Topworx DXP Instruction manual

Installation, Operation & Maintenance Manual
3300 Fern Valley Road, Louisville, Kentucky 40213 USA www.topworx.com
502.969.8000 phone [phone] 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
2
Features and Specifications
4-20mA Position Monitorinig Description4-20mA Position Monitorinig Description
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
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 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 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 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
TT
TT
Typical 4-20mA Positionypical 4-20mA Position
ypical 4-20mA Positionypical 4-20mA Position
ypical 4-20mA Position
TT
TT
Transmitter in aransmitter in a
ransmitter in aransmitter in a
ransmitter in a TT
TT
TopWopW
opWopW
opWorx DXPorx DXP
orx DXPorx DXP
orx DXP

www.topworx.com
3
Potentiometer Electrical Data:Potentiometer Electrical Data:
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
IllustraIllustra
Illustration 2tion 2
tion 2tion 2
tion 2
4-20 position4-20 position
4-20 position4-20 position
4-20 position
transmitter moduletransmitter module
transmitter moduletransmitter module
transmitter module
and bracketand bracket
and bracketand bracket
and bracket
IllustraIllustra
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
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
0
in counter-clockwise rotation applications from the 4mA position to the 20mA position
and from valve rotation ranges from 20 to 90
0
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
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
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: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
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 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:Option #2:
Option #2: No Under and OverNo Under and Over
No Under and OverNo Under and Over
No Under and Over TT
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 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 4Illustration 4
Illustration 4
PotentiometerPotentiometer
PotentiometerPotentiometer
Potentiometer
ShaftShaft
ShaftShaft
Shaft AssemblAssembl
AssemblAssembl
Assemblyy
yy
y
ALIGNMENT MARKS
POTENTIOMETER
MOUNTING EAR
FLAT

www.topworx.com
5
1 2 3 4 5 6 7 8 9 10 11 12
POTENTIOMETER
TRANSMITTE
R
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 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 -Illustration 5 -
Illustration 5 -
CalibrationCalibration
CalibrationCalibration
Calibration
ConnectionsConnections
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
6
Figure 1 CalibraFigure 1 Calibra
Figure 1 CalibraFigure 1 Calibra
Figure 1 Calibration Flow Charttion Flow Chart
tion Flow Charttion Flow Chart
tion Flow Chart

www.topworx.com
7
Maintenance
TT
TT
Taa
aa
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
TT
Taa
aa
ableble
bleble
ble
OperaOpera
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
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
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.

8
3300 Fern Valley Road
Louisville, Kentucky 40213 USA
502.969.8000 phone
502.969.5911 fax
[email protected]
www.topworx.com
About Valvetop™
Valvetop valve networking and control devices link on/off valves to process control systems via a variety of fieldbus protocols. Valvetop valve
controllers and monitors support multiple bus protocols, operate in the most demanding plant conditions, and carry a variety of global approvals.
Whether your application is rotary or linear, fieldbus or conventional, hazardous or general purpose, we have a suitable solution for you.
For inquiries, contact TopWorx at: 502.969.8000
www.topworx.com
[email protected]
About TopWorx
TopWorx is the leader in field networking, valve control, and position sensing solutions for the process industries. Our products and services help
plants, mills, and pipelines improve their performance by making it easy to implement modern automation technologies.
TopWorx, Valvetop, Lumitech, GO Switch, and VIP are all trademarks of TopWorx, Inc.
All other marks used in this document are the property of their respective owners.
Information contained herein is subject to change without notice.
©TopWorx, Inc. All rights reserved. ES-00568-1 R4