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™ Valvetop D-Series with FF Option FOUNDATION Fieldbus Installation, Operation & Maintenance Manual

Table of Contents 2 Introduction 2 Quick Installation Guide 4 Installation 4 Storage 5 Pneumatic Connection 6 Electrical Connection 8 FF Operation 10 Troubleshooting and Maintenance 16 Appendix A: FF Technology 18 Appendix B: Resource Block 20 Resource Block DD Menu Structure 21 Appendix C: Transducer Block 26 Transducer Block DD Menu Structure 27 Appendix D: Discrete Output (DO) Block 29 Appendix E: Discrete Input (DI) Block 31 Appendix F: Dimension & Assembly Drawings 35 Appendix G: Specifications & Reference Data

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D-Series with FF Option Installation, Operation & Maintenance 502.969.8000

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Introduction This manual is intended to provide instruction for Installing, Operating and Maintaining the TopWorx Model DXP/DXS-FF Discrete Valve Controller with FOUNDATION™ Fieldbus.

Warnings and Precautions that require special instructions or considerations are noted by this symbol.

DXP Quick Start Installation Guide Step 1 - Mount DXP/DXS-FF (Fig. 1)

a) Connect bolts firmly between switchbox and bracket b) Connect bolts loosely between actuator and bracket c) Cycle actuator to limits in both directions 3 times to center shaft d) Tighten the bolts between the actuator and bracket

Step 2 - Secure pneumatic connections

a) Refer to Figure 2 for details b) Use of Locktite 567 is recommended

Step 3 - Make electrical connections

a) Attach fieldbus wiring to FF terminals (Fig. 2) b) FOUNDATION Fieldbus wiring is polarity insensitive

Step 4 - Calibrate switches

a) Move the valve to the CLOSE position, push and rotate lower cam to activate the Red LED

b) Move the valve to the OPEN position, push and rotate upper cam to activate the Green LED

c) Verify calibration by actuating valve open and closed several times NOTE: Switches can be set using calibration switch without FF connection by using any 9-32VDC power source. Step 5 - Commission DXP-FF

a) Connect single DO to Channel 5 • No DI needed - Readback_D provides the actual valve position

b) Set the Mode to AUTO (Automatic) in the Transducer Block

Mounting - Figure 1

FLASH RESET

CLOSE

FF

AUX

OPEN

- V2 + - V1 +

WrtPrt

FF Sim

SCM-FF

Calibration Switch

Auxilliary InputTerminals(Dry contacts only)

FoundationFieldbus LoopTerminals

Piezo PilotTerminals

Single PilotDual Pilot

Std Operation Jumper Location

+ = Orange- = Black

NOTE: TopWorx has pre-configured modules and faceplates available for

DeltaV control systems. Contact TopWorx factory for more

information.

Wiring - Figure 2

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Installation on Actuator Orientations, Normal and Reverse Acting Normal acting is full CW when the process valve is closed and CCW when the process valve is open. Reverse acting is full CW when the process valve is open and CCW when the process valve is closed. 90° indicator dome assemblies are design to accommodate any mounting arrangement and can be adjusted up to 9° off axis if needed. 45° indicator dome assemblies can only accommodate normal acting applications that are mounted parallel ±9°. Consult your local distributor or factory representative for 45° reverse acting or mounted perpendicular applications.

Illustration #1:

The image to the left shows a Valvetop unit mounted parallel to the process valve in the closed position. The green arrow at the top shows the “normal acting” direction of travel to open the valve. This is the standard orientation and your unit unless otherwise specified will be factory set to operate in this fashion.

Illustration #2: The image to the right shows a Valvetop mounted perpendicular to the process valve in the closed position. The green arrow at the top shows the “normal acting” direction of travel to open the valve. Notice that the indicator dome has been rotated 90° compared to the unit above.


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Installation on Actuator (continued) Mounting TopWorx has numerous mounting bracket kits available to meet your specific application, whether rotary or linear. Consult your local distributor or factory representative for ordering information. The illustration shows a direct Namur mount on a quarter turn valve. Refer to your mounting kit documentation for specific mounting instructions. Storage Until conduit, conduit plugs, and any applicable spool valve port connections are properly installed, the ValveTop unit will not support its IP/NEMA rating as the unit ships with temporary covers. Ensure that it is stored in a dry environment with a relative humidity range between 10%-95% and a temperature ranging from -40ºF (-40ºC) to 160ºF (71ºC). Once properly installed, the temperature range listed on the nameplate will supersede this storage temperature range.

Illustration #3: Mounting Assembly

Installation Notes 1. Use caution not to allow undue axial (thrust) load on the shaft.

2. Cycle the valve a couple of times prior to final tightening of the

mounting kit hardware. This allows the shaft to self-center in the pinion slot, or coupler. Refer to the dimensions and materials section of this document for appropriate tightening torque.

3. Always use sound mechanical practices when torquing down any-hardware or making pneumatic connections. Refer to the Integrated Pneumatic Control Valves section for detailed information on pneumatic connections.

4. This product comes shipped with conduit covers in the conduit entries in an effort to protect the internal components from debris during shipment and handling. It is the responsibility of the receiving and/or installing personnel to provide appropriate permanent sealing devices to prevent the intrusion of debris, or moisture, when stored outdoors or when installed. It is the responsibility of the installer, or end user, to install this product in accordance with the National Electrical Code (NFPA 70) or any other national or regional code defining proper practices.

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Pneumatic Hookup Procedures Prior to connecting the supply air to the spool valve, flush the system to remove any debris or contaminates. Galva-nized pipe can easily flake and contaminate the system and therefore is not recommended. A 40 micron point of use filter at every device is recommended. 4-Way Spool Valves The TopWorx spool valve is a 5 port, 4-way valve driven by an internally mounted pilot. The spool valve supply port and work ports are marked as follows:

***Never Plug, Block or Restrict Port 5***

Supply

Port to OpenPort to Close

Always install ventsor speed controls Supply

DOUBLE ACTING ACTUATORS SPRING RETURN ACTUATORS

1 35

24

1 35

24

Port to OpenPlug /Close

Supply

Always install ventsor speed controls

Highly Recommended TopWorx highly recommends Locktite 567 brand thread sealant. Do not use a hard setting pipe compound. If Teflon thread seal tape is used, start the wrap on the second thread from the leading thread of the fitting. This will pre-vent tape shreds from contaminating the spool valve seals. Breathers (AL-M31) should be installed in the exhaust ports to keep debris from falling into the spool valve and damaging the seals. This must be addressed prior to instal-lation, or storage. A flow control may be used in Port 3, but should NEVER BE USED in Port 5. Any blockage or restriction may cause an internal pressure build-up inside the enclosure and pose a safety issue.

Spool Valve Specifications Medium Dried, filtered air (40 micron)

Max Operating Pressure 100psi (0.69 MPa) (6.89Bar)

Min. Operating Pressure 30psi (0.21 MPa) (2.07Bar)

Ambient Temperature Range Refer to Product Nameplate Marking

Flow Coefficient 1.2Cv or 3.0Cv

Environment Rating Type 4, 4X, IP67

Port Size 1/2” NPT for 3.0Cv valve 1/4" NPT for 1.2Cv valve

Manual Override Available in Latching/Non-Latching Push Type & Palm Actuator Type

Valve Body Available in Hardcoat Anodized Aluminum, 304, or 316 Stainless Steel

Valve Seals Spool Seals: Buna-N Valve Body Seals available in Buna-N, Silicone, EPDM & Viton.

Max Consumption Rate 600 cc/min @ 80psi


6

Electrical / FF Connections The FOUNDATION Fieldbus Sensor Communications Module (SCM-FF) combines integral switch relays for position sensing with FOUNDATION Fieldbus communications and pilot valve output drivers.

Pilot Valve Wiring Single Pilot Valve

· The Orange (or Red) lead is terminated on V1+. (+ = Orange) · The Black lead is terminated on V1-. (- = Black)

Dual Pilot Valve · The open valve wiring to the V1 terminal (+ = Orange) · The close valve wiring to the V2 terminal (- = Black)

FOUNDATION Fieldbus Wiring The Fieldbus Segment Wiring is connected to the FF Terminals on the SCM. These terminals are NOT polarity sensitive.

It is strongly recommended that FF wiring leads are not daisy-chained together and each drop provides short-circuit protection.

Auxiliary Dry Contact Attach dry contact wiring to the AUX terminals.

FLASH RESET

CLOSE

FF

AUX

OPEN

- V2 + - V1 +

WrtPrt

FF Sim

SCM-FF

Calibration Switch






+ = Orange- = Black

Flash Reset Button When there is an active device alarm, the LEDs will blink. The Flash Reset Button will stop the flashing indications.

For testing of the pneumatics and calibration of the target assembly, a 9 to 32 VDC power supply can be used with the calibration switch to open and close the valve without a fieldbus loop attached.

Illustration #4: Mounting Assembly

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Calibration of Target / Feedback Calibration of the FOUNDATION Fieldbus SCM-FF Never perform calibration procedure unless area is known to be safe.

· For Intrinsically Safe models, unit must be wired in accordance with Control Drawing S-K088A, or I.S.

components may be damaged. · For standard explosion-proof models: The OPEN and CLOSED limit switches encapsulated within the

SCM-FF may be calibrated using a DC power supply set between 9-32V, or calibrated once connected to the Fieldbus network.

Step 1 Connect the power supply, or Fieldbus wires, to the FF terminals. The terminals are not polarity sensitive. With power applied to the FF terminals, the valve may be manually stroked using the Calibration Switch on the SCM-FF. Step 2 Place calibration switch to the CLOSE position. Valve should move to CLOSE position. If it does not, consult troubleshooting section of page 11. Step 3 Disengage the bottom Cam from the splined hub and rotate the bottom Cam clockwise until the Red LED lights. Release the Cam to re-engage the splined hub. Step 4 Slide the calibration switch to the OPEN position. Valve should move to OPEN position. If it does not, consult troubleshooting section on page 11. Step 5 Disengage the top Cam from the splined hub and rotate the top Cam counter-clockwise until the Green LED lights. Release the Cam to re-engage the splined hub. Step 6 Cycle the valve CLOSED and OPEN a few times using the calibration switch to verify both limit switches are maintaining their set points. Step 7 Place calibration switch in the FF position. If using a power supply to calibrate, disconnect leads to the supply, and connect the Fieldbus loop when ready to put into service. Step 8 Manipulate the transducer parameters via the control system as necessary for desired mode of operation. NOTE: If using a reverse acting actuator, re-calibrate switches using Steps 3-6, but rotate counter-clockwise for close and clockwise for open. Reverse Action must be set in the Transducer Block (see “Transducer Block Initialization, Single-Dual Action”).


8

Section 2: Operation This section of the manual provides operational information for configuring the SCM-FF device on the FOUNDATION Fieldbus Host Control System. This section includes both required Control Configuration and optional Monitoring Configuration information.

Control Configuration (Required)

The TopWorx FOUNDATION Fieldbus products should be configured for operation using a single Discrete Output (DO) Function Block with Channel Parameter assignment of 5. This module configuration will provide a multi-value DO Block that will fully control a single or a dual output device. The Readback_D parameter will provide actual valve position based on the Open / Closed Limit Switches in the device. Discrete Input (DI) Blocks are neither required nor desired for feedback function.

The values of these parameters are as follows: Figure 4

NOTE: TopWorx has pre-configured modules and faceplates available for DeltaV control systems. Contact the TopWorx factory or www.topworx.com for more information.

The Transducer Block is shipped from the factory in the OOS (Out of Service) Mode to allow field installation/testing using the SCM calibration switch. Once the installation and the configuration above are complete, The Transducer Block must be placed in the AUTO (Automatic) Mode for device operation. The complete device control algorithm should be as depicted below:

DO ChannelAssignment

Definition Readback_DValves

Control Method

5 Open/Close/StopOutputs

0 - Closed1 - Open2 - Stopped3 - Opening4 - Closing

Single Block,Dual Action

Readback_D Parameter

Discrete Control

Function Block

Discrete Output (DO)

Function Block

DO

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DI ChannelAssignment

Definition OUT_D Values

13 Device Alarms 0x00 - No Alarm0x01 - Cycle Count0x02 - Time to Open0x04 - Time to Close0x08 - Time Board Temp Hi0x10 - Board Temp Lo

Alarm Configuration (Optional)

Discrete Input (DI) Block may be configured for monitoring internal Device Alarms within the Control Strategy of the Host System. The Internal Device Alarms can be monitored using a Discrete Input (DI) Block with the Channel Parameter assignment of 13. All alarms that are activated (checked in the Transducer Block) can be read by this single DI block in a masked fashion. See Appendix C for Transducer Block parameter settings.

Multiple active alarms are depicted by a HEX value representing the sum of all active alarms OUT_D Val-ues. For example, a device with a Cycle Count Alarm and a Time to Close Alarm both active would have an OUT_D Value of 0x05.

Auxiliary Input Configuration (Optional)

The AUX Input terminal may be monitored using a Discrete Input (DI) Block with the Channel Parameter assignment of 9.

DI ChannelAssignment

Definition OUT_D Values

9 Aux Input 0 - Aux Dry Contact Closed1 - Aux Dry Contact Open


10

Section 3: Maintenance This Section provides information on Troubleshooting and Component Replacement for the DXP-FF.

Troubleshooting

Description of Problem Possible Cause Possible Solution

Red or green LED does not illuminate whenthe valve is either in closed or open position

Target not calibrated properly Use calibration procedure on page 7

LED's do not operate, regardless of valveposition

Power not connected to FF terminals

LED's not enabled

Make sure at least 9 VDC connected to FF terminals

Transducer block parameter "LED_ENABLE" set to ENABLE

Calibration switch will not operate Transducer Block in incorrect mode

Power not connected to FF terminals

Piezo and spool valve is not pressurized

Set transducer block actual model to "Out of Service"

Make sure at least 9VDC connected to FF terminals

Verify proper air pressure. Reference mechanicaltroubleshooting chart

LEDs flash from red to green after valve hasshifted

Time to open/close alarm has triggered Target not calibrated properly. Recalibrate using theprocedure on page 7

LEDs flash from red to green as soon as unitstarts moving during a setpoint change

Operational setpoints do not match limit switch positions(i.e. the closed switch is made when the unit has an opensetpoint)

Set Transducer Block Action_Element setting according tochart

Module goes "unattached" from the segment Power dropped below 9V

Excessive noise on the segment

Check voltage to ensure that it is consistently above 9VCheck for loose wire connections

Verify that the segment has a terminating resistor at eachend

Using a Fieldbus Monitor, verify that peak and averagenoise levels are <11db

Valve will not shift See mechanical troubleshooting flowchart on page 12

No response from operator interface DO Block and/or DO Channel not correctly assignedTransducer Block Out of ServiceConfiguration/DO Block NOT downloaded

Follow troubleshooting chart, (pg. 11) then continue withmechanical troubleshooting chart (pg. 12). If problempersists contact the factory

Bad Status on FeedBack Signal and/or NoFeedback signal

Transducer Block mode is Out of Service Place Transducer Block in Auto Mode

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DO

DO

DO

DO DO DO

DO


12

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Component Replacement

RED UrethaneTubing (Supply)

YELLOWUrethane

Tubing (Work)

10-32 Nylon PlugUsed in Fail ClosedApplications

10-32 NylonBarb Fitting

PiezoelectricPilot Device

O-rings,Buna

Manifold

Inserts

Bracket

4-40x.25 (x2)

Orangeto V+

Blackto V -

M4x35

Flame arrestor O-ring(x5)

Spool Valve with No Manual Override

Spool Valve with Single Palm Actuator Override

Spool Valve with Dual Palm Actuator Override

Push-button Style Override

M5 x 25mm SHCS (x4)(4mm hex wrench)

Fail Closed Spool Valve Replacement Assemblies

AV-BFCVA20 Std Alum Spool Valve Assy w/Buna seals

AV-BFCVS20 Std 304SS Spool Valve Assy w/Buna seals

AV-BFCV620 Std 316SS Spool Valve Assy w/Buna seals

Fail Last Position Spool Valve Replacement Assemblies

AV-BFLPVA20 Std Alum Spool Valve Assy w/Buna seals

AV-BFLPVS20 Std 304SS Spool Valve Assy w/Buna seals

AV-BFLPV620 Std 316SS Spool Valve Assy w/Buna seals

Block-Center Spool Valve Replacement Assemblies

AV-BBCVA20 Std Alum Spool Valve Assy w/Buna seals

AV-BBCVS20 Std 304SS Spool Valve Assy w/Buna seals

AV-BBCV620 Std 316SS Spool Valve Assy w/Buna seals


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Indicator / Dome Replacement

Color-coded Indicator isavailable in severalcoordinating rotations andforms for various valvetypes, such as 90deg, 180degand Thru-divert applications.

O-ringAvailable in Buna-N,

Silicone, EPDM, Viton

10-32 Captive screws,Stainless (x4)

Indicator Dome, 5 adjustable

Polycarbonate with keyed mask.

Several rotation and form options.

+ O

Shaft Replacement NAMUR Shaft,Stainless

Standard 0.25” DD Shaft,Stainless

LubricationAreas

1

2

3

4mm

0.375 [9.53mm]

0.375 [9.53mm]

0.25 in

For more shaft dimensiondetails, see Page 1.

Indicator / Dome Replacement Kits

AV-GB002 90º, Green/Open, Red/Closed, Buna O-Ring

AV-YB002 90º, Yellow/Open, Black/Closed, Buna O-Ring

AV-TB002 90º, Green/Thru, Red/Divert, Buna O-Ring

AV-4B002 90º, Green/Open, Red/Closed, Buna O-Ring

NAMUR Shaft Replacement Kits SCM’s with (2) Reed Switches

AV-NSB202 NAMUR Shaft w/Buna-N O-Rings & (2) Cam Assembly with Installation Hardware

Standard Shaft Replacement Kits SCM’s with (2) Reed Switches

AV-SSB202 Standard Shaft w/Buna-N O-Rings & (2) Cam Assembly with Installation Hardware

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Sensor Communications Module (SCM-FF) Replacement

Resetting Factory Defaults in SCM There are five restart options available for the Resource Block Restart parameter in the TopWorx DXP/DXS-FF. The fifth parameter is Reset with Factory Defaults and will be implemented by writing 0x05 to the RESTART parameter. This restart is used to reset the device to factory default initial values.

After Conducting a Reset of Factory Defaults the Device Tag Information will be lost, all DI & DO Functions Blocks will be assigned to Channel 0 and The Transducer Block will be placed in Out Of Service.

Do not power down the device for 40 seconds after you execute a “Restart with Factory Defaults.” Non-Volatile Random Access Memory (NVRAM) is being written and must complete before device loses power. The device condition is unpredictable if an early power cycle is executed.

FLASH RESET

CLOSE

FF

AUX

OPEN

- V2 + - V1 +

WrtPrt

FF Sim

SCM-FF

Calibration Switch






+ = Orange- = Black


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InputFunction

Block

CalculationOr ControlFunction

Block

OutputFunction

Block

InputFunction

Block

CalculationOr ControlFunction

Block

OutputFunction

Block

Channels

ResourceBlock

TransducerBlock

Process Sensors

Process Actuators

FunctionBlock

FunctionBlockChannels

ResourceBlock

TransducerBlock

Process Sensors

Process Actuators

FunctionBlock

FunctionBlock

Appendix A: FOUNDATION Fieldbus Technology Blocks and the User Application The Fieldbus Foundation has defined a standard for building user applications. The Foundation standard is built around “Blocks.” Blocks are used to represent different types of functions that the device performs and provide a way of grouping different parameters and functionality together in an easy to understand framework. A Fieldbus Foundation device has a Resource Block, Transducer Block, and Function Blocks. Once the hardware of the TopWorx Sensor-Communication Module (hereafter known as SCM-FF) is set up, fieldbus communication is used to set the transducer parameters to get the functionality desired. The desired transducer func-tionality is associated with a function block. The host system is then used to link the function blocks together, and the application is downloaded to all of the devices in the loop. Resource Block The Resource Block describes characteristics of the fieldbus device such as the device name, manufacturer, and se-rial number. There is only one resource block per device. Transducer Blocks Transducer Blocks are the connection of Function Blocks to the real world. Many of the settings unique to a Fieldbus Device are defined in the transducer block parameters. The Function Blocks are typically standard between devices, so that they may be linked together to form easily con-structed, interoperable applications. The Channels of a transducer block can be attached to a function block for use in the application. Function Blocks Function Blocks provide the control system behavior. The input and output parameters of Function Blocks can be linked over the fieldbus. The execution of each Function Block is precisely scheduled. There can be many function blocks in a single user application. The SCM-FF provides 5 Discrete Input (DI) and 3 Discrete Output (DO) function blocks. Configuration of all these blocks is NOT required for full device operation. Process Instrument and its Blocks An application is built by linking together function blocks.

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FOUNDATION Fieldbus Topology

General Purpose

ControlSystem

Power Supply w/ Terminator “ON”to power (1) Fieldbus segment

Terminator “ON”T

T = Fieldbus Terminator

T

Intrinsically Safe

ControlSystem

Power Supply w/ Terminator “ON”to power (1) Fieldbus segment

Repeaters

Terminator “ON”

Isolators w/ Terminators “ON”

T

TTT

T

T T

T

T = Fieldbus Terminator


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Appendix B: Resource Block The resource block contains the hardware specific characteristics associated with a device. It has no input or output parameters. This block of contained parameters includes such things as Manufacturer’s ID and revision information. Below is a complete listing of the SCM-FF Resource Block Parameters.

Complete Resource Block Parameter Listing ST_REV The revision level of the static data associated with the function block. To support tracking changes

in static parameter attributes, the associated block's static revision parameter will be incremented each time a static parameter attribute is written but the value is not changed.

TAG_DESC The user description of the intended application of the block.

STRATEGY The strategy field can be used to identify grouping of blocks. This data is not checked or processed by the block.

ALERT_KEY The identification number of the plant unit. This information may be used in the host for sorting alarms, etc.

MODE_BLK The actual, target, permitted, and normal modes of the block.

BLOCK_ERR This parameter reflects the error status associated with the hardware of software components associated with a block. It is a bit string, so that multiple errors may be shown.

RESOURCE STATE State of the function block application state machine.

TEST READ WRITE Read/write test parameters - used only for conformance testing.

DD_RESOURCE String identifying the tag of the resource which contains the Device Description for this resource.

MANUFAC_ID Manufacturer identification number - used by an interface device to locate the DD file for the resource.

DEVICE TYPE Manufacturer's model number associated with the resource - used by interface devices to location the DD file for the resource.

DD REVISION Revision of the DD associated with the resource - used by an interface device to locate the DD file for the resource.

GRANT_DENY Options for controlling access of host computer and local control panels to operating, tuning and alarm parameters of the block.

HARD_TYPES The types of hardware available as channel numbers.

RESTART Allows a manual restart to be initiated. Several degrees of restart are possible. They are 1: Run, 2: Restart resource, 3: Restart with defaults, 4: Restart processor; and 5: Restart with factory defaults.

FEATURES Used to show supported resource block options.

FEATURE SELECTION Used to select resource block options. Enable 0 x 32 bit to allow readbacks from function blocks.

CYCLE_TYPEIdentifies the block execution methods available for this resource.

CYCLE SELECTION Used to select the block execution method for this resource.

MINIMUM CYCLE TIME Time duration of the shortest cycle interval of which the resource is capable.

FREE_SPACE Percent of memory available for further configuration. Zero in a preconfigured resource.

FREE_TIME Percent of the block processing time that is free to process additional blocks.

SHED REMOTE CASCASE Time duration at which to give up on computer writes to function block RCAS locations. Shed from RCAS shall never happen when SHED REMOTE CASCASE = 0.

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Complete Resource Block Parameter Listing (cont’d) SHED REMOTE OUT Time duration at which to give up on computer writes to function block Rout locations. Shed from

Rout shall never happen when SHED REMOTE OUT = 0.FAULT_STATE Condition set by loss of communication to an output block, fault promoted to an output block or a

physical contact. When Fault State condition is set, then output function blocks will perform their FSTATE actions.

SET FAULT STATEAllows the Fault State condition to be manually initiated by selecting Set.

CLEAR FAULT STATE Writing a Clear to this parameter will clear the device fault state if the field condition, if any, has cleared.

MAXIMUM NOTIFYMaximum number of unconfirmed alert notify message possible.

LIMIT NOTIFY Maximum number of unconfirmed alert notify messages allowed.

CONFIRM_TIME The time the resource will wait for confirmation of receipt of a report before trying again. Retry shall not happen when CONFIRM_TIME = 0.

WRITE_LOCK If set, no writes from anywhere are allowed, except to clear WRITE_LOCK. Block inputs will continue to be updated.

UPDATE_EVT This alert is generated by any change to the static data.

BLOCK_ALM The block alarm is used for all configuration, hardware, connection failure or system problems in the block. The cause of the alert is entered in the subcode field. The first alert to become active will set the Active status in the Status attribute. As soon as the Unreported status is cleared by the alert reporting task, another block alert may be reported without clearing the Active status, if the subcode has changed.

ALARM SUMMARY The current alert status, unacknowledged states, unreported states, and disabled states of the alarms associated with the function block.

ACKNOWLEDGE OPTION Selection of whether alarms associated with the block will be automatically acknowledged.

WRITE PRIORITY Priority of the alarm generated by clearing the write lock.

WR_ALM This alert is generated if the write lock parameter is cleared.

ITK_VER Major revision number of the interoperability test case used in certifying this device as interoperable. The format and range of the version number is defined and controlled by the Fieldbus Foundation. Note: The value of this parameter will be zero (0) if the device has not been registered as interoperable by the FF.

DETAILED BLOCK ERRORS Provides list of all active block alarms in the block.

SUPPORTED_MODES The modes supported by this particular block.

IKEY TopWorx revision control.

REVISION_IDTopWorx revision control.

REVISION_DATETopWorx revision control.

DEVICE REVISION Manufacturer revision number associated with the resource. Used by an interface device to locate the DD file for the resource.

CHARACTERISTICS: BLOCK_TAG Defined to be unique throughout the control system at one plant site. The Tag may be changed using the FB_TAG service.

MEMORY SIZE Available configuration memory in the emptry resource. To be checked before attempting download.

NONVOLATILE CYCLE TIMEInterval between writing copies of NV parameters to non-volatile memory. Zero means never.


20

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21

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Appendix C: Transducer Block Transducer Block Initialization There are several settings in the transducer block that should be set before commissioning of the SCM-FF. Through these parameters, a user can configure a wide range of diagnostics and alarms. These include cycle timers, and counters, as well as temperature monitoring. The alarm conditions can be configured through a transducer channel in one DI Block. Also, the user may configure the SCM-FF for use in Single or Dual pilot valves for Direct or Reverse Acting applications, all through convenient Transducer settings. (a) Diagnostics & Alarming There will be 5 limit parameters that must be set during calibration. These parameters will vary with the type of valve the device is operating. The alarm priorities must also be set, depending on the application. By simply changing the settings in the transducer, all the diagnostic limits and functional settings can be set by the end user.

1. Cycle Times Set the Cycle Time Open Limit (LIM_CYC_OPEN_TIME) and the

Cycle Time Close Limit (LIM_CYC_CLOSE_TIME) parameters to the maximum amount of time in seconds the valve is allowed to complete its stroke before an alarm condition is invoked. If the LEDs are enabled, they will blink for local notification of the time limit alarms. If the Cycle Time Open Limit is exceeded, the green LED will flash. If the Cycle Time Close Limit is exceeded, the red LED will flash. Pushing the Alarm Reset Pushbutton on the board will stop the flashing.

The default setting for both the Cycle Time Open and Cycle Time

Closed Time Limit is 10 seconds. 2. Cycle Count Set the Cycle Count Limit (LIM_CYC_COUNT) parameter to the

maximum number of valve cycles allowed before a Cycle Count Alarm condition is activated.

The default setting for the Cycle Count Limit is 50000 cycles.

3. Temperature The Temperature High Limit (HI_LIM_BOARD_TEMP) parameter

should be set to alarm when the temperature sensor reads above a user specified value and the Temperature Low Limit (LO_LIM_BOARD_TEMP) will be set to alarm when the temperature sensor reads below a user specified value.

The default setting for the Temperature High Limit is 50°C. The default setting for the Temperature Low Limit is -10°C.

(b) Functional Settings

1. Single-Dual Action The ACTION_ELEMENT parameter is used to determine what

direction the actuator goes when energized. The 2 settings of the ACTION_ELEMENT parameter are Direct and Reverse Acting. “Reverse Acting” is to be used when the energized state is to close the valve.

The Default setting for Action Element is DIRECT Action.

2. Channel 13 Channel 13 is a user configurable input channel. The user can

define the functionality of a DI block associated with Channel 13 by selecting the appropriate bits in the CHAN_13_MASK parameter. One of several alarms can be used to trigger a DI including cycle count, over stroke timer, temperature or any combination of these. The unit is shipped with Channel 13 set up for over/under tempera-ture indication.

The following is a list of bit selections for Channel 13. Simply select the appropriate bit to activate the desired functionality.

0x00, No Selection 0x01, Cycle Count 0x02, Time to Open 0x04, Time to Close 0x08, Board Temp Hi 0x10, Board Temp Lo

(c) Calibration Switch Functionality The SCM-FF is shipped in a mode where the calibration switch is active. A 9 to 32 VDC power supply can be used to activate and deactivate the device, to open and close the valve, and set the target. In order to enable the calibration switch in a safe manner, three conditions are required to be true simultaneously. These are:

1. CAL_SW_ARM parameter is TRUE/Armed. The operator may consider this like a calibration switch lock out parameter when disabled.

2. The calibration switch on the SCM-FF must be in the FF position. This allows smooth transition to the manual control condition.

3. Transducer block must be in the Out Of Service (OOS) mode. This sets all of the connected output parameters to a BAD status, allowing upstream controllers to recognize the device is not controlled by the control scheme.

The CAL_SW_STATE parameter transitions to Enabled when all three conditions have been met simultaneously. This parameter will transition to the disabled state when the Transducer Block is placed into service or the CAL_SW_ARM is set to disabled. NOTE When the transducer mode changes from OOS mode, the valve will go to the FF position calculated at the time regardless of the current position of the valve or the Calibration switch. Transducer Special Diagnostic Features During installation, a special diagnostic parameter called ACTIVE _BLOCK_ALMS can be used to alert the user of configura-tion errors specific to the device. This block is used to conveniently identify some of the issues that may arise with installing the SCM-FF. The values returned are explained below:

a. None Active - No active block alarms are active. b. Invalid Mode - The computed actual mode for the block is

not supported the block’s actual mode will go to out of service.

c. Mode Error - The mode calculator detected an error. d. Both Contacts Closed - Both contacts are closed. e. Conflicting Channels Assigned - Conflicting output

channels have been assigned. (See DO Block Section for a description of the correct configuration of output channels).

f. Open without Close - An ‘Open’ output channel has been assigned without a ‘Close’ channel.

g. No Output Channels - No output channels have been assigned.

h. Out Of Service - Transducer block is out of service. i. Invalid Input - The target position is not valid for the

current device configuration. Check the target setting to insure that it is in the correct position.

Stroke Valve Method The method allows the user to simply invoke the method, receive appropriate warnings of using an operating process and then allow the user to repeatedly open/close the valve while viewing the actual feedback from the valve on the screen. This method automatically makes the necessary transducer block mode changes to enter the method and automatically reinstate the previous transducer block mode when the method exits. This prevents the user from uninten-tionally rendering the device unusable from the host control system.


22

Transducer Parameters to be set before an application is configured. For a complete list of transducer parameters, refer to Page 24.

*The timer accuracy for stroke time open and stroke time closed is 60mS minimum.

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23

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Fieldbus Foundation Transducer Channel Architecture The SCM-FF has one transducer block with 13 channels. The 5 DI and 3 DO function blocks will link to these trans-ducer channels through the standard channel selection capability. (See Function Blocks) The 13 Transducer Channels are listed below. Transducer Channels

Notes on Channels Channels 1 and 5 These are Multi-value DO blocks standard with Fieldbus Foundation. Channel 1 is intended for use with a single control signal, while Channel 5 is to be used with a dual control signal. Channels 2, 3 and 4 Channels 2, 3 and 4 use 0 = false and 1 = true for open, close, and stop. This gives a more comfortable interface for users more familiar with ladder logic. In the situation where Open and Close are both true (or false) at the same time, the last input is rejected as invalid. Readback signals are 0 = false and 1 = true for is-opened, is-closed or is-stopped. Channels 2, 3 and 4 cannot be used simultaneously with channels 1 or 5. Channels 4 and 5 Available with a Dual-Control Pneumatic valve. Channels 6, 7 and 8 Echoes the Readback information from channels 1, 2 and 3. Channel 9 Reflects the input from a dry contact type of input wired into the Auxiliary input screw terminals and uses 0 = closed, 1 = opened reflecting the contact condition.

Channels 10, 11 and 12 Reflects alarm conditions in the valve. When something needs to happen in response to these error conditions, a DI should be used to publish the state of the alarm condition. These channels use 0 = false (no alarm), 1 = true (alarm condition exists). CTOA, CTCA, and CCA are transducer channels that allow alarms to be scheduled into the system. These alarms are:

Cycle Time Open Alarm (CTOA – Channel 10) Cycle Time Closed Alarm (CTCA – Channel 11) Cycle Count Alarm (CCA – Channel 12)

Above inputs are used in preventative maintenance and indicate when a valve is operating outside of acceptable times. These channels exist so that some action on the loop can be scheduled in critical applications. Cycle times may increase with an increase in valve stiction, and/or a loss of air pressure. The times and counts used as alarm limits are user settable (see Appendix 2). Regardless of whether these alarms are linked to function blocks, these FF standard alarms are always reported to the alarm handling host when one of these conditions exists and the corresponding priority is set to greater than 1. Channel 13 Stimulates activity when a set of alarm conditions exist. This channel uses a user-settable mask to allow any of five alarm conditions to cause the linkable DI parameter to become true. Channel 13 is a masked OR function. It includes the previous alarms, as well as a Temperature High (TMPH), and Temperature Low (TMPL) alerts. For TMPH and TMPL, a sensor is used to sense the temperature of the circuit board. The user can select which of these alerts on Channel 13 are to be used by masking out the undesired ones.


24

Complete Transducer Parameter Listing

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Complete Transducer Parameter Listing (cont.)


26

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DD

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27

TM

Appendix D: Discrete Output (DO) Discrete OUTPUT Blocks (DO Block) There are 3 FOUNDATION Fieldbus standard DO blocks and 5 output channels. The DO blocks take discrete control data and translate it to actuation in the field. These blocks are used to open and close the valve. There are 4 different strate-gies provided to open and close a valve, depending on the system being used, and whether a single or dual action pilot valve is being used. Single Block Control Method, Single Action (Default) Set the Channel Parameter of DO1 to 1(Open/Close Output), and DO2 and DO3 to 0 (No Connection). The valve is now controlled by the wiring going to the V1 terminals. By writing a 0 or a 1 to this DO block will now open and close the valve. Single Block Control Method, Dual Action Set the Channel Parameter of DO1 to 5 (Open/Close/Stop Output), and DO2 and DO3 to 0. The valve is now controlled by the wiring going to the V1 termi-nals and V2 terminals. By writing a 0 or a 1 to this DO block will now open and close the valve. Writing a 2 to the DO block will de-energize both the V1 and V2 terminals, stopping a valve using a block center type of pneumatic valve. Dual Block Control Method, Single Action Set the Channel Parameter of DO1 to 2 (Open), DO2 to 3 (Close), and DO3 to 0. Now by writing a 1 to DO1, the valve will Open. Changing this value back to 0, and writing a 1 to DO2 will cause the valve to close. Three Block Control Method, Dual Action Set the Channel Parameter of DO1 to 2 (Open) , DO2 to 3 (Close), and DO3 to 4 (Stop). Now by writing a 1 to DO1, the valve will Open. Changing this value back to 0, and writing a 1 to DO2 will cause the valve to close. Changing this value back to 0, and writing a 1 to DO3 will cause the outputs to terminals V1 and V2 to turn off, stopping an actuator using a block center pneumatic valve. Note on Energize to Close To energize to close (also called Reverse Acting), the ACTION_ELEMENT parameter must be reset to Reverse Acting. See the Transducer section for more details.

To use the READBACK_D values for the BACK CALCULATION OUTPUT DISCRETE parameter of the DO block, the following two options must be selected: 1. In the Resource Block the “Output Readback” option should be selected. 2. In the DO Block under IO_OPTS, select the “Use PV for BKCAL_OUT” option.

Configuration Error Handling In order to minimize configuration errors, several write checking features have been added to the SCM-FF. Write checks to the CHANNEL parameter of the DO blocks should prevent illegal configurations. These illegal configurations are:

1. If the two-state Channel 1 Open-Close has been assigned, an attempt to assign Channel 2 Open, Channel 3 Close or the Channel 5 Open/Close/Stop channels will be rejected with a write check.

2. If the three-state Channel 5 Open-Close-Stop has been assigned, an attempt to assign the Channel 2 Open, the Channel 3 Close or the Chan-nel 1 Open/Close channels will be rejected with a write check.

3. If the channel you are trying to assign has already been assigned to an-other Function Block, the write will be rejected with a write check.

4. If the Open channel has been assigned and the Close channel has not, an ‘Open without Close’ block alarm is generated by the block. NO OTH-ER LOCK-OUTS ARE IMPLEMENTED (no write-check). This becomes an open only valve. Without the close signal, the last position will be maintained.

5. If the Close channel has been assigned and the Open channel has not, a ‘Conflicting Channels Assigned’ block alarm is generated by the block. NO OTHER LOCK-OUTS ARE IMPLEMENTED (no write-check). This becomes a close only valve.

Error handling for the configuration of channels has been modified as well. The Transducer Block has a special BLOCK_ALARMS_ACTIVE parameter which may be used to diagnose a configuration problem. The configuration errors are listed in Table 2.

Table 1. Discrete Output Channel Assignments

Table 2. Transducer Block’s BLOCK_ALARMS_ACTIVE Parameter


28

Complete Discrete Output Block Parameter Listing

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29

TM

Appendix E: Discrete Input (DI) Block

Discrete INPUT Blocks (DI Block) There are 5 Discrete Input Blocks available on the SCM-FF. The DI block takes the manufacturer’s discrete input data, selected by channel number, and makes it available to other function blocks at its output. These DI blocks become available to the user when linked to one of the Transducer Channels available for inputs. A host may retrieve internal information at any time and alarms are reported as they occur. To make a light come on or another valve close requires a DI to publish the information on the bus. Channels The 5 DI Function Blocks in the device are associated to the real world by setting the CHANNEL parameter to the desired Transducer Channel. Illustration 11 shows the relationship between Transducer channels and the DI assigned channels. The output of the DI block (viewed in the OUT_D parameter) is defined by the DI block’s CHANNEL assignment. The valid settings for the CHAN-NEL parameters are listed in Table 7. By resetting a DI CHANNEL parameter to a different transducer channel number (0, 6-13, see Table 1) an end user may customize the functionality of the SCM-FF to fit a particular application requiring DI’s on temperature limits and cycle counts instead of the defaults.

Illustration 11. Channel Assignment for DI Function Blocks

Channels

Valve is Opened/ Valve is Closed 6Valve is Opened 7Valve is Closed 8Auxillary Limit Switch.input 9Cycle Time Open Alarm (CTOA) 10Cycle Time Closed Alarm (CTCA) 11Cycle Count Alarm (CCA) 12CTOA | CTCA | CCA| TMPH|TMPL 13

Transducer DI Function Block

Channel = 6

OUT_D

Is Closed Is Opened Is Stopped Is Opening Is Closing

PV_D

1 2 3 4 5

Channels



Channel = 6

OUT_D


PV_D

Channels



Channel = 6

OUT_D


PV_D

1 2 3 4 5

Table 1: DI Channel Parameter Settings List


30

Complete Discrete Input Block Parameter Listing

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31

TM

Appendix F: Dimension and Assembly Drawings

Valvetop DXP

MOUNTING SURFACE

.85 2.10

4.52

6.21

MINIMUM 2.5" REQUIRED CLEARANCE IN ORDER TO DISINGAGE THE SHAFT FROM THE ID BUSHING

AND REMOVE LID WHERE OPTIMUM CONDITIONS APPLY

SHAFT TYPE OPTIONALSEE SHAFT DETAIL

SECTION

2.13

6.65

6.76

3.85

2.25

2.25 5/16-18 UNC - 2B .44 DEEP

VALVE TYPE OPTIONALSEE INTEGRATED PNEUMATICCONTROL VALVES SECTION

2.19

OPTIONAL CONDUIT ENTRIESUSED ONLY WHEN 4 ENTRIESARE SPECIFIED

OPTIONAL CONDUIT ENTRIES

MATERIALS OF CONSTRUCTION

Enclosure Cast A360 aluminum with dichro-mate conversion coating inside & out, epoxy coated exterior rated for 250 hrs salt spray per ASTM B117

Fasteners 304 Stainless Steel standard 316 Stainless Steel optional

Shaft 304 Stainless Steel standard 316 Stainless Steel optional

Shaft Bushing Oilite Bronze

Indicator Dome Polycarbonate, UV F1 rated

Seals O-ring seals available in: Buna, Silicone, EPDM & Viton

Maximum Fastener Torque Specifications Enclosure Housing Bolts 8 ft-lbs [10.8 N·m]

Indicator Dome Screws 20 in-oz [141 mN·m]

Bottom Mounting Holes 10 ft-lbs [13.6 N·m]

Illustration #4


32

Valvetop DXP - IIC


Enclosure Cast A360 aluminum with dichro-mate conversion coating inside & out, epoxy coated exterior rated for 250 hrs salt spray per ASTM B117



Shaft Bushing Oilite Bronze



Maximum Fastener Torque Specifications

Enclosure Housing Bolts 8 ft-lbs [10.8 N·m]



Illustration #5

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33

TM

Valvetop DXS

MOUNTING SURFACE

.85 2.10

4.52

6.21

MINIMUM 2.5" REQUIRED CLEARANCE IN ORDER TO DISINGAGE THE SHAFT FROM THE ID BUSHING



SECTION

2.13

6.65

6.76

3.85

2.25

2.25 5/16-18 UNC - 2B .44 DEEP

VALVE TYPE OPTIONALSEE INTEGRATED PNEUMATICCONTROL VALVES SECTION

2.19




Enclosure Cast 316 Stainless Steel



Shaft Bushing N/A



Maximum Fastener Torque Specifications Enclosure Housing Bolts 8 ft-lbs [10.8 N·m]



Illustration #6


34


SECTION

2.00

1.10

2.10

4.51

6.21

MINIMUM 2.5" REQUIRED CLEARANCEIN ORDER TO DISINGAGE THE SHAFT FROM THE ID BUSHING


2.25

2.25

5.03

3.66

6.10

2.14

VALVE TYPE OPTIONALSEE INTEGRATED PNEUMATIC

CONTROL VALVES SECTION

5/16-18 UNC - 2B.44DP

MOUNTING SURFACE



Valvetop DXR


Enclosure Valox® 364



Shaft Bushing Delrin® 500P white



Maximum Fastener Torque Specifications Enclosure Housing Bolts 10 in-lbs [903 mN·m]



Illustration #7

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35

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Safe Use

Special Conditions of Safe Use (All installations) Clean only with a damp cloth to prevent possibility of electrostatic discharge. For Explosion Proof installations, the internal ground connection shall be used and the external ground connection, if supplied in addition, is supplemental bonding allowed where local authorities permit, or is required. When installing with a third party listed nipple-mount solenoid, it is the responsibility of the installer to provide fittings, and apparatus, suitable for the area classification in accordance with the National Electrical Code. All cable entry devices or conduit stopping boxes shall be certified in type of explosion protection ‘d’, suitable for the conditions of use and correctly installed. The IIC enclosures are excluded from use in carbon disulphide atmospheres. The air pressure to the valve block, when fitted, shall not exceed 7bar.

Preventative Maintenance The TopWorx Valvetop is designed to operate for one million cycles without servicing. Call TopWorx when you are approaching this milestone for a preventative maintenance kit and instructions.

Appendix G: Specifications and Reference Data

Table 1. Intrinsically Safe Entity Parameters

Table 2. Electrical Specifications

Table 3. Fieldbus Specifications


36

Certifications & Approvals

0518 AREA CERTIFICATION

DXP

0

Ex ia IIC T4 –40°C ≤ Tamb ≤ 80°C, IP67 DEMKO 02ATEX0223499X Ui:24Vdc, Ii:250mA, Pi:1,2W, Ci:2.5nF, Li:129µH Class I Div 1&2 Groups A,B,C,D; T4; Type 4, 4X Intrinsically Safe / Securite Intrinsique Electrical Rating: 9-32Vdc, 20mA

1

Class I Div 1 Groups C,D; Class 1 Div 2 Groups A,B,C,D Type 4, 4X Ex d IIB+H2 T6 –40°C ≤ Tamb ≤ 60°C, IP67 SIRA 07ATEX1273X IECEx SIR 07.0093X Electrical Rating: 9-32Vdc, 20mA

2 Class I Div 2 Groups A,B,C,D; Type 4, 4X Ex nC IIC T6 –40°C ≤ Tamb ≤ 60°C, IP67 Electrical Rating: 9-32Vdc, 20mA

C

Ex d IIC T6 –40°C ≤ Tamb ≤ 60°C, IP67 SIRA 07ATEX1273X IECEx SIR 06.0093X Max Current 500mA @ Max Voltage 25V

W NEMA 4, 4X

DXS

0

Ex ia IIC T4 –40°C ≤ Tamb ≤ 80°C, IP67 DEMKO 02ATEX0223499X Ui:24Vdc, Ii:250mA, Pi:1,2W, Ci:2.5nF, Li:129µH Class I Div 1&2 Groups A,B,C,D; T4; Type 4, 4X Intrinsically Safe / Securite Intrinsique Electrical Rating: 9-32Vdc, 20mA

1

Class I Div 1 Groups C,D; Class 1 Div 2 Groups A,B,C,D Type 4, 4X Ex d IIB+H2 T6 –40°C ≤ Tamb ≤ 60°C, IP67 SIRA 07ATEX1273X IECEx SIR 07.0093X Max Current 500mA @ Max Voltage 25V

2 Class I Div 2 Groups A,B,C,D; Type 4, 4X Ex nC IIC T6 –40°C ≤ Tamb ≤ 60°C, IP67 Electrical Rating: 9-32Vdc, 20mA

W NEMA 4, 4X

DXR G Type 4, 4X

Electrical Rating: 9-32Vdc, 20mA

W Type 4, 4X Electrical Rating: 9-32Vdc, 20mA

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37

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Warranty


38

NOTES:

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39

TM

NOTES:

S-K131 R13

Visit www.topworx.com for comprehensive information on our company, capabilities, and products — including model numbers, data sheets, specifications, dimensions, and certifications. [email protected]

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™

™

The Emerson logo is a trademark and a service mark of Emerson Electric Co. ©2014 Emerson Electric Co. ©2014 TopWorx™, All rights reserved.TopWorx, Valvetop, and GO Switch are trademarks of TopWorx™. All other marks used in this document are the property of their respective owners. Information contained herein - including product specifications is subject to change without notice.

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