positioner)
NOTE
Do not remove braid.
d. Strip conductors by .160” (4 mm)
and tin.
e. Separate and twist braid.
• Terminate the cable to remote transmitter.
See Figure 14.
• After all connections have been made replace
remote transmitter cover.
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 14 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
5 SAFETY INSTRUMENTED
FUNCTIONS
This section provides the required information
needed to design, install, verify and maintain a
Safety Instrumented Function (SIF) utilizing the
Digital EPIC-2 (DEPIC-2) in ESD applications.
This manual provides requirements for
conforming to the IEC 61508 or IEC 61511
functional safety standards.
5.1 REFERENCES AND STANDARDS
Listed below are functional safety standards
and references related to the DEPIC-2:
• IEC 61508: 2000 - Functional safety of
electrical/electronic/programmable
electronic safety-related systems.
• IEC 61511 (ANSI/ISA 84.00.01-2004)
Functional safety - safety instrumented
systems for the process industry sector.
• NAMUR NE-43 Standardization of the signal
level for the failure information of digital
transmitters.
5.2 DEPIC-2 ESD DESCRIPTION
An ESD valve is a valve that reacts to ensure
that the process is brought to a safe state.
During normal operating conditions, these
ESD valves are typically energized to remain
open/closed depending upon Fail-Closed or
Fail-Open configuration. In case of an unsafe
situation, the ESD valve is de-energized by the
Safety Instrumented System. The DEPIC-2 ESD
device (DEPIC-2 configured for ESD support)
performs this shutdown function for Safety
Instrumented Functions (SIF) which requires
field devices to be certified for safety related
applications in accordance with IEC-61508 as
certified by EXIDA for use up to SIL3 with an
HFT of 0 in low demand applications.
The DEPIC-2 ESD is a valve controller which
mounts on a pneumatically actuated valve
assembly. Its role is to position an emergency
shutdown valve to 0% or 100% with a PFDavg in
accordance with IEC-61508 for SIL3 application.
Because of its capability of monitoring data
from its embedded sensors, the DEPIC-2 ESD
is capable of validating the health of its integral
components. In addition, due to the ability to
perform PST and SOVT of the ESD valve while
in normal operations (from energized position),
it becomes possible to validate the health of
the valve and actuator assembly. Configurable
time based testing of the ESD valve (Auto PST
and Auto SOVT) reduces the PFDavg by detecting
dangerous failures or potential dangerous
failures before they become failures thereby
preventing the device from performing its
safety functions on demand.
5.3 DESIGNING A SIF USING A DEPIC-2 ESD
The following points must be taken into
consideration when designing a SIF
(Safety Instrumented Function) using the
DEPIC-2 ESD:
• Safety function
• Environmental limits
• Design verification
• SIL Capability
• Connecting the DEPIC-2 ESD to the SIS
logic-solver
• General requirements
5.3.1 Safety function
When de-energized, the DEPIC-2 ESD moves
to its fail-safe position. For a single-acting
PST controller the safe state is when the port
Actuator 1 is exhausted to a pressure less than
1 psig (0.069 bar, 6.9 kPa) allowing the actuator
spring to move the valve to its fail-safe position.
For a double-acting PST controller the safe
state is when Actuator pressure 1 is equal
or below the Actuator pressure 2. The valve
actuation must automatically move the valve to
the safe state when the digital valve controller
falls in safe state.
The DEPIC-2 ESD is intended to be part of the
final element subsystem, as per IEC-61508,
and the achieved SIL level of the function must
be verified by the function designer.
5.3.2 Environmental limits
The designer of a SIF must check that
the product is rated for use within the
environmental limits it is being used.
5.3.3 Application limits
Listed below are the application limits for the
DEPIC-2 ESD installed in a SIF:
• The application of the DEPIC-2 ESD is limited
for SIF where the safe state is the de-
energized state (shutdown) of the valve. The
device is operated as a position transmitter
with an output loop signal: 4-20 mA or
any user selected range of 3.8-21.0 mA.
Furthermore, the 4-20 mA output shouldn’t
be used as a decision point for safety demand.
• The DEPIC-2 is a non-interfering device
during safety demand. The safety signal
(solenoid voltage) should come from the
safety system. If the device detects SIS
voltage to the solenoid, it is in energized
position. In the absence of SIS voltage, it is
in de-energized or fail-safe position (ESD).
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 15 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
5.3.4 Design verification
The following describes the design verification
criteria for the SIF and the DEPIC-2 ESD:
• A detailed Failure Mode, Effects,
and Diagnostics Analysis (FMEDA)
report is available online at
www.westlockcontrols.com. This report
details all failure rates and failure modes as
well as the expected lifetime.
• The achieved Safety Integrity Level (SIL) of
an entire Safety Instrumented Function (SIF)
design must be verified by the designer by
means of PFDavg calculation, considering
redundant architectures, proof test interval,
proof test effectiveness, any automatic
diagnostics, average repair time and specific
failure rates of all products included in the
SIF. Each subsystem must be checked to
assure compliance with minimum hardware
fault tolerance (HFT) requirements.
When using DEPIC-2 ESD in a redundant
configuration, include a common cause
factor of 5% in safety integrity calculations.
• The failure rate data listed in the FMEDA
report is valid only for the useful life time of
a DEPIC-2 ESD. The failure rates sometimes
increase after this time period. Reliability
calculations based upon the data listed in the
FMEDA report for mission times beyond the
lifetime can yield results too optimistic, i.e.
the calculated Safety Integrity Level will not
be achieved.
5.3.5 SIL capability
The DEPIC-2 ESD will meet SIL 3 requirements
as outlined below.
5.3.5.1 Systematic integrity
The product has met manufacturer design
process requirements of Safety Integrity Level
(SIL) 3. These are intended to achieve sufficient
integrity against systematic errors of design
by the manufacturer. A Safety Instrumented
Function (SIF) designed with this product must
not be used at a SIL level higher than stated
without prior use justification by end user or
diverse redundant technology in the design.
5.3.5.2 Random integrity
The DEPIC-2’s ESD safety critical function
is maintained as a Type A Device. Therefore
based upon the SFF > 90%, when the DEPIC-2
ESD is used as the sole component in a final
element subassembly, a design can meet SIL 3
at HFT=0.
When the final element assembly consists
of many components (DEPIC-2 ESD, quick
exhaust valve, actuator, isolation valve, etc.)
the SIL must be verified for the entire assembly
taking into consideration failure rate of each
component. This analysis must account for
any hardware fault tolerance and architecture
constraints.
5.3.5.3 Safety parameters
For detailed failure rate information refer to
the Failure Modes, Effects and Diagnostic
Analysis (FMEDA) Report for the DEPIC-2 ESD
available from the Westlock Controls Website
at www.westlockcontrols.com
5.3.5.4 SIL certification
This product is designed to respond to a
commanded trip signal (ESD) with a PFD
in accordance to IEC61508 SIL3, capable
of partially stroking the valve using one of
the following initiation methods, that will be
IEC61508 SIL3 certified:
• Allows built-In scheduling (periodic Auto-PST
and Auto SOVT) within the DEPIC-2 ESD.
• PST Locally with an external pushbutton.
• FST, PST, and SOVT locally with built-in
keypad menu.
• FST, PST, and SOVT from HART commands.
Note, it is the responsibility of the user to
interrogate the results of any Auto-PST or
Auto-SOVT periodically to ensure that they
were performed and no potential failures were
detected. Even though there may not have
been any failures, the Alarm database should
be checked for any Alarms that may suggest
trending toward a possible future failure.
5.3.6 Connecting the DEPIC-2 ESD to the
SIS logic solver
When connecting the DEPIC-2 ESD to the SIS
logic solver follow the guidelines below.
• The DEPIC-2 ESD is connected to the safety
rated logic solver which is actively performing
the safety function. Connections must be
made as per the instructions supplied by
the safety rated logic solver.
• The output rating of the I/O module has to
meet or exceed the electrical specifications
of the DEPIC-2 ESD as referenced in the
DEPIC-2 ESD Quick Start Guide.
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 16 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
5.3.7 General requirements
The following general requirements for the
DEPIC-2 ESD must comply with the following:
• The system response time shall be less than
the process safety time. The DEPIC-2 ESD
switches to its fail safe state in less than
100ms. Response time is actuator dependent.
• The end user must add the DEPIC-2 ESD
response time to actuator/valve response
to obtain overall response time.
• All SIS components, including the DEPIC-2
ESD, must be operational before process
start-up.
• In order to use the PST as an automatic
diagnostic tool the PST shall be scheduled
(using Auto-PST) to run at least once per
month or ten times within the expected
hazard demand interval, whichever comes
first. Detailed failure rate data is specified in
the FMEDA report available from the factory.
• In order to use the SOVT as an automatic
diagnostic tool the SOVT shall be scheduled
(using Auto-SOVT) to run at least once per
week or twenty times within the expected
hazard demand interval, whichever comes
first. Detailed failure rate data is specified in
the FMEDA report available from the factory.
• Personnel performing maintenance and
testing on the DEPIC-2 ESD has to be
qualified to do so.
• Results from the FST, PST, and SOVT proof
tests shall be recorded and periodically
reviewed.
• The useful life of the DEPIC-2 ESD is
discussed in the Failure Modes, Effects and
Diagnostic Analysis (FMEDA) Report for the
DEPIC-2 ESD.
5.4.4 Signatures
If enabled, signatures of FST and PST may
be collected for analysis. The signatures are
graphical representations of the FST and PST
and can be used for trending information.
5.4.5 Proof test
You can automatically or manually run a proof
test (any of above tests). The objective of proof
testing is to detect failures within a DEPIC-2
and ESD valve that are not detected normal
operation of the system.Of main concern are
undetected failures that prevent the safety
instrumented function from performing its
intended function.
Proof testing frequency or proof test interval,
has to be determined in reliability calculations
for the safety instrumented functions to which
DEPIC-2 ESD is applied. The proof tests must
be performed either more frequent or as
frequently as specified in the PFDavg calculation
in order to maintain the required safety integrity
of the safety instrumented function.
The following proof test is recommended as a
guideline to increase the safety and reliability of
the operation. Report any detected failures that
compromise functional safety to the factory.
5.4 DIAGNOSTICS
The DEPIC-2 provides several types of
diagnostic information from proof testing:
• Full-Stroke Testing (FST) diagnostics.
• Partial-Stroke Testing (PST) diagnostics.
• Solenoid Operated Valve Test (SOVT)
diagnostics.
• Signatures on FST and PST if enabled.
5.4.1 FST
You can configure and run FST manually at
any. For more information on FST refer to
“Full-Stroke Testing” section in this document.
5.4.2 PST
You can configure and run PST manually at
any time or set it up to be automated and run
periodically. For more information on PST
refer to “Partial-Stroke Testing” section in
this document.
5.4.3 SOVT
You can configure and run SOVT manually at
any time or set it up to be automated and run
periodically. For more information on SOVT
refer to “Solenoid Operated Valve Testing”
section in this document.
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 17 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
TABLE 1 - PROOF TEST STEPS
Step Action
1Read the DEPIC-2 ESD data record using either a HART handheld device or DTM software.
Solve any active faults before proceeding (Failure Alerts and Alarms).
2Bypass the valve, or isolate or take other appropriate action to avoid a false trip, following appropriate
procedures.
3Inspect the DEPIC-2 valve/actuator/solenoid for dirty or clogged ports and other physical damage.
4De-energize the DEPIC-2 and observe that the actuator and valve move. Energize the DEPIC-2 after
the valve has moved to its full stroke length. This will automatically collect a Full-Stroke Signature
if enabled which can be evaluated against a Baseline Signature.
5Inspect the DEPIC-2/valve/actuator/solenoid for dirt, corrosion or excessive moisture. Clean if
necessary and take corrective action to properly clean the air supply. It has to be done in order to
avoid incipient failures due to dirty air.
6Record any failures in your company’s SIF inspection database. Restore the loop to full operation.
7Remove bypass or otherwise restore normal operation.
5.5 DEPIC-2 ESD PRODUCT SAFETY
The DEPIC-2 ESD is intended for use with
industrial compressed air systems only.
Ensure that an adequate pressure relief
provision is installed where the application of
system supply pressure may cause peripheral
equipment malfunctioning. Installation must
be in accordance with local and national
compressed air and instrumentation codes.
5.5.1 General installation, maintenance or
replacement
• Products must be installed in compliance
with all local and national codes and
standards by qualified personnel using safe
site work practices. Personal Protective
Equipment (PPE) must be used per safe site
work practices.
• Ensure proper use of fall protection when
working at heights, per safe site work
practices. Use appropriate safety equipment
and practices to prevent the dropping of tools
or equipment during installation.
• Under normal operation, compressed air
is vented to the surrounding area, and may
require additional precautions or specialized
installations if used in areas with potentially
explosive atmospheres.
This test should detect approximately 99% of
possible dangerous undetected failures in the
DEPIC-2 (Proof Test Coverage).
The person(s) performing the proof test of a
DEPIC-2 must be trained in SIS operations,
including bypass procedures, maintenance
and appropriate procedures.
ATTENTION
Before using these products with fluids/
compressed gases other than air or for
non-industrial applications, consult the
factory. This product is not intended for
use in life support systems.
ATTENTION
Do not use damaged instruments.
ATTENTION
Installation in poorly ventilated confined
areas, with any potential of gases other
than oxygen being present, can lead to a
risk of personnel asphyxiation.
Use only genuine replacement parts which
are provided by the manufacturer, to guarantee
that the products comply with the essential
safety requirements of the European Directives
mentioned on the front cover.
Changes to specifications, structure, and
components used may not lead to the revision
of this manual unless such changes affect the
function and performance of the product.
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 18 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
6 OPERATION
The DEPIC-2 can operate in three basic
functional characteristics. Even if the DEPIC-2
uses three different modes of operations, it
uses the same hardware and software so the
external look and user interfaces will remain
the same during these different modes of
operation. Please refer to the ordering guide to
select different configurations and features of
the device while ordering. Furthermore, many
features are controlled through software also
so it might be possible to enable those features
later on after the purchase. Please contact
Westlock Controls sales team for more details.
• Valve position transmitter with 4-20 mA
position feedback.
• ESD monitor and basic diagnostics.
• Advanced diagnostics with pressure profiling.
Each mode is described in more details in the
following sections.
6.2 ESD MONITOR AND BASIC DIAGNOSTICS
For applications in SIS, the DEPIC-2 with ESD
enabled (DEPIC-2 ESD) is a solution to improve
safety in a processing plant; specifically
designed to prevent and mitigate possibly
uncontrollable situations. DEPIC-2 ESD is a SIL
3 compliant valve smart monitor interface that
continuously monitors the ESD valve operation
of the plant and reports any operational
failures. The installation and wiring is still the
same as mentioned in earlier sections.
An emergency shutdown (ESD) valve is a valve
that operates to insure a safe state of a plant
when process conditions become or could
become uncontrollable. Hundreds of ESD
valves are part of every petro-chemical and
offshore production plant, as well as part of
pipeline installations. During normal operation,
these valves are energized to stay open or
closed, with the means of a solenoid valve. If
an unsafe situation occurs, the ESD valve is
de-energized to go to its fail-safe position (fail-
closed or fail-open). The solenoid valve vents
the pressure from the spring-return actuator
chamber, to atmosphere. The accumulated
static energy in the actuator spring provides the
necessary force to bring the valve to its closed
position.
Because of its data monitoring capability,
the DEPIC-2 ESD is capable of validating the
health of its integral components. The limited
partial stroke test enables validation of valve,
actuator, and solenoid assembly health without
interfering with the plant process. Periodic
ESD valve testing reduces PFD (Probability of
Failure on Demand) since exercising the valve
reduces the risk of improper operations due to
sticking, and confirms if an impending problem
would prevent the ESD valve to properly
operate.
6.1 VALVE POSITION TRANSMITTER
In this mode, the DEPIC-2 is used only for valve
position. The field wiring remains the same
as mentioned in the earlier sections. However
the device doesn’t have pressure sensor
manifold in this mode so the air is not tubed
to monitor the pressure and perform other
diagnostics functions. After calibration, the
device basically measures the signal from hall
sensor and coverts the reading into 0% to 100%
position signal after compensation for rotary/
linear conversion. The position reading is then
represented by the 4-20 mA on the loop. The
DEPIC-2 is basically a current sinking device
so the transmitter output is represented on the
same 4-20 mA loop being used to power up the
device. The HART communication is available
in this configuration so the device can be
operated using other user interfaces discussed
in later sections of the document. In this
mode, the device has some basic information
for diagnostics like valve cycle count, valve
opening/closing time etc. The device doesn’t
monitor the ESD signal in this mode and
doesn’t generate an ESD alarm if there is a
safety demand and the valve moves to fail safe
position.
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 19 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
• The ESD device performs as a smart solenoid
to pneumatically activate an ON/OFF valve.
• It is primarily used for Safety Instrumented
Systems (SIS) that require field devices to
be certified for safety related applications
according to IEC-61508.
• It is certified by EXIDA for usage to a SIL3
safety integrity level.
• Interacts with a SIS Logic solver.
• Works with existing 24 VDC as a 4-20 mA
output signal (position transmitter), 2 wire
installations with superimposed HART
communications.
• Monitors SIS voltage to solenoid as a control
signal to determine a set-point for 0% or
100% in conjunction with a discrete 0-24 VDC
signal as the safety trip trigger.
• Communicates HART over existing wires
(4-20 mA).
• Generates an alarm during ESD condition
to notify the user.
In addition, DEPIC-2 ESD is a PST controller
that mounts on a pneumatically actuated
valve assembly. Its role is to position an
emergency shutdown valve to 0% or 100%
with a Probability of Failure on Demand
(PFD) in accordance with IEC-61508 for SIL3
application (SIL = Safety Integrity Level).
It replaces solenoid valves, typically utilized
to actuate a spring-return or double-acting
actuator, while providing extensive online valve
diagnostics. The PST function offered in this
mode has limited functionality as it doesn’t
use the pressure sensor data during the PST.
In this mode, the PST is basically a time based
test, where it monitors the valve moves to the
pre-configured travel limit and returns to its
fully energized position. It can still generate an
alarm if the PST fails. However more advanced
PST and other tests like SOVT and FST are not
available in this mode of operation.
6.3 adVaNCEd dIagNOsTICs wITH
PrEssurE PrOfIlINg
In this mode, the DEPIC-2 has the pressure
sensor manifold and the air is tubed to the
manifold to monitor the actuator and/or
supply pressure. The DEPIC-2 can collect
signature information on any Full-Stroke
or Partial-Stoke movement of a valve if
configured to do so (Signatures Enabled
and Pressure Sensors used). It also offers a
pressure based diagnostic test SOVT (Solenoid
Operated Valve Test), where it monitors the
change in the actuator pressure to make sure
the spool valve of the solenoid is working.
A Signature is a collection of sensor readings
(position and pressure) read periodically
during valve movement. The Full-Stroke and
PST Signatures consist of both a Baseline
and Maintenance Signatures. The Baseline is
obtained shortly after commissioning of a valve
in process and is used as a reference of normal
operating performance. The Maintenance
Signature is collected anytime the valve moves
after the Baseline is collected and is used to
compare with the Baseline to aid in detecting
degradation in valve/actuator performance
over time which can be used to predict possible
failures before they occur. This feature can be
very important in safety applications.
The following 2 figures show examples of
Full-Stroke Signatures as they might appear
displayed on a HART host using the HART DD.
FIGURE 15
Closing full stroke signature
FIGURE 16
Opening full-stroke signature
Copyright © Crane Co. All rights reserved.

VCIOM-05044
Page 20 of 75
DIGITAL EPIC-2 TECHNICAL MANUAL
InstallatIon and operatIng InstructIons
Note with Full-Stroke Signatures they are
actually broken into two signatures, one
for opening direction and one for closing
direction which makes up one full-stroke
cycle. In addition, there are certain critical
points within these signature plots which are
very meaningful in determining if a valve/
actuator is performing properly. These critical
points or data are found by the device during
the capture of the signatures and save in a
database called Run-Time Data. There is
Run-Time Data for the Baseline Signature and
for the latest Maintenance Signature only. The
device in analyzing the Maintenance Signature
against the Baseline actually uses this data
derived from the signatures to determine if
there is degradation in performance. This way
the user does not need to actually analyze the
signature plots especially if unfamiliar. The
device looks at the Run-Time Data and makes
decisions and sets or clears Alerts in an Alert
File as notification to the user of any potential
problems. It is only up to the user to set
hysteresis settings in configuration as a guide
for the device to know what is out of tolerance.
Figure 17 shows an example of a PST signature
plot as they might appear displayed on a HART
host using the HART DD:
Again, there are certain critical points within
these PST signature plots which are very
meaningful in determining if a valve/actuator
is performing properly. These critical points or
data are found by the device during the capture
of the signatures and saved in a PST database.
There is data for the Baseline PST Signature
and for the latest Maintenance PST Signature.
The device in analyzing the Maintenance
PST Signature against the Baseline actually
uses this data derived from the signatures
to determine if there is degradation in
performance. This way the user does not
need to actually analyze the signature plots
especially if unfamiliar. The device looks at the
data and makes decisions and sets or clears
Alerts in an Alert File as notification to the user
of any potential problems and also sets Alarms
in the Alarm File if there is a hard failure. It is
only up to the user to set hysteresis settings in
configuration as a guide for the device to know
what is out of tolerance.
FIGURE 17
PST signature
Copyright © Crane Co. All rights reserved.