Emerson TopWorx PD100 User manual

Installation, Operation, and Maintenance Manual
ES-09373-1
August 17, 2022
Emerson TopWorx TM PD100
Smart Valve Positioner

Safe Use - User Instructions
Installation, Operation, and Maintenance Manual
ES-09373-1
Safe Use - User Instructions
August 17, 2022
Safe Use - User Instructions
To reduce risk of death, serious injury or property damage:
• Personnel installing, maintaining, or operating this equipment must be qualified, must read,
understand, and follow these instructions before proceeding.
• This document must be retained for future reference.
• Please contact local Topworx representative for questions, clarifications, or comments.
Instructions for safe selection, installation, use, maintenance, and repair
• Do not use the positioner outside the operating range, as it may cause failures or
even accidents with serious injuries. See: Section 2 - Specifications
• For installation in a potentially explosive atmosphere, make sure you have the
positioner correctly specified for this purpose. Products for explosion hazard
areas have the -EN or -ES suffix at the end of the code.
• Never touch the moving parts of the positioner when it is in operation, as the
movement of the valve may cause accidents with serious injuries.
• The positioner must be installed by qualified technical personnel. We warn of the
risk of damage to persons and goods resulting from improper installation or
configuration.
NOTICE

Installation, Operation, and Maintenance Manual Safe Use - User Instructions
ES-08436-1 August 17, 2022
Safe Use - User Instructions c
DANGER
IMPORTANT
Warning Symbols Used in this Manual
This manual contains notes that must be observed for your personal safety as well as
to prevent material damage.
The following symbols and explanations are listed according to their degree of
danger:
DANGER - Serious damage to health / danger of death
This symbol in combination with the signal word “DANGER” indicates an immediate
danger. Failure to observe the safety warning causes death or very serious injury.
ATTENTION - Personal Injury
This symbol in combination with the signal word “WARNING” indicates a possibly
dangerous situation. Failure to observe the safety warning can cause death or very
serious injury.
CAUTION - Risk of injury
This symbol in combination with the signal word “CAUTION” indicates a possibly dan-
gerous situation. Failure to observe the safety warning can cause injury.
WARNING - Material Damage
This symbol in combination with the signal word “WARNING” indicates a possibly
harmful situation. Failure to observe the safety warning may permanently damage
the product or lead to loss of process control.
IMPORTANT (Note)
This symbol in combination with the signal word “IMPORTANT” indicates tips for the
user or especially useful information about the product or its use. It does not signal a
dangerous or harmful situation.
ATTENTION
CAUTION

Table of Contents i
Installation, Operation, and Maintenance Manual
ES-09373-1
Table of Contents
August 17, 2022
Contents
Section 1: Introduction 1
1.1 General Notes ............................................................................ 1
1.2 Proper Use.................................................................................. 1
1.3 Qualified Technical Staff............................................................. 2
1.4 Exclusion of Liability ................................................................... 2
Section 2: Specifications 3
Section 3: Overview 5
3.1 Enclosure ................................................................................... 6
3.2 Identification Label Information ................................................. 6
3.3 Scope of Supply.......................................................................... 7
Section 4: Principle of Operation 8
Section 5: Mechanical Installation 10
5.1 What are Rotary Pneumatic Actuators?..................................... 10
5.2 What are Pneumatic Linear Actuators?...................................... 10
5.3 Rotary Actuator Installation ...................................................... 11
5.3.1 Mounting the Rotary NAMUR Bracket to the Actuator.. 12
5.4 Linear Actuator Installation ....................................................... 15
5.4.1 Assembling the Guide Arm ........................................... 16
5.4.2 Installing the Feedback Lever and Bracket..................... 16
5.4.3 Yoke Castle Mount........................................................ 17
5.4.4 Mounting on a Pillar Type Castle ................................... 17
5.4.5 Types of Feedback Lever................................................ 18
5.4.6 Standard Installation..................................................... 19
Section 6: Pneumatic Connections 24
6.1 Manifold Types.......................................................................... 25
6.2 Pneumatic Connection on Rotary Actuator ............................... 26
6.3 Pneumatic Connection on Linear Actuator ................................ 26
Section 7: Electrical Connections 27
7.1 Cable Entry ............................................................................... 27
7.2 Grounding ................................................................................ 28
7.3 Electrical Connection................................................................ 28
Section 8: Configuration 30
8.1 Configuration Buttons............................................................... 30
8.2 Entering and Navigating the Configuration Menu...................... 31
8.3 Fast Callibration ........................................................................ 32
8.4 Configuration Menu.................................................................. 33
8.4.1 Setup Menu ................................................................. 34
8.4.2 PID Menu ..................................................................... 35
8.4.3 CTR Menu .................................................................... 40
8.4.4 T OUT Menu................................................................. 42

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Table of Contents
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Contents
Section 9: Certifications 45
Section 10: Mechanical Dimensions 46
10.1 Rotary Positioner Dimensions................................................. 46
Section 11: How to Specify 47

Introduction 1
Installation, Operation, and Maintenance Manual
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Introduction
August 17, 2022
Introduction
The PD100 Smart valve positioner is IP66 rated and designed to operate in the
harshest environmental conditions. Proportional air consumption and fast response
contribute to efficient operation and the device is unaffected by vibration.
The PD100 is compact and can be installed on rotary or linear actuators and is used
in single or double acting actuator applications. It is powered directly by the control
current loop from 4 to 20mA.
The Ex version is certified as non-incendive (Ex n) and indicated for installation in
potentially explosive atmospheres of flammable gases and vapors in Class I, Div 2
environments.
1.1 General Notes
The positioner leaves the factory with default settings and must be installed and
configured following the information in this manual. In addition, special care must be
taken during transport, storage, operation and maintenance according to industrial
standards and in compliance with technical regulations.
This manual contains the information necessary for the proper use of the positioner.
It is intended for qualified and authorized technicians who have received applicable
training or have general knowledge in the field.
Knowledge and technical application of the safety instructions and warnings in this
manual are of utmost importance for risk-free mounting and commissioning. This will
ensure safety during operation and maintenance of the product.
This manual is not an integral part of the delivery of the positioner and is subject to
change without notice. The manual is available for download on our website at www.
emerson.com
For the sake of clarity, the manual does not contain all the detailed information on all
versions of the product described, nor does it refer to all possible cases of installation,
operation, maintenance and use in systems. If you need additional information
or if problems arise that are not mentioned in this documentation, please ask our
application engineering department for the necessary information.
Special attention must be paid to the warning texts. These texts are specially marked
by their symbols. See Section 1.6 - Warning symbols used in this manual
1.2 Proper Use
The PD100 positioners are electro-pneumatic position controllers intended for
positioning rotary or linear final control elements and may only be used for the
applications described in the instruction manual or in its data sheet.
The positioner was developed in accordance with the current safety standards. Before
field installation, make sure you have the correct positioner for your environment.

Introduction
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Introduction
1.3 Qualified Technical Staff
Installation, configuration and maintenance of the positioner is permitted only by
technicians qualified to perform this procedure in accordance with the information in
the operating instructions.
The responsible technician must be familiar with the process and be able to identify
risks and avoid potential dangers both during installation and during setup and
maintenance of the positioner.
1.4 Exclusion of Liability
This manual contains the most relevant information for the positioner to be mounted
and configured correctly.
It is the responsibility of the technician to know the safety regulations and practices
applicable in your country. It is also your responsibility to read and understand the
information described here.
In case of questions, the technician must contact our application engineering to
answer them prior to installing/ configuring the positioner.
All mounting and configuration of the positioner must be performed by qualified
personnel strictly following the guidelines contained in this manual.
Emerson TopWorx is not responsible for damages caused to persons or property
resulting from incorrect installation and/or configuration.

Specifications 3
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Specifications
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Specifications
Table 1 Specifications
Physical Specification Min. Typ. Max.
4-20mA input Signal 3.6 mA 4-20 mA DC, Nominal 25 mA (Overcurrent
Protection)
Input Voltage 12.2 VDC for analog
control
35 VDC
Overcurrent Protection Yes
Reverse Polarity
Protection
Yes
Operation with reverse
Polarity
Yes
Voltage Drop 12.2 VDC @ 4 mA DC /
24 VDC
Impedance - Input 470 Ω@ 20 mA / 24 VDC
(external power supply)
Impedance - Output 800 Ω @ 20mA / 24 VDC
Linearity 0.8% of Full Scale
Hysteresis 1.5% of Full Scale
Repeatability 1.45% of Full Scale
Minimum Step
Response
≥0.3125% Full Scale or
≥50 µA
Start-up 8 seconds
Insulation Resistance > 25 G [ohms] Approved
in dielectric resistance
test 500 VDC
Lifetime > 150 K cycles
Operating Temperature
Limits
-40 °C (40 °F) LCD may not be
readable below -20 °C
(-4 °F)
80°C (176 °F)
Output Signal Actuator Output from
0 to 100% of the supply
pressure
Valve Action Double, Direct Action
and Reverse Action
LCD-PD100 Digital – 4 Digit
Numeric
Shaft Rotation 60° 120°
Stroke Range Linear 12 mm 200 mm
Supply Air Pressure140 psi (2.8 bar) 116 psi (8bar)

Specifications
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Specifications
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Table 1 Specifications
Maximum Bearable
Pressure 2
145 psi (10 bar)
Output Position
Transmitter
Nominal signal range:
4 - 20 mA
Power Supply:
10 – 30 Vdc
External Load
Resistance:
800 Ω @ 24 Vdc
Position Error:
< 0.33%
Temperature
Error Effect:
0.01%/K °C
Resolution:
< 0,33%
Output Type:
Electrically isolated
output
Air Consumption 8.8 l/min = 0.5 N m3/h
= 0,31 scfm = 18.6 scfh
considering the pres-
sure of 60 psi = 4.1 bar
Maximum air output 311 l /min = 17.7 N
m3/h = 11 scfm = 660
scfh considering the
pressure of 60 psi = 4.1
bar
Valve Flow
Characteristics
Linear, Equal Percent-
age, fast Opening
Pneumatic Connections Supply and Output
Pressure:
¼”NPT Female
Conduit Connections ½” NPT Female
Housing and Cover
Material
FARADEX
Display window Polycarbonate
Module Base Assembly Aluminum
Manifold ZAMAK 5
Elastomers Nitrile (NBR)
Protection class IP66, Type 4X, NEMA 4X
Weight 2.2 Kg
0.55 Kg linear mounting
bracket
0.4 Kg rotary mounting
bracket
Note 1: or the maximum pressure allowed by the actuator.
Note 2: Although the positioner will resist this pressure, it is not recommended to
work at this pressure as it will affect the accuracy and stability of the controller.

Overview 5
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Overview
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Overview
See below for parts of the PD100 positioner. To access the mechanical configuration
buttons and electrical terminals you must remove the product cover
Figure 3-1 Overview
Item Description
1 Four-Digit LCD display
2Plate Cover
3 Manifold with Pressure Gauges
4 Mechanical UP Button
5 Mechanical ENTER Button
6 Mechanical DOWN button
7 Air Exhaust
8 Electrical Terminals (Control and Feedback Signals)
9 Cable Entry

Overview
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3.1 Enclosure
Enclosure manufactured in engineering plastic with conductive characteristics allowing
the housing to be grounded to avoid the accumulation of electrostatic charges that in
classified areas can cause the ignition of the explosive atmosphere.
3.2 Identification Label Information
Figure 3-1 Enclosure
Figure 3-2 Front Label Figure 3-3 Side Label
Figure 3-4 Internal Label Front Label
This label contains the following information:
• Manufacturer ID
• Order code
Side Label
This label carries the following information:
• Model number
• Serial Number
• Operation Information
Internal Label
This label contains the following information:
• How to perform a quick calibration
• How to enter and navigate the configuration menu

Overview 7
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Overview
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3.3 Scope of Supply
Check the packaging immediately after receiving the product. Make sure that the
contents are undamaged and that they are in accordance with the scope of delivery
and as described on the invoice. If there are any discrepancies, please contact us
immediately.
The positioner is supplied in a closed package containing the following items:
• Intelligent electropneumatic positioner
• Linear or rotary actuator adaptor (as specified)

Principle of Operation8
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Principle of Operation
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Principle of Operation
The PD100 smart positioner is powered by the 4-20 mA loop, with the control signal.
The supply air is connected to the inlet on the manifold and passes though the
pneumatic spool valve that controls the valve position.
The air passes through the Pressure Regulator and reaches the I / P Converter.
The valve position is detected through the Position Feedback Sensor (Hall effect
sensor) and transmitted to the electronic board ( Main Microprocessor).
The fast microprocessor compares the control signal and the position feedback, and
the difference is the input to the PID controller that will generate an appropriate signal
(in frequency) to be applied to the coil of the I/P converter.
The I / P Converter is the nozzle / vane that generates a pressure signal to the
Diaphragm Module that will create a dynamic force on the spring that breaks the
balance of the spool valve, that then moves the valve to the new required position.The
microcontroller repeats the process and when the difference between the requested
position signal and the actual position feedback trends to zero, the interference of the
Diaphragm Module will cease and there will be a new balance on the spool valve, and
the valve will reach the new position.

9Principle of Operation
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Principle of Operation
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Principle of Operation
Figure 4-1 Working Principle

Mechanical Installation10
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Mechanical Installation
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Mechanical Installation
The installation of the positioner will depend on the actuator type (linear or rotary).
The following shows the types of pneumatic actuators and a brief overview of their
operation.
Be sure to install the air filter and regulator before the positioner. The supply pressure
should be sufficient to fully open and close the valve.
5.1 What are Rotary Pneumatic Actuators?
Rotary pneumatic actuators are devices that convert the stored energy of compressed
air into a rotary mechanical motion. These devices can be single-acting, where they
receive air to open or close the valve and return to their original position by means of
a spring, without the need for air, or double-acting, which requires compressed air to
move in both directions.
5.2 What are Pneumatic Linear Actuators?
Linear pneumatic actuators are devices that convert the stored energy of compressed
air into a linear mechanical motion. This linear motion allows the valve to open or
close.
Similarly, to rotary actuators, they can also be single-acting, requiring air for only one
direction, or double-acting, requiring air for both directions.
Observe the maximum pressure that the pneumatic actuator can withstand.
Diaphragm actuators can be easily damaged by excessive pressure.
Figure 5-1 Rotary Actuator Types
Figure 5-2 Linear Actuator Types

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5.3 Rotary Actuator Installation
Figure 5-3 Installation on a Rotary Actuator Figure 5-4 Mounting Kit for Rotary Actuator
NOTICE
When installing the mounting bracket on the positioner and the set on the rotary
pneumatic actuator, observe the maximum torque indicated below:
Positioner on the mounting brackets (4xM6): 10 Nm (7.38 ft/lbs.).
Mounting bracket on the rotary actuator (4xM5): 10 Nm (7.38 ft/lbs.).
Before installing the positioner, check the area classification. Never use a general-
purpose positioner in a classified area with explosion risk. The positioner allows
mounting to standard NAMUR rotary actuators (VDI/VDE 3835, IEC 60534-6-2). The
figure below illustrates the parts of the universal rotary mounting kit.

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5.3 Rotary Actuator Installation (Continued)
5.3.1 Mounting the Rotary NAMUR Bracket to the Actuator
Check the L and H position for correct mounting of the positioner to the pneumatic
actuator.
Figure 5-5 Assembling the Bracket
NOTICE

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5.3 Rotary Actuator Installation (Continued)
5.3.1 Mounting the Rotary NAMUR Bracket to the Actuator
1 - Mount the rotary adapter and tighten the screw with an 8 mm hex wrench.
2 - The rotary support is factory assembled for actuators with 30x80 holes and 30mm
shaft height. If you need to modify these measures, refer to sec 5.3.1 - Mounting the
Rotary Support to the Actuator.
3 - Mount the bracket to the positioner by placing the four M6x10 screws with lock
washers and plain washers. Tighten the screws with a 10 mm wrench.
The positioner can be installed at any starting angle and operates in any position,
vertical or horizontal.
Be careful when handling compressed air hoses, make sure the line is disconnected
before connecting it to the positioner.
The positioner can be installed at any starting angle and operates in any position,
vertical or horizontal.
Figure 5-6 Rotary Adaptor
Figure 5-7 Universal Rotary Mounting Kit
Figure 5-8 Mounting the Bracket on the Positioner
ATTENTION
IMPORTANT
CAUTION

Mechanical Installation14
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5.3 Rotary Actuator Installation (Continued)
5.3.1 Mounting the Rotary NAMUR Bracket to the Actuator
4 - Mount the positioner with bracket by engaging the positioner end cap on the shaft
of the rotary actuator, attach the four M5x10 screws with lock washers and plain
washers. Tighten the screws with an 8 mm wrench.
5 - Make the pneumatic and electrical connections. See Section 6 Pneumatic
Connections and item 7 Electrical Connections.
6 - Perform a fast calibration. See Section 8.3 - Fast Calibration.
Figure 5-9 Fitting on the Actuator Shaft
Figure 5-10 Tightening the Bracket Bolts
Figure 5-11 Mounted Positioner

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5.4 Linear Actuator Installation
See below the installation of the positioner on linear valves.
Figure 5-12 Installation on a Linear Actuator
DANGER
Before installing the positioner, check the area classification. Never use a General
Purpose positioner in an area classified as an explosive atmosphere.
Excess pressure can permanently damage the actuator diaphragm. Check the
actuator manual for the maximum pressure supported.
IMPORTANT
When installing the mounting bracket on the positioner and then setting on the linear
pneumatic actuator, observe the maximum torque indicated below:
Positioner on the mounting brackets (2xM8): 15 Nm. Mounting bracket on the linear
actuator (2xM8): 15 Nm.