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

Table of Contentsii
Installation, Operation, and Maintenance Manual
ES-09373-1
Table of Contents
August 17, 2022
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
ES-09373-1
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
2
Installation, Operation, and Maintenance Manual
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Introduction
August 17, 2022
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
Installation, Operation, and Maintenance Manual
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Specifications
August 17, 2022
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
4
Installation, Operation, and Maintenance Manual
ES-09373-1
Specifications
August 17, 2022
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
Installation, Operation, and Maintenance Manual
ES-09373-1
Overview
August 17, 2022
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