Related Manuals for Emerson TopWorx PD100
Summary of Contents for Emerson TopWorx PD100
- Page 1 Installation, Operation, and Maintenance Manual ES-09373-1 August 17, 2022 Emerson TopWorx PD100 Smart Valve Positioner...
- Page 2 Installation, Operation, and Maintenance Manual Safe Use - User Instructions ES-09373-1 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.
- Page 3 Installation, Operation, and Maintenance Manual Safe Use - User Instructions ES-08436-1 August 17, 2022 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 DANGER - Serious damage to health / danger of death...
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Page 4: Table Of Contents
Installation, Operation, and Maintenance Manual Table of Contents ES-09373-1 August 17, 2022 Contents Section 1: Introduction General Notes ................1 Proper Use.................. 1 Qualified Technical Staff ............. 2 Exclusion of Liability ..............2 Section 2: Specifications Section 3: Overview Enclosure ................... 6 Identification Label Information .......... - Page 5 Installation, Operation, and Maintenance Manual Table of Contents ES-09373-1 August 17, 2022 Contents Section 9: Certifications Section 10: Mechanical Dimensions 10.1 Rotary Positioner Dimensions..........46 Section 11: How to Specify Table of Contents...
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Page 6: Section 1: Introduction
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. -
Page 7: Qualified Technical Staff
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. Introduction... -
Page 8: Section 2: Specifications
Installation, Operation, and Maintenance Manual Specifications ES-09373-1 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 35 VDC control Overcurrent Protection Reverse Polarity... - Page 9 Installation, Operation, and Maintenance Manual Specifications ES-09373-1 August 17, 2022 Table 1 Specifications Maximum Bearable 145 psi (10 bar) Pressure Output Position Nominal signal range: Transmitter 4 - 20 mA Power Supply: 10 – 30 Vdc External Load Resistance: 800 Ω @ 24 Vdc Position Error: <...
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Page 10: Section 3: Overview
Installation, Operation, and Maintenance Manual Overview ES-09373-1 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 Four-Digit LCD display Plate Cover Manifold with Pressure Gauges Mechanical UP Button... -
Page 11: Enclosure
Installation, Operation, and Maintenance Manual Overview ES-09373-1 August 17, 2022 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. Figure 3-1 Enclosure Identification Label Information Figure 3-2 Front Label... -
Page 12: Scope Of Supply
Installation, Operation, and Maintenance Manual Overview ES-09373-1 August 17, 2022 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. -
Page 13: Section 4: Principle Of Operation
Installation, Operation, and Maintenance Manual Principle of Operation ES-09373-1 August 17, 2022 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. - Page 14 Installation, Operation, and Maintenance Manual Principle of Operation ES-09373-1 August 17, 2022 Principle of Operation Figure 4-1 Working Principle Principle of Operation...
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Page 15: Section 5: Mechanical Installation
Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 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. -
Page 16: Rotary Actuator Installation
Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 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.). -
Page 17: Mounting The Rotary Namur Bracket To The Actuator
Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 Rotary Actuator Installation (Continued) 5.3.1 Mounting the Rotary NAMUR Bracket to the Actuator Figure 5-5 Assembling the Bracket NOTICE Check the L and H position for correct mounting of the positioner to the pneumatic actuator. - Page 18 Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 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. Figure 5-6 Rotary Adaptor 2 - The rotary support is factory assembled for actuators with 30x80 holes and 30mm shaft height.
- Page 19 Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 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.
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Page 20: Linear Actuator Installation
Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 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. -
Page 21: Assembling The Guide Arm
Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 Linear Actuator Installation (Continued) 5.4.1 Assembling the Guide Arm Figure 5-6 Assembling the Guide Arm 5.4.2 Installing the Feedback Lever and Bracket Figure 5-7 Installing the Feedback Lever and Support IMPORTANT The feedback lever is graduated. -
Page 22: Yoke Castle Mount
Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 Linear Actuator Installation (Continued) 5.4.3 Yoke Castle Mount Figure 5-8 Yoke-Type Bonnet Assembly 5.4.4 Mounting on a Pillar Type Castle Figure 5 -9 Mounting on a Pillar-Type Castle DANGER Before installing the positioner, check the area classification. -
Page 23: Types Of Feedback Lever
Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 Linear Actuator Installation (Continued) 5.4.5 Types of Feedback Lever The feedback levers are classified by two stroke lengths (K3, and K4), which are di- rectly linked to the minimum and maximum operating stroke. Figure 5-10 Types of Feedback Levers IMPORTANT Check the maximum valve travel to use the correct feedback lever. -
Page 24: Standard Installation
Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 Linear Actuator Installation (Continued) 5.4.6 Standard Installation The following procedure refers to standard yoke-type bonnet installation. It is important to remember that regardless of the type of yoke, the positioner must operate within the angle range of -30°... - Page 25 Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 Linear Actuator Installation (Continued) 5.4.6 Standard Installation 1 - Perform a test by applying compressed air directly to the valve through a pressure regulating valve. To check the maximum and minimum stroke, start by applying 0% (valve closed).
- Page 26 Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 Linear Actuator Installation (Continued) 5.4.6 Standard Installation 2 - Install the feedback lever on the positioner shaft. Tighten the setscrew with a 5 mm hex wrench. Figure 5-20 Installing the Feedback Lever IMPORTANT You can perform the assembly with the valve at 0% (fully closed) or 100% (fully open), but pay attention to the 60°...
- Page 27 Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 Linear Actuator Installation (Continued) 5.4.6 Standard Installation 4 - Install the guide pin in the feedback lever, observing the maximum travel of the valve. Tighten the retaining nut with a 10 mm hex wrench. Figure 5-22 Installing the Dowel Pin Figure 5-23: Guide Pin in the Correct Position (Valve Travel)
- Page 28 Installation, Operation, and Maintenance Manual Mechanical Installation ES-09373-1 August 17, 2022 Mechanical Installation Linear Actuator Installation (Continued) 5.4.6 Standard Installation 6 - Install the positioner with bracket onto the valve bonnet, using M8x16 screws. The guide pin should pass through the middle of the guide arm. Do not fully tighten the screws, to allow adjustment of the feedback lever.
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Page 29: Section 6: Pneumatic Connections
Installation, Operation, and Maintenance Manual Pneumatic Connections ES-09373-1 August 17, 2022 Pneumatic Connections Instrument air must be of better quality than industrial compressed air. Humidity, suspended particles, and oil can impair the instrument’s operation temporarily or permanently if internal parts wear out. Impurities in the supply air can partially or completely damage the positioner’s internal components. -
Page 30: Manifold Types
Installation, Operation, and Maintenance Manual Pneumatic Connections ES-09373-1 August 17, 2022 All pneumatic connections are on the right side of the positioner. Threaded holes are available for pneumatic connections. All connections are marked and their NPT standards must be observed. Connectors for pneumatic hoses are not supplied with the positioner. -
Page 31: Pneumatic Connection On Rotary Actuator
Installation, Operation, and Maintenance Manual Pneumatic Connections ES-09373-1 August 17, 2022 Pneumatic Connection on Rotary Actuator Check below the pneumatic connection for each type of rotary actuator. Table 6-2 Pneumatic Connections on Rotary Actuators Pneumatic Connection on Linear Actuator Check below the pneumatic connection for each type of linear actuator. Table 6-3 Pneumatic Connections in Linear Actuators IMPORTANT The unused outlet must be capped. -
Page 32: Section 7: Electrical Connections
Installation, Operation, and Maintenance Manual Electrical Connections ES-09373-1 August 17, 2022 Electrical Connections Cable Entry IMPORTANT The cable terminals are supplied in a closed state and must be unscrewed before inserting the cables. The positioner has one 1/2” NPT entry. Figure 7-1 Cable Gland and Plug DANGER Hazardous area equipment must not operate with cable entries open. -
Page 33: Grounding
Installation, Operation, and Maintenance Manual Electrical Connections ES-09373-1 August 17, 2022 Grounding Grounding the positioner is extremely important and highly recommended. Two grounding points are provided, one internal and one external. If the cable used is shielded, it is recommended that the shield be grounded at one end only. The ungrounded end should be carefully isolated. - Page 34 Installation, Operation, and Maintenance Manual Electrical Connections ES-09373-1 August 17, 2022 Electrical Connection (Continued) Figure 7-3 Electrical Connection of Positioner with Feedback Connected to Active Input Card Figure 7-4 Electrical Connection of Positioner with Feedback Connected to Active Input Card Electrical Connections...
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Page 35: Section 8: Configuration
Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Configuration Buttons The PD100 positioner has three mechanical buttons for configuration. To configure the positioner, you must open the cover by removing the four screws which fasten it to the positioner housing. Figure 8-1 Positioner with Cover Figure 8-2 Positioner without Cover Figure 8-3 Position of Mechanical Buttons... -
Page 36: Entering And Navigating The Configuration Menu
Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Entering and Navigating the Configuration Menu To enter and navigate the configuration menu via the mechanical buttons, you must remove the cover. See below how to enter and navigate in the configuration menu of the positioner. -
Page 37: Fast Callibration
Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Fast Calibration When executing fast calibration, the positioner performs a complete calibration, obtaining all valve parameters. For example: the opening and closing positions and the PID values. To perform a fast calibration, follow the steps below: 1 - Press the DOWN button until “Sure”... -
Page 38: Configuration Menu
Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu The PD100’s configuration menu has four functions that can be configured using the mechanical buttons. Figure 8-6 Configuration Menu Configuration... -
Page 39: Setup Menu
Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.1 Setup Menu In this function you can perform the 3 modes of positioner calibration: 1 - FULL: Recognizes the open and closed points and adjusts the best parameters for the PID. -
Page 40: Pid Menu
Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.2 PID Menu Proportional, integral and derivative control (PID control or simply PID) is a process control technique. It unites proportional, integral and derivative actions so that an error signal is minimized by the proportional action, zeroed by the integral action and obtained with an anticipative speed by the derivative action. - Page 41 Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.2 PID Menu Integral Control • In integral action the correction speed is proportional to the error, that is, in integral action the control variable is time (Tr). •...
- Page 42 Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.2 PID Menu PID Control • PID control uses proportional, integral, and derivative actions together. • As it joins all the control actions, it makes the error correction faster and more assertive by eliminating the offset left by the proportional and derivative actions.
- Page 43 Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.2 PID Menu PID Tuning Methods Trial and Error Method This is one of the most used methods because it is simple. It consists in modifying the control actions and observing the effects on the process (as the name suggests).
- Page 44 Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.2 PID Menu 1 - GP: Allows you to adjust the proportional gain of the PID control with values between 0 to 50. 2 - TR: Allows you to adjust the integral time of PID control with values between 0.1 to 50 (s).
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Page 45: Ctr Menu
Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.3 CTR Menu It allows you to correct for a small variation in the 4-20 mA signal. See the example below: 4: Define the inlet current as 0% dated valve. 20: Define the inlet current as 100% dated valve. - Page 46 Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.3 CTR Menu Testing the Feedback Output The feedback signal is automatically obtained in the positioner calibration process. You can measure this signal to check possible differences between the control and feedback signals before putting the positioner into operation.
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Page 47: T Out Menu
Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.4 T OUT Menu It is the time set in the menu for the positioner to move the valve during the calibration process. A failure is indicated after three consecutive errors occur in the calibration process. Tout is factory programmed for 10 seconds, but can be adjusted from 10 to 120 seconds. - Page 48 Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.4 T OUT Menu 8.4.4.2 Calibration Failure Alarm - Tout Alert A failure is indicated if the valve does not respond within the time set in the menu. Three consecutive failures must occur for the positioner to indicate an alarm.
- Page 49 Installation, Operation, and Maintenance Manual Configuration ES-09373-1 August 17, 2022 Configuration Menu (Continued) 8.4.4 T OUT Menu 8.4.4.2 Calibration Failure Alarm - Tout Alert 3 - Failure in the learning cycles of the open and closed points: Imagine the condition where Tout is set to 10 seconds and that the set (positioner/ actuator) was able to perform the 1st cycle of learning the open and closed points, but when starting the second or third cycle, a failure of lack of compressed air occurs.
- Page 50 Installation, Operation, and Maintenance Manual Certifications ES-09373-1 August 17, 2022 Certifications (Pending) • Non-Incendive: • Class I, Div. 2, Groups A, B, C, & D; T4; • Class II, Div. 2, Groups F & G; • Class III • Type 4X, IP66 •...
- Page 51 Installation, Operation, and Maintenance Manual Mechanical Dimensions ES-09373-1 August 17, 2022 Mechanical Dimensions 10.1 Rotary Positioner Dimensions Figure 10-1 Rotary Positioner Mounting Torque: Positioner in the mounting bracket (4xM6): 10 Nm Mounting bracket on the rotary actuator (4XM5): 10 Nm Figure 10-2 Linear Positioner Mounting Torque: Positioner in the mounting bracket (2xM8):...
- Page 52 How to Specify Installation, Operation, and Maintenance Manual August 17, 2022 ES-09373-1 How to Specify PD100-CFNGXX0000-EN PD100-C (4-20 mA) - F (4-20 mA position transmitter) - N (One input conduit 1/2” NPT / Manifold 1/4” NPT standard) - G (Long manifold with two PSI manometers) - XX (RN [Rotating NAMUR adapter], K3 [Linear with 12 to 120mm feedback lever), and K4 (Linear with 80 to 200mm feedback lever]) –...
- Page 53 © 2013-2022 TopWorx, All rights reserved. TopWorx™, and GO™ Switch are all trademarks of TopWorx™. The Emerson logo is a trademark and a service mark of Emerson Electric. Co. © 2013-2022 Emerson Electric Company. All other marks are the property of their respective owners.