Topworx Dxp Instruction manual

Installation, Operation & Maintenance Manual

3300 Fern Valley Road, Louisville, Kentucky 40213 USA www.topworx.com

502.969.8000 phone 502.969.5911 fax [email protected]

Table of Contents

2Features and Specifications

3Installation

4Calibration & Operation

6Calibration Flow Chart

7Maintenance

DXP with 4-20mA Position Transmitter

The DXP combines position sensors, internal mount pilot device and an

on-board spool valve into a single enclosure.

•Explosion-proof Class I, Div.1, Groups C & D (Ex d IIB+H2, II 2 G)

•GO Switch, Mechanical, Proximity and Inductive Sensor switch

options

•Optional Solenoid Pilot Valve

0518

502.969.8000

DXP 4-20mA Installation, Operation & Maintenance

Features and Specifications

4-20mA Position Monitorinig Description4-20mA Position Monitorinig Description

4-20mA Position Monitorinig Description

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.

FeaFea

Features:tures:

tures:tures:

tures:

1) Single push button easy calibration eliminates zero/

span calibration interaction in both clockwise and

counterclockwise actuator/valve rotation directions.

2) Non-volatile memory of set points (set points remain

after loss of power)

3) 4-20mA power connection is not polarity sensitive

4) No internal backlash – direct shaft position feedback

5) No gear wear or mechanical binding

6) 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

7) Position measurement range from 200to 3200.

Factory set for 200to 1800operation in counter

clockwise rotation to open and 200to 900operation

in clockwise rotation to open applications.

8) Advanced diagnostics includes detection of dead

band, out of range indication and detection of

internal memory errors

9) Transmitter PCB is potted and sealed

10) Included with all valve monitoring switching options,

incl. DPDT mechanical

11) +/- 1% position linearity for the complete device

12) Selectable +/- 3% over and under travel capability

or full linear options set during calibration

13) Hysteresis:

0.5% of full-scale

14) Repeatability:

0.3% of full scale.

15) Temperature Range: -400to 850C

Electrical DaElectrical Da

Electrical Data:ta:

ta:ta:

ta:

-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 OnlPotentiometer Onl

Potentiometer Only Shaft Position Monitoring Descriptiony Shaft Position Monitoring Description

y Shaft Position Monitoring Descriptiony Shaft Position Monitoring Description

y 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 FeaPotentiometer Fea

Potentiometer Features:tures:

tures:tures:

tures:

1) Hollow shaft mounting requires no gears and has no backlash

2) Direct shaft position feedback

3) Capable of 4,000,000 lifetime operations

4) Better than 0.3° resolution

5) Conductive plastic Potentiometric sensor for excellent environmental protection

6) Temperature Range: -400to +850C

Typical 4-20mA Positionypical 4-20mA Position

ypical 4-20mA Positionypical 4-20mA Position

ypical 4-20mA Position

Transmitter in aransmitter in a

ransmitter in aransmitter in a

ransmitter in a TT

TopWopW

opWopW

opWorx DXPorx DXP

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Potentiometer Electrical Data:Potentiometer Electrical Data:

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%

Installation (Use the fUse the f

Use the fUse the f

Use the following installaollowing installa

ollowing installaollowing installa

ollowing installation procedure to upgtion procedure to upg

tion procedure to upgtion procedure to upg

tion procedure to upgrade an existing DXP in the field)rade an existing DXP in the field)

rade an existing DXP in the field)rade an existing DXP in the field)

rade an existing DXP in the field)

4-20mA Position Transmitter Module and Stand Alone Potentiometer

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 (for removal instructions please refer the applicable TopWorx Valve Controller

Instruction, Operation and Maintenance Manual)

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

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

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 oring seals on shaft.

IllustraIllustra

Illustration 2tion 2

tion 2tion 2

tion 2

4-20 position4-20 position

4-20 position

transmitter moduletransmitter module

transmitter module

and bracketand bracket

and bracket

IllustraIllustra

Illustration 3tion 3

tion 3tion 3

tion 3

POTENTIOMETER CONNECTION METHOD:

KX & MX MODELS:

CONNECTOR PLUGS INTO CIRCUIT BOARD.

KA, MA, KB & MB MODELS:

POTENTIOMETER ONLY CONNECTED

ACCORDING TO WIRING DIAGRAM.

4-20 mA POSITION

TRANSMITTER

POTENTIOMETER

1K OR 10K

502.969.8000

DXP 4-20mA Installation, Operation & Maintenance

4) The alignment boss on the bracket (indicated in Illustration 2) 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. (As shown in Illustration 6)

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 Illustration 4 with the valve in the closed position.

NOTE:**The potentiometer has been factory set for typical valve rotation ranges from 20 to

180

in counter-clockwise rotation applications from the 4mA position to the 20mA position

and from valve rotation ranges from 20 to 90

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.

Calibration and Operation

CalibraCalibra

Calibration of the 4-20mA Current Positiontion of the 4-20mA Current Position

tion of the 4-20mA Current Positiontion of the 4-20mA Current Position

tion of the 4-20mA Current Position TT

Transmitterransmitter

ransmitterransmitter

ransmitter

The 4-20 current transmitter can be used for any rotation range between 20 and 3200**.

Reverse directions are automatically accounted for during the calibration process.

Option #1:Option #1:

Option #1: +/- 3% Over and Under+/- 3% Over and Under

+/- 3% Over and Under+/- 3% Over and Under

+/- 3% Over and Under TT

Trara

rara

ravel avel a

vel avel a

vel at the Set End Points:t the Set End Points:

t the Set End Points:t the Set End Points:

t the Set End Points:

1) Apply power to unit (LED should be continuously on)

2) Counter-clockwise calibrationCounter-clockwise calibration

Counter-clockwise calibrationCounter-clockwise calibration

Counter-clockwise calibration - Press the button greater than 0.5 secs and less than three secs if you are going to calibrate using a

counter-clockwise rotation from the 4mA position to the 20mA position. (LED will start flashing a 3 – 1 code indicating that calibration mode is

active and the unit is waiting to calibrate the 4ma position).

Clockwise calibrationClockwise calibration

Clockwise calibration - Press the button greater than three secs and less than 5.5 secs if you are going to calibrate using a clockwise

rotation from the 4ma position to the 20ma position. (LED will start flashing a 3 – 2 code indicating that calibration mode is active and the unit

is waiting to calibrate the 4mA position).

3) Rotate valve to the desired position corresponding to 4mA. (This can be the open or closed position)

4) Press the button to capture the 4mA value (The LED will start flashing a 3-3 code indicating that the unit is waiting to calibrate the 20mA

position)

5) Rotate valve to the desired position corresponding to 20mA (This will be the position opposite of the position in step 3)

6) Press the button to capture the 20mA value (The LED will turn on continuously)

Option #2:Option #2:

Option #2: No Under and OverNo Under and Over

No Under and OverNo Under and Over

No Under and Over TT

Trara

rara

ravel avel a

vel avel a

vel at Set End Points (Full Linear):t Set End Points (Full Linear):

t Set End Points (Full Linear):t Set End Points (Full Linear):

t Set End Points (Full Linear):

1) Apply power to unit (LED should be continuously on)

2) Counter-clockwise calibrationCounter-clockwise calibration

Counter-clockwise calibrationCounter-clockwise calibration

Counter-clockwise calibration - Press the button greater than 5.5 secs and less than eight secs if you are going to calibrate using a

counter-clockwise rotation from the 4mA position to the 20mA position. (LED will start flashing a 5 - 1 code indicating that calibration mode

is active and the unit is waiting to calibrate the 4ma position).

Clockwise calibrationClockwise calibration

Clockwise calibration - Press the button greater than 8 secs if you are going to calibrate using a clockwise rotation from the 4ma

position to the 20ma position. (LED will start flashing a 5 - 2 code indicating that calibration mode is active and the unit is waiting to calibrate

the 4mA position).

3) Rotate valve to the desired position corresponding to 4mA. (This can be the open or closed position)

4) Press the button to capture the 4mA value (The LED will start flashing a 3-3 code indicating that the unit is waiting to calibrate the 20mA

position)

5) Rotate valve to the desired position corresponding to 20mA (This will be the position opposite of the position in step 3)

6) Press the button to capture the 20mA value (The LED will turn on continuously)

Illustration 4Illustration 4

Illustration 4

PotentiometerPotentiometer

Potentiometer

ShaftShaft

Shaft AssemblAssembl

AssemblAssembl

Assemblyy

ALIGNMENT MARKS

POTENTIOMETER

MOUNTING EAR

FLAT

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1 2 3 4 5 6 7 8 9 10 11 12

POTENTIOMETER

TRANSMITTE

BOARDASSY

LED

CALIBRATION

BUTTON

TERMINAL STRIP

24Vdc POWER SUPPLY

VOM

Set to mA

1 2 3 4 5 6 7 8 9 10 11 12

4-20mAHAND HELD CALIBRATOR

UNIT NOT POLARITY

SENSITIVE

Set Up fSet Up f

Set Up for the Standor the Stand

or the Standor the Stand

or the Stand Alone PotentiometerAlone Potentiometer

Alone PotentiometerAlone Potentiometer

Alone Potentiometer

1) Remove cover and rotate actuator/valve to fail or start position

2) Use an ohmmeter to measure the resistance value at fail or start position (see illustration 6)

3) Connect an ohmmeter to feedback terminal

4) Rotate actuator/valve to end position. Check that resistance increases (or decreases) over stroke and that potentiometer does not rotate

past maximum or minimum resistance (through dead band)

5) Replace cover

Illustration 5 -Illustration 5 -

Illustration 5 -

CalibrationCalibration

Calibration

ConnectionsConnections

Connections

The complete calibration process including error paths is shown in the Figure 1. The software can detect several errors during calibration (See Table 1).

502.969.8000

DXP 4-20mA Installation, Operation & Maintenance

Figure 1 CalibraFigure 1 Calibra

Figure 1 Calibration Flow Charttion Flow Chart

tion Flow Charttion Flow Chart

tion Flow Chart

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Maintenance

Taa

able 1.ble 1.

ble 1.ble 1.

ble 1. Error Code and ProblemError Code and Problem

Error Code and ProblemError Code and Problem

Error Code and Problem TT

Taa

ableble

bleble

ble

OperaOpera

Operation of the 4-20mA Current Positiontion of the 4-20mA Current Position

tion of the 4-20mA Current Positiontion of the 4-20mA Current Position

tion of the 4-20mA Current Position TT

Transmitterransmitter

ransmitterransmitter

ransmitter

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.

OperaOpera

Operation of the Standtion of the Stand

tion of the Standtion of the Stand

tion of the Stand Alone PotentiometerAlone Potentiometer

Alone PotentiometerAlone Potentiometer

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.

Problem

Transmitter Module has no current output

Transmitter does not output 4 or 20mA (+/-1%) at desired end of

travel

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

Probable Cause/Solution

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)

Unit not calibrated (calibrate)

Unit is calibrated (recalibrate - if still fails, replace board)

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. See illustration 9

Start Position is too high

Start and stop positions are less than 200, increase valve rotation

between start and stop positions to greater than 200.

Rotation has exceeded the 3200limit. Decrease valve rotation between

start and stop positions to less than 3200.

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.

Warranty

TopWorx warrants that each item of new equipment manufactured by it will be free from defects in material and workmanship under normal use and service; its obligation under this Warranty, being limited to making good,

at its factory, and part of parts thereof, which shall be returned to it with transportation charges prepaid, within one year after the date of the purchase of such equipment by the original purchaser, and which its

examination shall disclose to its satisfaction to have been thus defective. TopWorx however, assumes no risk or liability for results of the use of the products purchased from it.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, WHETHER OF MERCHANTABILITY FITNESS, OR OTHERWISE EXPRESSED OR IMPLIED, AND ALL OTHER OBLIGATIONS OR LIABILITIES AND TOPWORX NEITHER

ASSUMES , NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS EQUIPMENT.

No claims for labor in replacing defective parts and equipment and consequential damages will be allowed by the Company.

This Warranty shall not apply to equipment which has been subjected to misuse, negligence or accident.

This Warranty shall not apply to any equipment which shall have been repaired or altered, outside the Company's factory so as to affect such equipment's stability or reliability in the judgement of the Company.