ROSOV Manual - L & T

Installation, Operation and
Maintenance Instructions for

Remote Operated Shut-off Triple Offset
Butterfly Valve with Pneumatic Actuators
Contents
Annexure Title
1 Handling of Valve Actuator Assembly
Installation, Operation and maintenance

2
Instructions for Triple Offset Butterfly Valve
3 Control Panel - operating instructions
Installation And Maintenance Manual – CP Range

4
Pneumatic actuators
Installation And Maintenance Manual – GP Range

5
Pneumatic actuators
Annexure -1
Handling of Valve-Actuator Assembly
Handling Requirements
Valves in crates are to be lifted or handled by a fork lift truck, by means of the
appropriate fork hitches. Lifting of valves in cases are to be carried out in the
lifting points in the case. Transportation of all packed material must be carried
out safely and following the local safety regulations
Lifting fasteners, hooks, etc are to be selected considering the weight of the
whole assembly as indicated in the packing list or the general assembly
drawings. Lifting has to be performed only by a qualified personnel.
Typical lifting method for the valve-actuator assembly is shown below.
Method to lift a Typical valve assembly

Installation, Operation and
Maintenance Instructions for
L&T Valves Metal Seated
Triple Offset Butterfly Valves
REV. DATE MODIFICATION DETAILS PREPARED CHECKED APPROVED

BY BY BY
ZN DIMNS. CORRECTED. RETAINER
TIGHTENING & GLAND TIGHTENING
1 12.04.2010 BMSN BSB SMV
TORQUE VALUES CORRECTED.
EXPLODED VIEW MODIFIED.
GLAND BOLT TIGHTENING TORQUE VALUES
2 29.03.2011 GSV PAP NVD
ADDED FOR EXTENDED SIZE RANGE
NAME CHANGE FROM AIL TO L&T VALVES
3 10.07.2013 SPT SEN SEN
LIMITED
1
Installation, Operation and Maintenance Instructions for L&T Valves Metal Seated Triple Offset Butterfly Valves
Installation, Operation and Maintenance Instructions for
L&T valves Metal Seated Triple Offset Butterfly Valves
1.0 Typical Metal Seated Triple Offset Butterfly Valve with parts
1.1 L&T Valves Metal Seated Triple Offset Butterfly valves are of sturdy design and give
tight sealing.
1.2 It has a Triple offset seat geometry to provide friction-less seal with uniform
compressive sealing. A typical valve construction is shown below.
2
2.0 Identification of valves
2.1 Each valve has a stainless steel name plate fixed to the body. The nameplate is
marked with details such as valve size (in inches and mm), ASME class rating,
materials of construction, limiting temperature and serial number of the valve. A
typical name plate is shown below.
2.2 Tag number will also be attached to the valve if requested at the time of order.
3.0 Storage
3.1 On receipt check that the valve and accessories are intact. Ensure that the valve is in
fully closed position.
3.2 End protectors on either side of the valve should be kept intact and removed only at
the time of installation.
3.3 Valve should be stored in a covered area. If covered area is not available waterproof-
covering material should be spread over the valves and the valves should be kept on
a wooden pallet atleast 6” (150mm) above the ground level.
3.4 Do not apply tar, paint, grease or any other material inside the valve, as this will
impair the performance of the valve.
3.5 While transporting the valve from storage to installation site, it shall not be dragged
on the floor.
4.0 Planning and Responsibilities
4.1 Conduct a risk assessment and eliminate or reduce hazards to an acceptable level.
4.2 Work in accordance with safe systems of work.
4.3 Observe all site health safety rules.
4.4 Due to variety of duties in which this valve can be employed, it is the end user’s
responsibility to ensure compatibility of media with the material of construction of the
product for each specific application.
4.5 Before equipment is installed in areas which may be subject to extreme seismic
activity consult L&T valves with data.
5.0 Do’s & Don’ts
5.1 These valves are not to be used for End of line service.
5.2 Wear all necessary protective equipment for conducting the work.
5.3 Never remove or maintain a valve or joint unless the line has been fully drained and
de-pressurized.
5.4 Ensure that the valves are used within the pressure temperature
service conditions as per ASME B16.34. Also refer name plate for
pressure temperature limits. In case of additional assistance consult
with L&T valves.
5.5 Valve hand wheels are designed only for operation. The hand wheel
must not be used for handling the valve.
5.6 Lined Pipes and Heavy walled pipes should have a minimum inside
diameter well clear of Dimension "Z n" (Refer Figure) in Disc full open
position
3
Zn (Max.) -Dimension of protruding disc, mm
SIZE 3 4 6 8 10 12 14 16 18 20 24
in
mm 80 100 150 200 250 300 350 400 450 500 600
Class 150 75 99 151 197 248 299 331 381 432 483 578
Class 300 71 94 143 188 242 292 324 375 422 472 562
Class 600 71 94 143 183 230 275 302 348 392 437 519
6.0 Installation
6.1 Preparation for Installation
6.1.1 Move the valves as close as possible to the installation site before removing
the end protectors. After removing the end protectors, check the inside of the
valve and remove any rust inhibitor or dirt.
6.1.2 Clean the pipe flanges of any rust / dirt.
6.1.3 In flanged end valves the raised face should be cleaned and free of any
damage/score marks.
6.1.4 In BW end valves ensure that the end preparation is in line with the mating
part and free from any damage / nicks etc.
6.1.5 Ensure that the pipe line has been flushed free of dirt, weld spatter etc. before
installation.
6.2 Pre-Commissioning Test
6.2.1 All valves are factory tested in accordance with API 598, as mentioned in the
product catalogue.
6.2.2 Wherever valves are required to be re-tested before installation, ensure that a
proper test rig is available at the site. Valves should be tested as per API 598,
by an authorized faculty as per approved procedures.
6.2.3 Only demineralised water free of dirt and suspended impurities shall
be used for testing. It is advisable to add corrosion inhibitor in the water and
it is also recommended that after testing is over, the valve internals are dried
with dry nitrogen or air.
6.3 Installation Configuration
6.3.1 For best performance it is recommended that these valves are installed with
the shaft horizontal with the hand wheel facing up.
6.3.2 This valve has bi-directional sealing capabilities and therefore can be installed
in either direction. However, a preferred flow direction is indicated in the valve
by means of an arrow mark and it is strongly recommended that the valve is
installed such that the flow is in the direction of the arrow.
6.4 Lifting Position
6.4.1 Valves should be lifted using suitable mechanical equipment. Chains,
Slings and other lifting equipment should be regularly inspected. Do
not attempt to lift the valve by applying load on hand wheel, Gear Unit,
actuator or any other accessory. Chains or slings should be fixed
around the valve body.
6.4.2 Use lifting lugs, eyebolts for handling.
6.4.3 Valves shall be in closed position during handling.
6.4.4 When valves are fitted with Fail-Open actuators, care is to be taken so
as to manually override the valves to close position.
6.5 Flanged End Connections

6.5.1 These valves are manufactured in accordance to the standards specified in the
product catalogue, unless otherwise specified by the customer.
4
6.5.2 Gaskets and flange bolting which are not supplied with the valve should meet
the requirement of the end flange standard of the valve. Pipe flanges shall be
pulled together evenly by tightening opposite pairs of bolts in star pattern.
6.5.3 For wafer type valves, it has to be ensured that the valve bore is along the
centerline of the pipe.
6.5.4 Ensure that the pipeline stresses are not transferred on to the valve as this
may impair the performance of the valve.
6.5.5 Do not use the valve as a jack to pull the pipe into alignment.
6.6 Butt welded Connections
6.6.1 The valve ends and the pipe ends should be aligned.
6.6.2 The pipe work in the butt weld end connection should also have the correct
gap to allow the end to end dimension of the valve.
6.6.3 Correct welding material shall be used as per approved procedures for welding.
WARNING: Valve should be kept in closed position during welding.
6.7 Bolting Arrangement

6.7.1 The bolting arrangement will vary according to the type of valve. Refer Fig for
details.
 
5
7.0 Operation
7.1 These valves are not to be used for End of line service.
7.2 These valves are provided with various operators such as Manual (Gear unit), Electric
or Pneumatic actuators.
7.3 Gear units are of worm type and are self-locking. The direction of rotation of the hand
wheel to shut the valve is indicated on it. Position indicators on the gear unit show
the angular movement of the disc and also the open and shut positions.
7.4 Electrical Actuators

7.4.1 Electrical actuators are fitted to the manual override gear unit or directly
mounted.
7.4.2 For operational details consult the manufacturer's instruction manual and the
appropriate wiring diagram.
7.4.3 Ensure that electrical connections are given as indicated in the wiring diagram
for the specific actuator.
7.4.4 Before making a test run move the disc to an intermediary position by means
of the hand wheel.
7.4.5 Start the motor and see if the working direction is correct.
7.4.6 Ensure correct phase connection to avoid failure of actuator.
7.5 Pneumatic Actuators

7.5.1 Pneumatic actuators are fitted to the manual override gear unit or directly
mounted.
7.5.2 For operational details consult the manufacturer’s instruction manual and
appropriate pneumatic circuit diagram.
7.5.3 Ensure that the port connections are as given in the pneumatic circuit.
7.5.4 For Double acting actuators, move the disc to an intermediate position by
using manual override.
7.5.5 Run a test by supplying air and see if the direction of operation is correct.
7.6 Operator Accessories
7.6.1 Mechanical Stopper – Mechanical stoppers are provided on gear units and
manual override gear units. These are factory set and should not be disturbed.
7.6.2 Limit Switch – Limit switches are factory set and should not be disturbed.
However, for valves with extension spindle, actuator is approximately pre-set
and should be reset at site. The pre-setting can also be modified if required
once the valve has been put into service. Consult manufacturer instruction for
more details.
7.6 Warning: In valves fitted with PTFE gland packings, and gasket with PTFE
filler, which have been exposed to an external fire, it is recommended that
the packing and the gasket be changed immediately before further use of
the valve.
8.0 In-line Maintenance

8.1 These butterfly valves require only minimum in-line maintenance for satisfactory
performance.
8.2 Check Gland nuts for tightness at regular intervals. If loose, tighten them evenly.
8.3 Refer Table II for Gland nut tightening Torque.
6
9.0 Routine Maintenance
9.1 Gland Leak
9.1.1 Check the tightness of the gland nuts and tighten evenly if required. If the leak
persists, the packing may be renewed.
9.2 Packing Replacement
9.2.1 Caution: DO NOT replace the gland packing when the line is
under pressure. Do not over-tighten packing and gland nuts.
Over-tightening will increase the torque required to operate
the valve.
9.2.2 Remove the gear unit/actuator and connecting keys. Its position relative
to the valve must be noted for reassembly of gear unit/actuator.
9.2.3 Remove gland nut, gland flange and gland.
9.2.4 Remove packing and carefully clean packing cavity and shaft.
9.2.5 Insert new packing rings. Most of the packing rings are already cut so
that they can be inserted around the stem. In case of solid molded
packing like Graphite rings, use a sharp knife and cut the ring at 30
angle. Then slightly twist the ring and insert it around the stem. Do not
open up the ring as it could break.
9.2.6 Reassemble gland, gland flange and gland nut.
9.2.7 Reassemble connecting keys, gear unit/actuator and close the valve.
Caution: The gear unit/actuator will be a free moving fit. Do not force
it on the stem.
9.2.8 Tighten the gland nuts and cycle the valve.
9.2.9 Pressurize the line. If leakage is detected, tighten the gland nuts slowly and
evenly until leakage stops.
9.3 Gear Units
9.3.1 Gear Operated valves are fitted with enclosed water tight worm gear units. The
gears are designed to function without maintenance for many years. All gear
units are lubricated with heavy bearing grease when assembled and may be
refilled as required.
10.0 Periodic Maintenance
10.1 Dismantling
10.1.1 The pipeline shall be drained of the line fluid and the valve removed from
the line before dismantling.
10.1.2 Care should be taken during the removal of wafer and wafer lugged
valves fitted with fail-open actuators. Such valves shall be closed
using the manual over-ride gear unit before removing from the
pipeline. If no manual over-ride is available, the fail open actuator
shall be dismantled before the valve is removed from the pipe line.
Subsequently, the valve shall be closed with a wrench and then
removed.
10.1.3 The Operator may be changed without removing the valve from the pipeline,
however, the line pressure should be relieved.
10.1.4 Maintenance of the operator shall be done as per manufacturer instruction.
10.1.5 Operator shall be changed when the valve shall be in the fully closed
condition.
10.1.6 If the operator has a fail-safe position that cannot be overridden then
unscrewing the bolting on the valve bracket should dismantle the actuator.
10.2 Inspection
10.2.1 Keep the valve in full open condition and examine the body seat and laminar
seal for wear / damage
7
10.2.2 The gland nuts can be loosened to operate the valve if no other means of
actuation is possible.
10.2.3 Check for tightness of the locking screw and grub screw on the disc hub.
10.2.4 Check if the retainer bolting is uniformly tight to the specified torque. For
torque details refer Table I.
10.3 Replacement of Seal
10.3.1 If there is excessive damage / wear on the seal, it shall be replaced by a new
spare.
10.3.2 Remove the retainer by unscrewing of the bolting.
10.3.3 Remove the old seal and the locating pin.
10.3.4 The gasket under the seal should also be replaced at the time of seal
replacement.
10.3.5 Place the gasket in the appropriate groove on the disc.
10.3.6 Insert the locating pin on the disc.
10.3.7 Place the laminar seal over the gasket (so as to mate with the seat in body).
Locate the seal ring using
the locating pin in the recess
provided in both the seal and
disc.
10.3.8 A Punch mark is provided on
the laminar seal and this shall
be facing the operator during
seal assembly.
10.3.9 Mount the retainer ring to the
disc using the retainer screws
and hand tighten them to allow
for seal movement.
10.3.10 Apply a thin film of
lubricant on the body seat as
well on the conical seat of the seal.
10.3.11 Operate the valve from full open to full
close atleast two times and after the seal has aligned with the body seat,
tighten the retainer screws to the specified torque. For torque details refer
Table I.
10.3.12 The Valve shall be in closed position during tightening of the
retainer bolting.
10.4 Reassembly
10.4.1 Gland nuts shall be tightened to the torque values given in Table II
10.4.2 With the valve in fully closed position, it shall be installed back in the pipe line
as stated in section 6.0
10.4.3 The gaskets have to renewed every time the valve is removed from the line.
11.0 Trouble Shooting Guide

TROUBLE PROBABLE CAUSE REMEDY (see section)
Leaks across Disc a. Valve not fully closed a. Re-tighten hand wheel
Dismantle and replace seal
b. Valve seating damaged b.
(10.3)
Leaks through gland a. Packing loosened a. Tighten Gland nuts (9.1)

b. Packing worn out b. Replace packing (9.2)
Not closing fully Accumulation of debris Flush the pipeline with the
a. a.
on seat valve in fully open condition
8
12.0 Valve Data
It is always advantageous to keep the valve detail handy as shown below for quick
reference during periodic maintenance.
Pressure Valve
Tag No. Valve Size Qty Location Remarks
Class SL. No.
Repair Kits
Repair kits are available for all L&T valves Metal Seated Triple Offset Butterfly Valves
consisting of a set of gland packings, seal and seal gasket. Details of the content are found
in the instruction sheet supplied with the kit.
Dismantling of valves for attending for gland packing replacement as well as replacement
of seal should be done under expert supervision, after de-pressurizing the line and
evacuating all the line fluid from the valve.
TABLE I – Retainer bolt tightening torque in Nm

Bolt Dimension (mm) Torque value (Nm)
8 18
10 34
12 58
14 92
16 140
18 196
20 273
22 375
24 473
TABLE II - Gland tightening torque in Nm (Max)

Valve Size (in) Class 150 Class 300 Class 600
3 8 8 13
4 9 9 34
6 9 11 75
8 18 29 113
10 55 55 91
12 55 61 99
14 29 91 67
16 36 98 90
18 36 54 222
20 73 216 260
24 78 135 300
30 115 170
32 170 220
34 170 260
36 170 335
9
15. Exploded view of valve assembly
10
Item Description Qty Item Description Qty
1. Hand wheel 1 17. Spiral Wound
1
2. Gear Unit 1 Gasket
3. Gear Unit Adaptor 1 18. Laminar Seal 1
4. Key (Gear Unit) As reqd. 19. Retainer 1
5. Shaft 1 20. Spring Washer As reqd.
6. Gland Nut As reqd. 21. Retainer Bolting As reqd.
7. Gland Stud As reqd. 22. Key (Disc) 2
8. Gland Flange 1 23. Disc 1
9. Gland 1 24. Slotted Grub Screw 1
10. Packing (Braided) 2 25. Locking Screw 1
11. Packing (Molded) 3 26. Locating Pin 1
12. Spacer 1 27. Thrust Plate 1
13. Bearing 2 28. Thrust plate Bolting 2
14. Bearing Seal 2 29. Spiral Wound
15. Bolts (Adaptor Gasket(Bottom 1
As reqd.
Mounting) Cover)
16. Body 1 30. Bottom Cover 1
31. Cover Bolting 4
11
ROSOV OPERATING INSTRUCTION
Normal operation:
1) Refer drawing LT3A2260 for pneumatic circuit diagram.
2) Refer drawing LT3A2263 for electrical circuit diagram.
3) Ensure the air filter regulator set pressure is 4 kg/cm2(g).
4) Ensure that the electrical connection is switched on and the solenoid valves are
energised.
5) Do not tamper the factory settings of the uni-directional flow regulators (UFR).
6) UFRs are already adjusted to the set point to control the required ROSOV opening
and closing time.
7) Press open button in the 2 push button local control station (LCS) to open the
ROSOV.
8) Press close button in the LCS to close the ROSOV.
Emergency operation:
1) Press the shutdown button of the emergency control station (ECS), which is
installed outside the DYKE area.
2) This de-energises the manual reset solenoid valve, and shuts down the ROSOV.
3) In order to restore the normal operation, reset the emergency shutdown button in
the ECS and manual reset solenoid valve.
Air failure: ROSOV will close
Electrical failure: ROSOV will close
Do not open the solenoid valves, LCS, or the ECS when energised
WI-ROSOV-IOCL-Rev.1 (Applicable for Batch – 2)

INSTALLATION & MAINTENANCE INSTRUCTIONS INSTRUCTIONS D'INSTALLATION ET D'ENTRETIEN
series 327, 3/2 high flow valve, direct operated, balanced poppet
1/4" & 1/2"
GB Series 327, 3/2 grand débit, à commande directe, à clapet équilibré
1/4 & 1/2
FR
GENERAL electrical power interruption. GENERALITES dans le sens inverse des aiguilles d’une montre pour revenir en position
This I&M sheet has to be supplemented by the particular I&M sheet 4. An adapter for under pressure removable operators MO and MS, Cette notice d’installation et d’entretien doit être complétée par la « OFF » (hors tension)
of the solenoid. Use both sheets for installation and maintenance. according to TPL-26710: Remove the plug of the adapter and notice d’installation et d’entretien de l’électrovanne. Utiliser les deux 3. Pas de libération de tension (NVR): La vanne ne fonctionnera
DESCRIPTION mount the MO, KIT 325323, (without seals and spring) or MS, KIT notices pour l’installation et l’entretien. pas si on met seulement le solénoïde sous tension. Appuyer sur
Series 327 are direct operated 3/2 solenoid valves of the balanced 325324; the system can be kept under pressure. Operate the MO DESCRIPTION le bouton pour commuter manuellement la vanne sur la position
construction type. The body material is brass or stainless steel. The and MS as described above. Remove the manual operator and Les vannes de la série 327 font partie de la gamme des électrovannes « ON » (sous tension). Mettre le solénoïde sous tension et pousser
valves are of the universal operation type and are intended for 2- or refit the plug. à commande directe 3/2. De conception, la construction est dite sur le bouton momentanément pour commuter et encliqueter la
3-way normally closed, normally open, selection and diversion flow. SOUND EMISSION “équilibrée”. Le corps est en laiton ou en acier inoxydable. Les vanne sur la position « ON » (sous tension). La vanne restera en
Pressure may be applied at any port. The emission of sound depends on the application, medium and électrovannes fonctionnent de manière universelle ; elles sont position non cliquetée (retour à la position « OFF » - hors tension)
nature of the equipment used. The exact determination of the normalement fermées, à 2 ou 3 voies, normalement ouvertes, pour en cas de coupure de courant.
INSTALLATION 4. Un adaptateur pour des commandes amovibles sous pression MO
ASCO Numatics components are intended to be used only within sound level can only be done by the user having the valve installed des débits dérivés ou de sélection. La pression peut être appliquée
in his system. à n’importe quel port. et MS, selon TPL-26710 : Retirer la fiche de l’adaptateur et monter
the technical characteristics as specified on the nameplate. Changes la MO, KIT 325323, (sans joints et ressort) ou MS, KIT 325324; le
to the equipment are only allowed after consulting the manufacturer MAINTENANCE MONTAGE système peut être gardé sous pression. Faire fonctionner les MO
or its representative. Before installation depressurise the piping Maintenance of ASCO Numatics products is dependent on service Les composants ASCO Numatics sont conçus pour les domaines et MS comme mentionné ci-dessus. Ôter la commande manuelle
system and clean internally. The equipment may be mounted in conditions. Periodic cleaning is recommended, the timing of which will de fonctionnement indiqués sur la plaque signalétique ou la et replacer la fiche.
any position. The flow direction and pipe connection of valves are depend on the media and service conditions. Handle the MO and MS documentation. Aucune modification ne peut être réalisée sur le
indicated on the body. Kit with care to avoid damage. During servicing, components should matériel sans l’accord préalable du fabricant ou de son représentant. BRUIT DE FONCTIONNEMENT
be examined for excessive wear. A complete set of internal parts is Avant de procéder au montage, dépressuriser les canalisations et Le bruit de fonctionnement varie selon l’utilisation, le fluide et le
The pipe connections have to be in accordance with the size available as a spare parts kit. If a problem occurs during installation/ effectuer un nettoyage interne. type de matériel employé. L’utilisateur ne pourra déterminer avec
indicated on the nameplate and fitted accordingly. maintenance or in case of doubt please contact ASCO Numatics or Les électrovannes peuvent être monté dans n’importe quelle position. précision le niveau sonore émis qu’après avoir monté le composant
CAUTION: authorised representatives. Le sens de circulation du fluide est indiqué par repères sur le corps sur l’installation.
• Reducing the connections may cause improper operation or VALVE DISASSEMBLY et dans la documentation. ENTRETIEN
malfunctioning. Disassemble in an orderly fashion. Pay careful attention to exploded La dimension des tuyauteries doit correspondre au raccordement L’entretien nécessaire aux produits ASCO Numatics varie avec leurs
• For the protection of the equipment install a strainer or filter views provided for identification of parts. indiqué sur le corps, l’étiquette ou la notice. conditions d’utilisation. Il est souhaitable de procéder à un nettoyage
suitable for the service involved in the inlet side as close to the 1. Remove retaining clip and spacer, and slip coil off solenoid base ATTENTION: périodique dont l’intervalle varie suivant la nature du fluide, les
product as possible. sub-assembly. CAUTION: when metal retaining clip disengages, • Une restriction des tuyauteries peut entraîner des dysfonctionne- conditions de fonctionnement et le milieu ambiant. Tenir le kit MO
• If tape, paste, spray or a similar lubricant is used when tightening, it can spring upwards. Remove spring washer. ments. et MS soigneusement pour éviter les dégâts. Lors de l’intervention,
avoid particles entering the system. 2. Unscrew solenoid base sub-assembly and remove O-ring. • Afin de protéger le matériel, installer une crépine ou un filtre les composants doivent être examinés pour détecter toute usure
• Use proper tools and locate wrenches as close as possible to the 3. Remove pin or spring (NVR type) adéquat en amont, aussi près que possible du produit. excessive. Un ensemble de pièces internes est proposé en pièces
connection point. 4. Pull out core assembly. All parts are now accessible for cleaning • En cas d’utilisation de ruban, pâte, aérosol ou un lubrifiant lors du de rechange pour procéder à la réfection. En cas de problème
• To avoid damage to the equipment, DO NOT OVER-TIGHTEN or replacement. serrage, veillez à ce qu’aucun corps étranger ne pénétre dans le lors du montage/entretien ou en cas de doute, veuillez contacter
pipe connections. circuit. ASCO Numatics ou ses représentants officiels.
• Do not use valve or solenoid as a lever. VALVE REASSEMBLY • Utiliser un outillage approprié et placer les clés aussi près que
Reassemble in reverse order of disassembly paying careful attention DEMONTAGE DE LA VANNE
• The pipe connections should not apply any force, torque or strain possible du point de raccordement. Démonter en suivant un certain ordre. Suivre attentivement les vues
to the product. to exploded views provided for identification and placement of parts. • Afin d’éviter toute détérioration, NE PAS TROP SERRER les
1. NOTE: Lubricate all gaskets/O-rings with high quality silicone en éclaté fournies dans la pochette et destinées à l’identification
ELECTRICAL CONNECTION raccords des tuyauteries. des pièces.
grease. • Ne pas se servir de la vanne ou de la tête magnétique comme
In case of electrical connections, they are only to be made by 2. Place core sub-assembly into body cavity and push it gently down 1. Ôter le clip de maintien et la bague d’espacement, et faire glisser
trained personnel and have to be in accordance with the local d’un levier. la bobine hors du sous-ensemble de la base du solénoïde.
until the gasket just seals in the cavity of the body. • Les tubes de raccordement ne devront exercer aucun effort, couple
regulations and standards. CAUTION: Prevent seat damage when placing core assembly ATTENTION : lorsque le clip de maintien métallique est ôté, il peut
CAUTION: ou contrainte sur le produit. bondir vers le haut. Ôter la rondelle élastique.
into body.
• Turn off electrical power supply and de-energise the electrical 3. Replace solenoid base O-ring and pin or spring (NVR type). RACCORDEMENT ÉLECTRIQUE 2. Dévisser le sous-ensemble de la base du solénoïde et ôter son
circuit and voltage carrying parts before starting work. 4. Replace solenoid base sub-assembly; torque according to Le raccordement électrique doit être réalisé par un personnel qualifié joint d’étanchéité.
• All electrical screw terminals must be properly tightened according torque chart. This will also push the core sub-assembly into its et selon les normes et règlements locaux. 3. Enlever la goupille ou le ressort (type NVR).
to the standards before putting into service. correct position. ATTENTION: 4. Extraire le sous-ensemble de noyau. Vous pouvez dès à présent
• Dependent upon the voltage electrical components must be 5. Replace Manual operator; torque according to torque chart, apply • Avant toute intervention, coupez l’alimentation électrique pour nettoyer ou remplacer toutes les pièces.
provided with an earth connection and satisfy local regulations Loctite® 243 for the adapter. mettre hors tension les composants. REMONTAGE DE LA VANNE
and standards. 6. Install spring washer, coil, spacer and retaining clip. • Toutes les bornes à vis doivent être serrées correctement avant Remonter selon l’ordre contraire au montage en suivant
The equipment can have one of the following electrical terminals: 7. After maintenance, operate the valve a few times to be sure of la mise en service. attentivement les vues en éclaté fournies dans la pochette et
Spade plug connections according to ISO-4400 (EN175301-803A), proper operation. • Selon la tension, les composants électriques doivent être mis à destinées à l’identification et l’emplacement des pièces.
embedded screw terminals in metal enclosure with cable gland or NOTE: For the stainless steel constructions it is highly recommended la terre conformément aux normes et règlements locaux. 1. REMARQUE : Lubrifier tous les joints toriques avec de la graisse
conduit, flying leads or cable. to use a suitable anti-seize lubricant to avoid galling. Selon les cas, le raccordement électrique s’effectue par: silicone de haute qualité.
PUTTING INTO SERVICE Connecteurs débrochables ISO-4400 (EN175301-803A), avec 2. Placer le sous-ensemble de noyau dans la cavité du corps et le
MANUAL OPERATORS bornes à vis solidaires du bobinage, sous enveloppe métallique,
Before pressurizing the system, first carry-out an electrical test. For detailed information please refer to installation & maintenance faire descendre délicatement en le poussant jusqu’au moment
Energize the coil a few times and notice a muffled click signifying presse-étoupe ou conduit, fils ou câbles solidaires de la bobine. où le joint d’étanchéité ferme hermétiquement la cavité du corps.
instructions Series 327 manual operators document 123620-322.
the solenoid operation (except NVR types). MISE EN SERVICE ATTENTION : Eviter d’endommager le siège lorsque vous placez
For testing of the system when pressurized with de-energized coils For additional information visit our website: Avant de mettre le circuit sous pression, effectuer un essai électrique. le montage du noyau dans le corps.
and adapter for under pressure removable operators MO and MS www.asconumatics.eu Mettre la bobine sous tension plusieurs fois et écouter le « clic » 3. Replacer le joint d’étanchéité et la goupille de la base du solénoïde
mount a MO or MS and operate the valve. Dismount the MO or MS sourd qui signale le fonctionnement de la tête magnétique (sauf ou le ressort (type NVR).
and mount the plug to avoid unauthorised operation. Loctite® is a registered trademark of Henkel pour les types NVR). 4. Remplacer le sous-ensemble de la base du solénoïde ; raccorder
SERVICE Pour tester le système une fois pressurisé avec les bobines et en suivant le schéma de couple. Le sous-ensemble de noyau sera
Most of the solenoid valves are equipped with coils for continuous l’adaptateur hors tension pour des commandes amovibles sous également poussé dans sa position correcte.
duty service. To prevent the possibility of personal or property pression MO et MS, monter une MO ou MS et faire fonctionner la 5. Replacer la commande manuelle ; la raccorder selon le schéma
damage do not touch the solenoid which can become hot under vanne. Démonter la MO ou MS et monter la fiche pour éviter un de couple, mettre du Loctite® 243 sur l’adaptateur.
normal operation conditions. If the solenoid valve is easily fonctionnement non autorisé. 6. Installer la rondelle élastique, la bobine, la bague d’espacement
accessible, the installer must provide protection preventing FONCTIONNEMENT et le clip de maintien.
accidental contact. La plupart des électrovannes comportent des bobinages prévus 7. Après l’entretien, faire fonctionner la vanne quelques fois afin de
pour mise sous tension permanente. Pour éviter toute brûlure, ne s’assurer qu’elle s’ouvre et se ferme correctement.
MANUAL OPERATION REMARQUE : Pour les constructions en acier inoxydable, il est
There are four optional manual operators: pas toucher la tête magnétique qui, en fonctionnement normal et en
permanence sous tension, peut atteindre une température élevée. fortement recommandé d’utiliser un lubrifiant antigrippant correct.
1. Push type, spring return, suffix MO: Push the button to switch the
valve manually to the “ON” position. Release button to return to Si l’électrovanne est facilement accessible, l’installateur doit prévoir COMMANDES MANUELLES
the “OFF” position. une protection empêchant tout contact accidentel. Pour de plus amples informations, se référer aux instructions
2. Screw type manually return, suffix MS: Push and turn knob FONCTIONNEMENT MANUEL d’installation et de maintenance des commandes manuelles Séries
clockwise to switch valve manually to the “ON” position. Turn knob Il existe quatre opérateurs manuels en option : 327, document 123620-322.
counterclockwise to return to “OFF” position. 1. Type poussoir, ressort de retour, suffix MO: Appuyer sur le bouton pour Pour toute information complémentaire, veuillez consulter notre
3. No Voltage Release (NVR): The valve will not operate by only commuter manuellement la vanne sur la position « ON » (sous tension). site Web: www.asconumatics.fr
energizing the solenoid. Push the button to switch the valve manu- Relâcher le bouton pour revenir en position « OFF » (hors tension).
ally to the “ON” position. Energize the solenoid and push button 2. Type à visser, retour manuel, suffix MS: Appuyer sur le bouton et le tour- Loctite® est une marque déposée de Henkel
momentarily to switch and latch the valve in the “ON” position. ner dans le sens des aiguilles d’une montre afin de commuter manuel-
The valve will unlatch (return to the “OFF” position) in case of lement la vanne sur la position « ON » (sous tension). Tourner le bouton

BETRIEBSANLEITUNG INSTRUCCIONES DE INSTALACIÓN Y MANTENIMIENTO
Series 327, 3/2 hoher Durchfluß, direkt betätigt, entlasteter Ventilkolben
1/4 & 1/2
DE Series 327, 3/2 alto flujo, mando directo, vástago equilibrado
1/4 & 1/2
ES
ALLGEMEINES 2. Schraubausführung manuelle Rückstellung, Nachsatz x MS: DATOS GENERALES “ON”. Gire el botón en sentido antihorario para volver a la posición
Dieses I&M-Datenblatt ist eine Ergänzung zum spezifischen I&M- Den Knopf drücken und im Uhrzeigersinn drehen, um das Ventil Esta hoja de I&M debe complementarse mediante la hoja I&M “OFF”.
Datenblatt des Magnetkopfes. Für die Installation und Wartung manuell in die Position “ON” zu schalten. Den Knopf entgegen dem específica del solenoide. Utilice ambas hojas para la instalación 3. Sin liberación de tensión (NVR): La válvula no funcionará sola-
müssen beide Anleitungen verwendet werden. Uhrzeigersinn drehen, um zur Position “OFF” zurückzukehren. y el mantenimiento. mente energizando el solenoide. Pulse el botón para poner la
BESCHREIBUNG 3. No Voltage Release (NVR): Das Ventil arbeitet nicht, indem nur der DESCRIPCION válvula manualmente en la posición “ON”. Energice el solenoide y
Bei der Baureihe 327 handelt es sich um direkt betätigte 3/2-Wege- Magnetkopf unter Spannung gesetzt wird. Den Knopf drücken, um La serie 327 está formada por válvulas de solenoide 3/2 de mando pulse el botón momentáneamente para conmutar y fijar la válvula
Magnetventile der Konstruktionsweise mit “entlastetem Ventilkolben”. das Ventil manuell in die Position “ON” zu schalten. Spannung an directo, del tipo construcción equilibrada. El material del cuerpo es de en la posición “ON”. La válvula se liberará (volviendo a la posición
Das Gehäuse besteht aus Messing oder rostfreiem Stahl. Die Ventile den Magnetkopf anlegen und sofort den Knopf drücken, um das bronce o acero inoxidable. Las válvulas son de tipo funcionamiento “OFF”) en caso de interrupción de la energía eléctrica.
sind Universalventile und für den 2- oder 3-Wege-Betrieb im NC- bzw. Ventil in die Position “ON” zu schalten und dort zu verriegeln. Das universal y están diseñadas para su utilización con 2 o 3 vías, 4. Un adaptador para operadores MO y MS bajo presión: conforme
NO-Betrieb, Selektiv- und Ablenkbetrieb ausgelegt. Der Druck kann Ventil wird entriegelt (und kehrt in die Position “OFF” zurück), wenn con TPL-26710: Retire el obturador del adaptador y monte el MO,
die Spannung unterbrochen wird. normalmente cerrada, normalmente abierta, mediante selección y
an jeden beliebigen Anschluss angelegt werden. flujo de desviación. Se puede aplicar presión en cualquier orificio. KIT 325323, (sin juntas ni resorte) o MS, KIT 325324; el sistema
4. Ein Zwischenstück für Betätigungselemente MO und MS unter puede mantenerse bajo presión. Accione el MO y MS como se ha
EINBAU Druck, gemäß TPL-26710: Stopfen des Zwischenstücks entfernen INSTALACION
Die ASCO Numatics-Komponenten dürfen nur innerhalb der auf den indicado anteriormente. Desmonte el operador manual y vuelva
und MO, KIT 325323 (ohne Dichtungen und Feder) oder MS, KIT Los componentes ASCO Numatics sólo deben utilizarse dentro de a colocar el obturador.
Typenschildern angegebenen Daten eingesetzt werden. Veränderun- 325324 montieren. Das System kann unter Druck bleiben. MO und las especificaciones técnicas que se especifican en su placa de
gen an den Produkten sind nur nach Rücksprache mit ASCO Numatics MS wie oben beschrieben betätigen. Manuelles Betätigungsele- características. Los cambios en el equipo sólo estarán permitidos EMISION DE RUIDOS
zulässig. Vor dem Einbau der Ventile muß das Rohrleitungssystem ment entfernen und Stopfen wieder anbringen. después de consultar al fabricante o a su representante. Antes La emisión de ruidos depende de la aplicación, medio y naturaleza
drucklos geschaltet und innen gereinigt werden. de la instalación, despresurice el sistema de tuberías y limpie del equipo utilizado. Una determinación exacta del nivel de ruido
Die Einbaulage der Produkte ist generell beliebig. GERÄUSCHEMISSION solamente se puede llevar a cabo por el usuario que disponga la
Die Geräuschemission hängt sehr stark vom Anwendungsfall, dem internamente. El equipo puede utilizarse en cualquier posición.
Die Durchflußrichtung und der Rohrleitungsanschluß von Ventilen En el cuerpo se indican el sentido del fluido y la conexión de las válvula instalada en su sistema.
sind gekennzeichnet. Medium, mit denen das Produkt beaufschlagt wird, und der Art des ver-
wendeten Produktes ab. Die exakte Bestimmung des Geräuschpegels válvulas a la tubería. MANTENIMIENTO
kann aus diesem Grund nur durch die Person durchgeführt werden, El mantenimiento de los productos ASCO Numatics depende de
Die Rohrleitungsanschlüsse sollten entsprechend den Größenanga- Las conexiones a la tubería deben corresponder al tamaño indicado las condiciones de servicio. Se recomienda una limpieza periódica,
ben auf den Typenschildern mit handelsüblichen Verschraubungen die das Ventil in das jeweilige System eingebaut hat.
durchgeführt werden. WARTUNG en la placa de características y ajustarse adecuadamente. dependiendo de las condiciones del medio y del servicio. Manipule
ACHTUNG: Die Wartung hängt von den Betriebsbedingungen ab. Es wird empfoh- PRECAUCION: el kit MO y MS con cuidado para evitar daños. Durante el servicio,
• Eine Reduzierung der Anschlüsse kann zu Leistungs- und len, das Produkt regelmäßig zu reinigen, wobei sich die Zeitabstände • La reducción de las conexiones puede causar operaciones los componentes deben ser examinados por si hubiera desgastes
Funktions-minderungen führen. nach dem Medium und den Betriebsbedingungen richten. MO- und incorrectas o defectos de funcionamiento. excesivos. Se dispone de un juego completo de partes internas
• Zum Schutz der Ventile sollten für die Betriebsbedingungen MS-Kit vorsichtig behandeln, um Schäden zu vermeiden. Während • Para la protección del equipo se debe instalar en la parte de la como recambio. Si ocurriera un problema durante la instalación/
geeignete Schmutzfänger oder Filter so dicht wie möglich in den der Wartung sollten die Komponenten auf übermäßigen Verschleiß entrada y tan cerca como sea posible del producto un filtro o mantenimiento o en caso de duda contactar con ASCO Numatics
Ventileingang integriert werden. überprüft werden. Für die Überholung der ASCO Numatics-Produkte tamizador adecuado para el servicio. o representantes autorizados.
• Bei Abdichtung am Gewinde ist darauf zu achten, daß kein sind komplette Sätze mit internen Teilen als Ersatzteilsätze erhältlich. • Si se utilizara cinta, pasta, spray u otros lubricantes en el ajuste, DESMONTAJE DE LA VALVULA
Dichtungs-material in die Rohrleitung oder das Ventil gelangt. Treten Schwierig-keiten bei Einbau, Betrieb oder Wartung auf sowie se debe evitar que entren partículas en el producto. Desmonte la válvula ordenadamente. Preste especial atención a
• Zum Einbau darf nur geeignetes Werkzeug verwendet werden, das bei Unklarheiten, ist mit ASCO Numatics Rücksprache zu halten. • Se debe utilizar las herramientas adecuadas y colocar llaves lo las vistas ampliadas que se suministran para identificar las partes.
so nahe wie möglich am Anschlußpunkt anzusetzen ist. más cerca posible del punto de conexión. 1 Retire el clip de sujeción y el anillo separador y deslice la
VENTILDEMONTAGE • Para evitar daños al equipo, NO FORZAR las conexiones a la
• Um eine Beschädigung der Produkte zu vermeiden, ist darauf zu Das Ventil muss in der angegebenen Reihenfolge zerlegt werden. bobina de la base auxiliar del solenoide. PRECAUCIÓN: al
achten, daß die Rohranschlüsse NICHT ZU STARK ANGEZOGEN tubería. desengancharse el clip de sujeción metálico, éste puede saltar
Dabei sind die Teile exakt anhand der mitgelieferten Explosionszeich- • No utilizar la válvula o el solenoide como palanca.
werden. nungen zu identifizieren. hacia arriba. Retire la arandela resorte.
• Spule und Führungsrohr von Ventilen dürfen nicht als Gegenhalter 1. Klammerhalterung und Distanzstück entfernen und Spule von • Las conexiones a la tubería no producirán ninguna fuerza, apriete 2. Desenrosque la base auxiliar del solenoide y retire la junta.
benutzt werden. Haltemutter abziehen. VORSICHT: Die Klammerhalterung kann o tensión sobre el producto. 3. Retire el pasador o el resorte (tipo NVR)
• Die Rohrleitungsanschlüsse sollten fluchten und dürfen keine beim Lösen nach oben wegfedern. Federscheibe entfernen. CONEXION ELECTRICA 4. Tire del conjunto del núcleo hacia afuera. Ahora tendrá acceso
Spannungen auf das Ventil übertragen. 2. Haltemutter lösen und Dichtungsring entfernen. En caso de requerirse conexiones eléctricas, estas serán realizadas a todas las piezas para su limpieza o sustitución.
ELEKTRISCHER ANSCHLUSS 3. Stift oder Feder (Typ NVR) entfernen. por personal cualificado y deberán adaptarse a las normas y REMONTAJE DE LA VALVULA
Der elektrische Anschluß ist von Fachpersonal entsprechend den 4. Magnetankerbaugruppe herausziehen. Nun sind alle Teile, die regulaciones locales. Vuelva a montar la válvula en el orden inverso de desmontaje
geltenden VDE- und CEE-Bestimmungen auszuführen. gereinigt oder ausgetauscht werden müssen, leicht zugänglich. PRECAUCION: prestando especial atención a las vistas ampliadas suministradas
ACHTUNG: VENTILZUSAMMENBAU • Antes de comenzar el trabajo, desconecte el suministro de energía para identificar e instalar las partes.
• Vor Beginn der Arbeiten ist sicherzustellen, daß alle elektrischen Ventil in der umgekehrten Reihenfolge wie bei der Zerlegung zusam- eléctrica y desenergice el circuito electrónico y los elementos 1. NOTA: Lubrique todas las guarniciones/juntas con grasa de
Leitungen und Netzteile spannungslos geschaltet sind. menbauen. Dabei sind die Teile anhand der Explosionszeichnungen portadores de tensión. silicona de buena calidad.
• Alle Anschlußklemmen sind nach Beendigung der Arbeiten vor- zu identifizieren und anzuordnen. • Todos los terminales eléctricos deben estar apretados 2. Coloque el conjunto del núcleo en la cavidad del cuerpo y llévelo
schriftsmäßig entsprechend den geltenden Normen anzuziehen. 1. HINWEIS: Alle Dichtungen/Dichtungsringe sind mit hochwertigem adecuadamente según normas antes de su puesta en servicio. suavemente hasta que la guarnición selle la cavidad del cuerpo.
• Je nach Spannungsbereich muß das Ventil nach den geltenden Silikonfett zu schmieren. • Según el voltaje, los componentes electrónicos deben disponer PRECAUCIÓN: Evite causar daños en el asiento al colocar el
Bestimmungen und Normen einen Schutzleiteranschluß erhalten. 2. Magnetankerbaugruppe in das Gehäuse einsetzen und vorsichtig de una conexión a tierra y satisfacer las normas y regulaciones conjunto del núcleo en el cuerpo.
Der Magnetantrieb kann je nach Bauart folgende elektrische nach unten schieben, sodass die Dichtung die Vertiefung im locales. 3. Vuelva a colocar la junta de la base del solenoide y el pasador o
Anschlüsse aufweisen: Gehäuse gerade abdichtet. El equipo puede tener uno de los siguientes terminales eléctricos: resorte (tipo NVR).
Flachsteckeranschlüsse gemäß ISO-4400 (EN175301-803A), integ- VORSICHT: Beim Einsetzen der Magnetankerbaugruppe in das Conexiones de tipo clavija plana según normativa ISO-4400
rierte Schraubklemmen im Metallgehäuse mit Kabelverschraubung 4. Reemplace el subconjunto de la base de solenoide y apriete
Gehäuse darauf achten, dass der Ventilsitz nicht beschädigt wird. (EN175301-803A), terminales atornillados empotrados en carcasa según el cuadro de pares de apriete. Esto también presionará el
oder Kabelkanal, eingegossene Kabelenden. 3. Dichtungsring und Stift, oder Feder (Typ NVR) der Haltemutter metálica con pasacables o conducto, hilos o cables aéreos. subconjunto del núcleo en su posición correcta.
INBETRIEBNAHME einsetzen. PUESTA EN MARCHA 5. Reemplace el operador manual, apriete según el cuadro de pares
Vor Druckbeaufaufschlagung des Produktes sollte eine elektrische 4. Haltemutter wieder einsetzen und entsprechend den Angaben Antes de aplicar presión al sistema, lleve a cabo primero una prueba de apriete y aplique Loctite 243 al adaptador.
Funktionsprüfung erfolgen. Dazu die Spannung an der Magnetspule im Drehmomentdiagramm anziehen. Dadurch wird auch die eléctrica. Active la bobina unas cuantas veces y observe un “clic” 6. Instale la arandela resorte, la bobina, el anillo separador y el clip
mehrmals ein- und ausschalten; es muss ein gedämpftes Klicken Magnetankerbaugruppe in die korrekte Position geschoben. que indica el funcionamiento del solenoide (excepto los tipos NVR). de sujeción.
zu hören sein, das die Magnetkopfbetätigung anzeigt (außer beim 5. Manuelles Betätigungselement wieder einsetzen und entsprechend Para probar el sistema al aplicar presión con bobinas desactivadas 7. Después de realizado el mantenimiento, opere la válvula unas
Typ NVR). den Angaben im Drehmomentdiagramm anziehen. Loctite® 243 für y adaptador para los operadores MO y MS bajo presión, monte un cuantas veces para asegurarse de su correcto funcionamiento.
Zum Testen des Systems bei Druckbeaufschlagung mit spannungslo- das Zwischenstück aufbringen. MO o MS y accione la válvula. Desmonte el MO o MS y coloque el NOTA: Para las construcciones de acero inoxidable se recomienda
sen Spulen und Zwischenstück für entfernbare Betätigungselemente 6. Federscheibe, Spule, Distanzstück und Klammerhalterung obturador para evitar que se utilice sin autorización. utilizar un lubricante antiagarrotamiento adecuado para evitar el
MO und MS unter Druck ein MO oder MS montieren und das Ventil anbringen. desgaste por rozamiento.
betätigen. MO oder MS demontieren und den Stopfen montieren, um 7. Nach der Wartung Ventil mehrmals betätigen, um sicherzustellen, SERVICIO
unbefugten Betrieb zu verhindern. dass es ordnungsgemäß funktioniert. La mayor parte de las válvulas solenoides se suministran con OPERADORES MANUALES
BETRIEB HINWEIS: Bei der Ausführung aus rostfreiem Stahl wird dringend bobinas para un servicio continuo. Con el fin de evitar la posibilidad Para obtener más información, consulte las instrucciones de
Die meisten Magnetventile sind mit Spulen für Dauerbetrieb aus- empfohlen, ein geeignetes Gleitmittel zu verwenden, um ein Fest- de daños personales o materiales no se debe tocar el solenoide, ya instalación y mantenimiento de operadores manuales serie 327,
gerüstet. Zur Vermeidung von Personen- und Sachschäden sollte fressen zu vermeiden. que puede haberse calentado en condiciones normales de trabajo. documento 123620-322.
jede Berührung der Magnetspule vermieden werden, da diese unter MANUELLE BETÄTIGUNGSELEMENTE Si la electroválvula es de fácil acceso, el instalador debe prever una
normalen Betriebs-bedingungen sehr heiß werden kann. Bei leicht Nähere Informationen finden Sie in der Installations- und War- protección que impida cualquier contacto accidental. Para obtener información adicional, visite nuestro sitio Web:
zugänglichem Magnetventil sollte vom Installateur ein Schutz vorge- tungsanleitung für manuelle Betätigungselemente der Serie 327, FUNCIONAMIENTO MANUAL www.asconumatics.es
sehen werden, um jegliches versehentliches Berühren zu vermeiden. Dokument 123620-322. Hay cuatro operadores manuales opcionales:
1. Tipo Presión, retorno de muelle, sufijo MO: Pulse el botón para Loctite® es una marca registrada de Henkel
MANUELLE BETÄTIGUNG
123620-227
Es gibt vier optionale manuelle Betätigungselemente: Weitere Informationen finden Sie auf unserer Website: poner la válvula manualmente en la posición “ON”. Suelte el botón
1. Druckausführung, Rückstellung durch Feder, Nachsatz x MO: Den www.asconumatics.eu para volver a la posición “OFF”.
Knopf drücken, um das Ventil manuell in die Position “ON” zu schal- 2. Tipo tornillo, retorno manual, sufijo MS: Pulse y gire el botón en
ten. Den Knopf loslassen, um zur Position “OFF” zurückzukehren. Loctite® ist ein eingetragenes Warenzeichen der Firma Henkel sentido horario para poner la válvula manualmente en la posición
ASCO CONTROLS BV
P.O. Box 3, 3925 ZG Scherpenzeel, The Netherlands
IM-123620-227-r4 (PIC-2-55) / pg. 1 Modified on: 2012-09-03 Tel. +31(0)33 277 79 11 - Fax +31(0)33 277 45 61 - www.asconumatics.eu

ISTRUZIONI DI INSTALLAZIONE E MANUTENZIONE ALGEMENE INSTALLATIE- EN ONDERHOUDSINSTRUCTIES
Series 327, 3/2 grande portata, a comando diretto, otturatore equilibrato
1/4 & 1/2
IT Series 327, 3/2 grote doorstroomfactor, direct werkend, gebalanceerde klep
1/4 & 1/2
NL
GENERALITÀ disattivazione “OFF”. ALGEMEEN schakelen. Draai de knop linksom om weer “UIT” te schakelen.
Questa piastra I&M dev’essere completata dalla particolare piastra 3. Rilascio senza tensione (NVR): La valvola non funzionerà con la Lees naast dit I&M-blad ook het aparte I&M-blad van de magneetkop 3. Aan tot wegvallen spanning (No Voltage Release - NVR): U
I&M del solenoide. Utilizzare entrambe le piastre per l’installazione sola applicazione di energia al solenoide. Premere il pulsante per zelf. Raadpleeg voor installatie en onderhoud beide documenten. kunt de afsluiter niet inschakelen door alleen de magneetkop te
e la manutenzione. commutare manualmente la valvola in posizione di attivazione BESCHRIJVING bekrachtigen. Bekrachtig de magneetkop en druk kort op de knop
DESCRIZIONE “ON”. Applicare energia al solenoide e premere temporaneamente De afsluiters uit de 327-serie met 2- of 3-wegfunctie zijn direct om de afsluiter handmatig “IN” te schakelen. De afsluiter valt bij
Le elettrovalvole Serie 327 sono del tipo 3/2 a comando diretto, il pulsante per commutare e bloccare la valvola in posizione werkende 3/2-magneetafsluiters met een gebalanceerd anker. Het stroomuitval terug in de “UIT”-stand en blijft uitgeschakeld ook
consumo ridotto, con costruzione equilibrata. Il corpo è in bronzo o d’attivazione “ON”. La valvola si sbloccherà (facendo ritorno afsluiterhuis is van messing of roestvast staal. 2- of 3-weg afsluiters als er weer spanning is.
in acciaio inossidabile. Le valvole sono di tipo operativo universale e alla posizione di disattivazione “OFF”), in caso di interruzione met universele werking zijn geschikt voor normaal gesloten, normaal 4. Een adapter voor onder druk verwijderbare koppen MO en MS,
sono intese per 2 o 3 vie normalmente chiuse, normalmente aperte, dell’alimentazione elettrica. open, verdeel- en mengtoepassingen. De drukaansluiting mag op volgens TPL-26710: Haal de dop van de adapter en monteer
per selezione e diversione del flusso. La pressione può essere 4. Un adattatore per operatori removibili MO e MS sotto pressione, alle poorten worden aangesloten. de MO, KIT 325323, (zonder afdichtingen en veer) of MS, KIT
applicata a qualsiasi porta. secondo TPL-26710: Rimuovere il tappo dell’adattatore e montare 325324, het systeem kan onder druk worden gehouden. Gebruik
l’operatore MO, KIT 325323, (senza guarnizioni e molla) o MS, KIT INSTALLATIE de MO en MS zoals hierboven beschreven. Verwijder de handbe-
INSTALLAZIONE 325324; il sistema può essere tenuto sotto pressione. Azionare ASCO Numatics producten mogen uitsluitend toegepast worden diening en monteer de dop.
Le elettrovalvole ASCO Numatics devono essere utilizzate gli operatori MO e MS come descritto qui sopra. Rimuovere binnen de op de naamplaat aangegeven specificaties. Wijzigingen
esclusivamente rispettando le caratteristiche tecniche specificate zijn alleen toegestaan na overleg met de fabrikant of haar GELUIDSEMISSIE
l’operatore manuale e reinserire il tappo. Dit hangt sterk af van de toepassing en het gebruikte medium. De
sulla targhetta. Variazioni sulle valvole o sui piloti sono possibili solo vertegenwoordiger. Voor het inbouwen dient het leidingsysteem
dopo avere consultato il costruttore ed i suoi rappresentanti. Prima EMISSIONE SUONI drukloos gemaakt te worden en inwendig gereinigd. De positie van bepaling van het geluidsniveau kan pas uitgevoerd worden nadat
della installazione, depressurizzare i tubi e pulire internamente. L’emissione di suoni dipende dall’applicazione e dal tipo di de afsluiter is naar keuze te bepalen. De doorstroomrichting wordt de afsluiter is ingebouwd.
Le elettrovalvole possono essere montate in tutte le posizioni. elettrovalvola. L’utente può stabilire esattamente il livello del suono bij afsluiters aangegeven op het afsluiterhuis. ONDERHOUD
La direzione del flusso ed i collegamenti ai tubi sono indicati sul solo dopo aver installato la valvola sul suo impianto. Het onderhoud aan de afsluiters is afhankelijk van de
corpo delle valvole. MANUTENZIONE De pijpaansluiting moet overeenkomstig de naamplaatgegevens bedrijfsomstandigheden. We raden u aan om het product regelmatig
La manutenzione dei prodotti ASCO Numatics dipende dalle plaatsvinden. te reinigen, in intervallen die afhankelijk zijn van het medium en
I raccordi devono essere conformi alla misura indicata sull’apposita condizioni di utilizzo. Questi componenti devono essere puliti LET HIERBIJ OP: de mate van onderhoud. Behandel de MO en MS Kit met zorg
targhetta. periodicamente. L’intervallo fra una pulizia e l’altra varia a seconda • Een reductie van de aansluitingen kan tot prestatie- en om beschadiging te voorkomen. Controleer tijdens het onderhoud
ATTENZIONE: delle condizioni di utilizzo. Maneggiare con attenzione il Kit MO e functiestoornis leiden. of onderdelen zijn versleten. In geval van slijtage zijn reserve-
• Ridurre i raccordi può causare operazioni sbagliate o MS per evitare di danneggiarlo. Durante gli interventi è preferibile • Ter bescherming van de interne delen wordt een filter in het onderdelensets beschikbaar om een inwendige revisie uit te voeren.
malfunzionamento. controllare che i vari componenti non siano eccessivamene usurati. In leidingnet aanbevolen. lngeval problemen of onduidelijkheden tijdens montage, gebruik of
• Per proteggere il componente installare, il più vicino possibile al caso di usura eccessiva è disponibile un set completo di parti interne • Bij het gebruik van draadafdichtingspasta of tape mogen er geen onderhoud optreden dan dient men zich tot ASCO Numatics of haar
lato ingresso, un filtro adatto al servizio. come kit di ricambio. In caso di problemi durante l’installazione e la deeltjes in het leidingwerk geraken. vertegen-woordiger te wenden.
• Se si usano nastro, pasta spray o lubrificanti simili durante il manutenzione o in caso di dubbi, rivolgersi ad ASCO Numatics o ai • Men dient uitsluitend geschikt gereedschap voor de montage te DEMONTAGE
serraggio, evitare che delle particelle entrino nel corpo della suoi rappresentanti autorizzati. gebruiken. Neem de afsluiter op een ordelijke wijze uit elkaar. Raadpleeg daarbij
valvola. SMONTAGGIO VALVOLE • Gebruik een zodanig koppel voor leidingverbindingen dat het de montagetekeningen die de afzonderlijke onderdelen benoemen.
• Usare attrezzature appropriate e posizionare le chiavi il più vicino Smontare procedendo con ordine. Consultare attentamente gli product NIET WORDT BESCHADIGD. 1. Verwijder de bevestigingsclip en de opvulring, en schuif de spoel
possibile al punto di raccordo. esplosi forniti per una corretta identificazione delle parti. • Het product, de behuizing of de spoel mag niet als hefboom van de ankergeleidingsbuis. LET OP: bij het verwijderen van de
• Per evitare danni al corpo della valvola, NON SERRARE 1. Smontare clip di fissaggio e distanziatore e sfilare la bobina dal worden gebruikt. bevestigingsclip kan deze omhoog springen. Verwijder de veerring.
ECCESSIVAMENTE i raccordi. gruppo cannotto. ATTENZIONE: quando si sgancia la clip metallica • De pijpaansluitingen mogen geen krachten of momenten op het 2. Schroef de ankergeleidingsbuis los en verwijder de O-ring.
• Non usare la valvola o il solenoide come una leva. di fissaggio, questa può scattare verso l’alto. Smontare la ghiera. product overdragen. 3. Verwijder de pen of de veer (type NVR).
• I raccordi non devono esercitare pressione, torsione o 2. Svitare il gruppo cannotto e togliere l’anello di tenuta. ELEKTRISCHE AANSLUITING 4. Trek de plunjer eruit. Alle delen zijn nu toegankelijk voor reiniging
sollecitazione sull’ elettrovalvola. 3. Rimuovere il perno o il molla (tipo NVR). In geval van elektrische aansluiting dient dit door vakkundig of vervanging.
ALLACCIAMENTO ELETTRICO 4. Sfilare il sottogruppo del nucleo. Ora tutte le parti sono accessibili personeel te worden uitgevoerd volgens de door de plaatselijke MONTAGE
L’allacciamento elettrico deve essere effettuato esclusivamente da per la pulizia o la sostituzione. overheid bepaalde richtlijnen. Monteer alle delen in omgekeerde volgorde als aangegeven is bij
personale specializzato e deve essere conforme alle norme locali. RIMONTAGGIO VALVOLA LET HIERBIJ OP: demontage, let daarbij wel op de montagetekening voor de juiste
ATTENZIONE: Rimontare procedendo nell’ordine inverso, facendo riferimento agli • Voordat men aan het werk begint moeten alle spanningsvoerende plaatsing van de onderdelen.
• Prima di mettere in funzione, togliere l’alimentazione elettrica, esplosi forniti per la corretta identificazione e collocazione delle parti. delen spanningsloos worden gemaakt. 1. OPMERKING: Vet alle afdichtingen/O-ringen in met hoogwaardig
diseccitare il circuito elettrico e le parti sotto tensione. 1. NOTA: Lubrificare tutte le guarnizioni/anelli di tenuta con grasso • Alle aansluitklemmen moeten na het beëindigen van het werk siliconenvet.
• I morsetti elettrici devono essere correttamente avvitati secondo al silicone d’alta qualità. volgens de juiste normen worden aangedraaid. 2. Plaats de plunjer in de opening in het afsluiterhuis en druk de
le norme prima della messa in servizio. 2. Inserire il sottogruppo del nucleo nell’apertura del corpo e spingere • Al naar gelang het spanningsbereik moet het product volgens de plunjer vervolgens omlaag tot de afdichting deze opening net
• Le elettrovalvole devono essere provviste di morsetti di terra a delicatamente finché la guarnizione non sigilli l’apertura. geldende normen van een aarding worden voorzien. helemaal afsluit.
seconda della tensione e delle norme di sicurezza locali. ATTENZIONE: Far attenzione e prevenire danni alla sede, quando Het product kan de volgende aansluitingen hebben: LET OP: Beschadig de zitting niet als u de plunjer in het huis
I piloti possono avere una delle seguenti caratteristiche elettriche: si sistema il sottogruppo del nucleo nell’apertura del corpo. Stekeraansluiting volgens ISO-4400 (EN175301-803A), plaatst.
Connessioni a innesto a paletta, secondo la norma ISO-4400 3. Rimettere a posto l’anello di tenuta del gruppo cannotto ed il perno schroefaansluitingen in een metalen huis met kabel- of 3. Monteer de O-ring van de ankergeleidingsbuis en de pen of
(EN175301-803A), morsetti a vite incorporata, in contenitore o il molla (tipo NVR) leidingdoorvoer, en losse of aangegoten kabels. veer (type NVR).
metallico, con premicavo o guaina protettiva, estremità o cavo mobili 4. Rimontare il gruppo della base del solenoide; utilizzare una forza IN GEBRUIK STELLEN 4. Monteer de kopstuk/deksel-combinatie en draai deze met het
MESSA IN FUNZIONE di serraggio pari a quella indicata nella relativa tabella. Questo Voordat de druk aangesloten wordt dient een elektrische test te juiste aandraaimoment vast. Hierdoor zal ook de plunjer in de
Prima di dare pressione al sistema, effettuare un test elettrico. consentirà anche di inserire il sottogruppo del nucleo nella sua worden uitgevoerd. Bekrachtig de spoel een paar keer, daarbij moet juiste positie worden geduwd.
Eccitare ripetutamente la bobina fino alla comparsa di un clic posizione corretta. een gedempt “klikken” hoorbaar zijn bij juist functioneren (behalve 5. Ver vang Handbediening, s c h ro e f d it me t h e t ju is t e
smorzato a testimonianza del corretto funzionamento del solenoide 5. Rimontare l’operatore manuale; forza di serraggio come da relativa bij de NVR-typen). aandraaimoment vast, breng Loctite 243 aan op de adapter.
(ad eccezione dei tipi NVR). tabella, applicare della Loctite® 243 per l’adattatore. Als u het systeem wilt testen wanneer dit onder druk staat met niet- 6. Monteer nu de veerring, de spoel, de opvulring en de
Per effettuare un test sul sistema pressurizzato con bobine e 6. Rimontare la ghiera, la bobina, il distanziatore e la clip di fissaggio. bekrachtigde spoelen en een adapter voor onder druk verwijderbare bevestigingsclip.
adattatore disenergizzati per operatori removibili tipo MO e MS 7. Dopo la manutenzione, azionare ripetutamente la valvola per koppen MO en MS monteert u een MO of MS en gebruikt u de 7. Na het onderhoud dient men de afsluiter een aantal malen te
sotto pressione, montare un operatore di tipo MO o MS e azionare accertarne il corretto funzionamento. afsluiter. Demonteer het MO of MS en monteer de dop om een bedienen om de werking ervan te controleren.
la valvola. Smontare l’operatore MO o MS e montare il tappo per NOTA: Per le strutture in acciaio inossidabile si raccomanda di usare onrechtmatig uitgevoerde verrichting te voorkomen. OPMERKING: Voor de roestvrijstalen afsluiters raden we ten sterkte
evitare un utilizzo non autorizzato. un lubrificante antigrippante adatto onde evitare l’usura. GEBRUIK aan om een specifiek smeermiddel te gebruiken tegen vastlopen,
SERVIZIO OPERATORI MANUALI De meeste magneetafsluiters zijn uitgevoerd met spoelen voor om vreten van het staal te voorkomen.
Molte elettrovalvole sono provviste di bobine per il funzionamento Per maggiori informazioni fare riferimento alle istruzioni di installa- continu gebruik. Om persoonlijk letsel en schade door aanraking van HANDBEDIENINGEN
continuo. Per prevenire la possibilità di danneggiare cose o persone, zione e manutenzione degli operatori manuali della Serie 327 nel het spoelhuis te voorkomen dient men het aanraken te vermijden, Raadpleeg voor meer gedetailleerde informatie de installatie- en
non toccare il solenoide. Se di facile accesso, l’elettrovalvola deve documento 123620-322. omdat bij langdurige inschakeling de spoel of het spoelhuis heet onderhoudsinstructies van het Serie 327 handbedieningsdocu-
essere protetta per evitare qualsiasi contatto accidentale. kan worden. In voorkomende gevallen dient men de spoel af te ment 123620-322.
OPERATIVITÀ MANUALE Per informazioni aggiuntive, visitate il nostro sito web: schermen voor aanraking.
Sono disponibili quattro operatori manuali opzionali: www.asconumatics.it HANDBEDIENING Ga voor meer informatie naar onze website:
1. Tipo a spinta, ritorno a molla, suffisso x MO: Premere il pulsante Er zijn vier opties voor handbediening: www.asconumatics.nl
per commutare manualmente la valvola in posizione di attivazione Loctite® è un marchio registrato di Henkel 1. Drukknop, met terugstelveer, achtervoegsel MO: Druk op de knop
“ON”. Rilasciare il pulsante per far ritorno alla posizione di disatti- om de afsluiter handmatig “IN” te schakelen. Laat de knop los om Loctite® is een geregistreerd handelsmerk van Henkel
vazione “OFF”. weer “UIT” te schakelen.
2. Tipo ad avvitamento con ritorno manuale, suffisso x MS: Pre- 2. Draaiknop, handmatige terugstelling, achtervoegsel MS: Druk op
mere e ruotare la manopola in senso orario per commutare la de knop en draai hem rechtsom om de afsluiter handmatig “IN” te
valvola manualmente in posizione di attivazione “ON”. Ruotare
la manopola in senso antiorario per far ritorno alla posizione di
DRAWING DESSIN ZEICHNUNG DRAWING DESSIN ZEICHNUNG

DISEGNO DIBUJO TEKENING DISEGNO DIBUJO TEKENING
1 SERIES GB DESCRIPTION
1. Retaining clip 12. Plug valve body
327 2. Spacer 16. Spring (NVR)
2 3. Coil & nameplate
4. Connector assembly Optional:
5. Washer, spring 13. Manual operator, push type (MO)
GB ● Manual operator optional 6. Sol.base sub-assembly 14. Manual operator, screw type (MS)
7. O-ring, s.b. sub-assy 15. Manual operator, adapter type
FR ● Commande manuelle en option 8. Slotted pin 17. Manual operator, push type (MO)
3 9. Core assembly
DE ● Handnotbetätigung (Sonderausstattung) 10. Valve body
11. Plug O-ring
ES ● Mando manual en opcion
4 IT ● Comando manuale in opzione FR DESCRIPTION
1. Clip de maintien 12. Corps de vanne à tournant
NL ● Handnoodbediening optioneel 2. Bague d’espacement 16. Ressort (NVR)
3. Bobine & plaque d’identification En option :
5 GB ¬ Supplied in spare part kit
4. Montage du connecteur
5. Rondelle élastique, ressort
13. Commande manuelle, de type
poussoir (MO)
6. Sol. sous-ensemble de base 14. Commande manuelle, de type vis
FR ¬ Livrées en pochette de rechange 7. Joint torique, s.e. de la base du sol. (MS)
8. Goupille à encoches 15. Commande manuelle, de type
DE ¬ Enthalten im Ersatzteilsatz 9. Noyau adaptateur
10. Corps 17. Commande manuelle, de type
6 ES ¬ Incluido en Kit de recambio 11. Joint torique à tournant poussoir (MO)
IT ¬ Disponibile nel Kit parti di ricambio DE BESCHREIBUNG

NL ¬ Geleverd in vervangingsset 1. Klammerhalterung 12. Ventilgehäuse, Verschlussstück
2. Distanzstück 16. Feder (NVR)
7 3. Spule & Typenschild
TORQUE CHART 4. Gerätesteckdose Optional:
16 5. Federscheibe 13. Manuelles Betätigungselement,
ITEMS NEWTON.METRES INCH.POUNDS 6. Haltemutter Druckausführung (MO)
8 7. Dichtungsring, Haltemutter 14. Manuelles Betätigungselement,
8. Schlitzstift Schraubenausführung (MS)
A 0.6 ± 0.2 5±2 9. Magnetankerbaugruppe 15. Manuelles Betätigungselement,
10. Ventilgehäuse Zwischenstückausführung
B 30 ± 3 260 ± 25 11. Dichtungsring, Verschlussstück 17. Manuelles Betätigungselement,
Druckausführung (MO)
C 20 ± 2 175 ± 10
9 ES DESCRIPCION
D 6±2 50 ± 5
1. Clip de sujeción 10. Cuerpo de la válvula
2. Anillo separador 11. Conector junta
3. Bobina y placa de 12. Conector cuerpo de la válvula
características 16. Resorte (NVR)
4. Conjunto del conector
5. Arandela, resorte Opcional:
6. Base auxiliar del solenoide 13. Operador manual, tipo presión (MO)
7. Junta, base auxiliar 14. Operador manual, tipo tornillo (MS)
del solenoide 15. Operador manual, tipo adaptador
8. Pasador 17. Operador manual, tipo presión (MO)
10 9. Conjunto del núcleo
IT DESCRIZIONE
1. Clip di fissaggio 12. Corpo della valvola a spina
Catalogue number Spare part kit 2. Distanziatore 16. Molla (NVR)
Code électrovanne 3. Bobina e targhetta
Code pochette de rechange 4. Gruppo connettore Opzionale:
● Katalognummer Ersatzteilsatz 5. Rondella, molla 13. Operatore manuale, tipo a spinta (MO)
11 Código de la electrovalvula Código del kit de recambio 6. Gruppo cannotto 14. Operatore manuale, tipo ad
7. Anello di ritenuta, sottogruppo avvitamento (MS)
Codice elettrovalvola Kit parti di ricambio di base del solenoide 15. Operatore manuale, tipo con
Catalogus nummer Vervangingsset 8. Perno a intaglio adattatore
9. Gruppo del nucleo 17. Operatore manuale, tipo a spinta (MO)
12 SCG327A605 / 606 / 645 / 646 C117638 10. Corpo valvola
11. Anello di ritenuta della spina
SCG327A607 / 608 / 647 / 648 C117640
13 NL BESCHRIJVING
SCG327A607V / 608V / 647V / 648V C117640V 1. Bevestigingsclip 11. O-ring dop
14 SCG327A609 / 610 / 649 / 650 C117640V 2.
3.
Opvulring
Spoel met naamplaat
12. Dop afsluiterhuis
16. Veer (NVR)
15 SCG327A615 / 616 / 655 / 656 C117639 4. Steker
5. Veerring Optioneel
SCG327A617 / 618 / 657 / 658 C117641 6. Ankergeleidingsbuis 13. Handbediening, drukknop (MO)
7. O-ring, kopstuk/deksel- 14. Handbediening, draaiknop (MS)
12
123620-227
SCG327A617V / 618V / 657V / 658V C117641V combinatie 15. Handbediening, adapterknop

17 8. Pen met sleuf 17. Handbediening, drukknop (MO)
SCG327A619 / 620 / 659 / 660 C117641V 9. Plunjer
14 10. Afsluiterhuis
ASCO CONTROLS BV
P.O. Box 3, 3925 ZG Scherpenzeel, The Netherlands
IM-123620-227-r4 (PIC-2-55) / pg. 2 Modified on: 2012-09-03 Tel. +31(0)33 277 79 11 - Fax +31(0)33 277 45 61 - www.asconumatics.eu
Valvetop™ D-Series Valve Controllers
Master Installation, Operation & Maintenance Manual
D-Series Master Installation, Operation & Maintenance 502.969.8000
Table of Contents
Cover Page………………………………………………………………………………………… 1
Table of Contents………………………………………………………………………………… 2
Installation on Actuator…………………………………………………………………………. 3
Mounting & Storage …………………………………………………………………………….. 3
DXP Dimensions and Materials……………………………………………………………….. 4
DXP-IIC Dimensions and Materials…..………………………………………………………. 5
DXS Dimensions and Materials……………………………………………………………….. 6
DXR Dimensions and Materials……………………………………………………………….. 7
Shaft & Indicator Assembly……………………………………………………………………. 8
Sensor Options…..……………………………………………………..……………………….. 9
Mechanical Switches (M/K/T)…………………………………..…………………….. . 9
P+F/Inductive Sensors (E/V)………………………………………..………………….. 11
GO Switches( L/Z)…………………..………………………………….………………… 15
4-20mA Transmitter (_X)……………..…………………………………………..……… 18
4-20mA Transmitter w/ HART (_H)……………………………………………..……… 22
FOUNDATION Fieldbus (FF)……………………………………………..……………….. 27
AS-I (AS)……………….…………...……………………………………………..….….. 37
SCM w/ Reed Switches (R)………...…………………………………………………... 38
ESD (ES)………………….…………...……………………………………………..…… 39
DeviceNet (DN)…………......………………………………………………..………….. 44
Spool Valves & Pilots…………………………………………………………………...………. 47
Proof Testing …………………………………………………………………………………….. 48
Safe use…………………………….…………………………………………………….……….. 51
Replacement Parts…...………….…………………………………….……………………….. 52
Warranty…...…………………………………………………………………….……………….. 53
Certifications & Approvals..………………………………………………….……………….. 54
Operating Temperatures……………………………………………………………………..… 55
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Installation
Installation on Actuator
Orientations, Normal and Reverse Acting
Normal acting is full clockwise when the process valve is closed and counterclockwise when the process valve is open. Reverse acting is full
clockwise when the process valve is open and counterclockwise when the process valve is closed.
90° indicator dome assemblies are designed 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.
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 unless otherwise specified,
your unit will be factory set to operate in this fashion.
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.
Mounting
TopWorx has numerous mounting bracket kits, both rotary and linear, available to meet your specific application. Consult your local distributor or
factory representative for ordering information. The illustration below shows a direct NAMUR mount on a quarter turn valve. Refer to your mount-
ing 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 -40⁰F (-40⁰C) to 160⁰F (71⁰C). Once properly installed, the temperature range listed on the nameplate will super-
sede this storage temperature range.
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. Please refer to the Proof Testing section for proper safety function setup.
3. Always use sound mechanical practices when applying torque to any hardware or making pneumatic
connections. Refer to the Integrated Pneumatic Control Valves section for detailed information.
4. This product comes shipped with plastic plugs 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 or installed outdoors.
5. 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.
Dimensions and Materials: Valvetop DXP
MATERIALS OF CONSTRUCTION
Cast A360 aluminum with
dichromate conversion coating
Enclosure inside & out, epoxy coated
exterior rated for 250 hrs salt
spray per ASTM B117
304 Stainless Steel standard
Fasteners
316 Stainless Steel optional

Shaft
Shaft Bushing Oilite Bronze
Indicator Dome Polycarbonate, UV F1 rated
O-ring seals available in: Buna,

Seals
Silicone, EPDM & Viton
Fastener Torque Specifications

Enclosure
8 ft-lbs [10.8 N·m] +/-10%
Housing Bolts
Indicator
320 in-oz [2.3 N·m] +/-10%
Dome Screws
Bottom
10 ft-lbs [13.6 N·m] +/-10%
Mounting Holes
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Dimensionals
Dimensions and Materials: Valvetop DXP - Flameproof Ex d IIC
Cast A360 aluminum with
dichromate conversion coating
Enclosure inside & out, epoxy coated
exterior rated for 250 hrs salt
spray per ASTM B117
Fasteners

Shaft
Shaft Bushing Oilite Bronze
O-ring seals available in: Buna,

Seals
Silicone, EPDM & Viton

Enclosure
8 ft-lbs [10.8 N·m] +/-10%
Housing Bolts
Indicator
320 in-oz [2.3 N·m] +/-10%
Dome Screws
Bottom
10 ft-lbs [13.6 N·m] +/-10%
Mounting Holes
Dimensions and Materials: Valvetop DXS
Enclosure Cast 316 Stainless Steel

Fasteners

Shaft
Shaft Bushing N/A
O-ring seals available in:

Seals
Buna, Silicone, EPDM & Viton

Enclosure
8 ft-lbs [10.8 N·m] +/-10%
Housing Bolts
Indicator
320 in-oz [2.3 N·m] +/-10%
Dome Screws
Bottom
10 ft-lbs [13.6 N·m] +/-10%
Mounting Holes
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Dimensionals
Dimensions and Materials: Valvetop DXR
Valox™ 364
Enclosure Lexan™ 123R
Grilamid™ TR 90
Fasteners
Shaft
Shaft Bushing Delrin™ 500P white
Seals Silicone

Enclosure
20 in-lbs [2.3 N·m] +/-10%
Housing Bolts
Indicator Dome
20 in-oz [2.3 N·m] +/-10%
Screws
Bottom
8 ft-lbs [10.8 N·m] +/-10%
Mounting Holes
Indicator Assembly
Indicator Dome,
±5° adjustable
Polycarbonate 10 - 32 Captive screws,
with keyed mask. stainless steel (x4)
Several rotation and
form options
O-Ring
Available in Buna-N,
Silicone, EPDM, Viton Color-coded indicator is
available in several
coordinating rotations and
forms for various valve
types, such as 90°, 180°,
and thru-divert applications
Cam/Shaft Assemblies
2
WASHER
1CIRCLIP SHAFT
3
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Mechanical Switches
Mechanical Switches: Options M2/M4/M6/K2/K4/K6/T2
Calibration Procedure
PRODUCT SPECIFICATIONS
Never perform switch calibration while an area is known to be OPTION M
hazardous. Calibration procedures for DPDT switches are the
same as those for SPDT switches. Switch Type Mechanical
Sealed No
Calibration may be performed using a Volt-Ohm meter by using the Ohm Circuitry SPDT
setting across COM and NO. When the switch is active, the meter will read
<0.5 Ohms, or the Diode setting may be used to indicate continuity. Termination Quick Connect
Rating 15A@125VAC or 250VAC
If a 120Vac source is used, an appropriately sized resistor must be used in Conforming to standards UL: 1054
series to limit current to a maximum of 15 Amperes when circuit rating is
unknown, or permanent damage may occur. Contact Resistance 15MΩmax. (initial)
Insulation Resistance 100MΩmin. (at 500V DC)
Step 1: With valve in the CLOSED position, disengage the BOTTOM cam OPTION K
from the splined Hub and rotate Clockwise until SW1 activates.
Release cam to re-engage splined Hub. Switch Type Mechanical
Sealed No
Step 2: Rotate valve to the OPEN position. Disengage the TOP cam from
Circuitry SPDT
the splined Hub and rotate Counter-clockwise until SW2 activates.
Release cam to re-engage the splined Hub. Termination Quick Connect
Rating 0.1A@125VAC MAX
Step 3: Cycle valve CLOSED and OPEN several times to insure switches
will maintain calibration. Conforming to standards UL: 1054
OPTION T
For Reverse Acting actuators: Switch Type Mechanical
Step 1: With valve in the CLOSED position, disengage the TOP cam from
the splined Hub and rotate Counter-clockwise until SW2 activates. Sealed No
Release cam to re-engage the splined Hub. Circuitry DPDT
Step 2: Rotate valve to the OPEN position. Disengage the BOTTOM cam Termination Quick Connect
from the splined Hub and rotate Clockwise until SW1 activates. Rating 15A 125V AC or 250V AC
Release cam to re-engage the splined Hub. UL recognized and CSA
Conforming to standards
certified, meets MIL-S-8805
Repeat Step 3 above.
Contact Gold or silver
*When using the (4) and (6) switch options, use the same calibration steps as Terminals End or side
above for the switches you determine to indicate OPEN and which indicate
CLOSED.
**Switches may also be set at midpoint, or any point, of travel for Dribble
Control, or any other logic necessary for the application.
Mechanical Switch Assembly
Switch Option M2/K2/T2 Switch Option M4/K4 Switch Option M6/K6

Mechanical Switches: Options M2/M4/M6/K2/K4/K6/T2
Wiring Diagrams and Charts
Option M/K Option T2
Switch# Connection Color Code Terminal# Switch# Connection Color Code Terminal#
NC Red 1 NC1 Red 1
1 COM Black 2 COM1 Black 2
NO Blue 3 NO1 Blue 3

1
NC Red/White 4 NC2 Red/White 4
2 COM Black/White 5 COM2 Black/White 5
NO Blue/White 6 NO2 Blue/White 6
NC Yellow 7 NC1 Yellow 7
3 COM Brown 8 COM1 Brown 8
NO Orange 9 NO1 Orange 9
NC White/Yellow 10 2 White/
NC2 10
Yellow
4 COM White/Brown 11
COM2 White/Brown 11
White/
NO 12
Orange White/
NO2 12
Orange
NC White 13
5 COM Gray 14
NO Violet 15
NC Pink 16
6 COM White/Gray 17
NO White/Violet 18
NOTE: Refer to the wiring diagram on the inside lid of your product
to determine actual pin out location
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Inductive Sensors
Inductive Sensors: Options E2/E4/E6
Never perform switch calibration while an area is known to be hazardous.
When installing a Valvetop product with P&F NAMUR sensors, use of a commercially available switch tester like P&F part# ST0-03 is
suggested.
Calibration may be performed using a 24Vdc power supply.
Step 1: With valve in the CLOSED position, disengage the BOTTOM cam from the splined hub and rotate clockwise until SW1 activates.
Release cam to re-engage splined hub.
Step 2: Rotate valve to the OPEN position. Disengage the TOP cam from the splined hub and rotate counter-clockwise until SW2 activates.
Release cam to re-engage the splined hub.
Step 3: Cycle valve CLOSED and OPEN several times to insure switches will maintain calibration.
For Reverse Acting actuators:
Step 1: With valve in the CLOSED position, disengage the TOP cam from the splined hub and rotate counter-clockwise until SW2 activates.
Step 2: Rotate valve to the OPEN position. Disengage the BOTTOM cam from the splined hub and rotate clockwise until SW1 activates.
Repeat Step 3 above.
*When using the (4) and (6) switch options, determine which switches are to indicate OPEN and which indicate CLOSED and then use the same calibration
steps as above.
**Switches may also be set at midpoint, or any point, of travel for Dribble Control, or any other logic necessary for the application.
P & F NJ2-V3-N Switch Assembly
Switch Option E2 Switch Option E4 Switch Option E6

Inductive Sensors: Options E2/E4/E6

Product Specifications Wiring Chart
PRODUCT SPECIFICATIONS LEAD WIRE TERMINATIONS CHART
General specifications
Switching element function NAMUR NC SWITCH # LEAD COLOR TERMINAL#
Rated operating distance sn 2 mm
BROWN + 1
Installation embeddable 1
Output polarity NAMUR BLUE - 2
Assured operating distance sa 0 ... 1.62 mm BROWN + 3
Reduction factor rAl 0.25
2
BLUE - 4
Reduction factor rCu 0.2
BROWN + 5
Reduction factor rV2A 0.7 3
Nominal ratings BLUE - 6
Nominal voltage Uo 8V BROWN + 7
4
Switching frequency f 0 ... 1000 Hz BLUE - 8
Hysteresis H typ. % BROWN + 9
5
Current consumption BLUE - 10
Measuring plate not detected ≥3 mA
BROWN + 11
Measuring plate detected ≤1 mA 6
Standard conformity BLUE - 12
EMC in accordance with IEC / EN 60947-5-2:2004
DIN EN 60947-5-6
Standards
(NAMUR)
Ambient conditions
Ambient temperature -25 ... 100 °C (248 ... 373 K)
Mechanical specifications
Connection type 0.1m, PVC cable
Core cross-section 0.14 mm2
Housing material PBT
Sensing face PBT
Protection degree IP67
General information
Use in the hazardous area see instruction manuals
Category 1G; 2G; 1D
NOTE: Refer to the wiring diagram on the inside lid of your
product to determine actual pin out location
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Inductive Sensors
Inductive Sensors : Options V2/V4

Target Arrangement
All Valvetop products are factory set for 90° rotation normal acting on parallel orientation with switch 1 (full clockwise) for the process valve closed
position
When changing orientation the target disk will have to be relocated for your application. All target disks are supplied with 4 slots on 90° increments
allowing the Valvetop unit to be rotated 90°, 180°, or 270° from standard.
TYPICAL V2 TARGET ARRANGEMENT

MINIMUM USABLE ROTATION 45°
MAXIMUM USABLE ROTATION 125°
TYPICAL V4 TARGET ARRANGEMENT

Inductive Sensors: Options V2/V4

PRODUCT SPECIFICATIONS
General specifications
P & F NJ3-18GK-S1N Switching element function NAMUR NO
Rated operating distance 3 mm
Installation Embed in mild steel
SWITCH 3 Output polarity Safety Function
Assured operating distance 0 ... 2.44 mm
TORQUE TO
7 IN-LBS Reduction factor rAl 1
Reduction factor rCu 1
Reduction factor rV2A 0
SWITCH 2 Nominal ratings
Nominal voltage 8V
Switching frequency 0 ... 200 Hz
SWITCH 4
Hysteresis typ. 0.1%
Current consumption
SWITCH 1 Measuring plate not detected 1mA
Measuring plate detected ≥3mA
Ambient conditions
Ambient temperature -25 ... 100 °C
Mechanical specifications
Connection type 2m Silicone cable
Core cross section 0.75mm2
Housing material Hostalen PPN, black
Sensing face Hostalen PPN, black
Protection degree IP68
Never perform switch calibration while an area is known to be
hazardous. Note Only for non-ferrous metal
General information
For intrinsically safe models, the unit must be wired in accordance with the Use in the hazardous area see instruction manuals
control drawing ES-00210-1. Category 1G; 2G; 3G; 1D
When installing a Valvetop product with P&F NAMUR sensors, use of a commercially available switch tester like P&F part# ST0-03 is suggested.
Calibration may be performed using a 24Vdc power supply.
For V2 models mounted in parallel orientation (see illustration on page 13)

Step 1: With the valve CLOSED position. Push down and slide the target
magnet #1 until SW1 activates. Release the target magnet to lock the position.
Step 2: Rotate the valve to the OPEN position. Push down and slide the target magnet #3 until SW3 activates. Release the target magnet to lock
the position.
Step 3: Cycle the valve CLOSED and OPEN several times to ensure proper calibration.
For V4 models mounted in parallel orientation (see illustration on page 13)

Step 1: With the valve CLOSED position. Push down and slide the target magnet #1 until SW1 activates. Release the target magnet to lock the
position. Push down and slide the target magnet #3 until SW3 activates. Release the target magnet to lock the position.
Step 2: Rotate the valve to the OPEN position. Push down and slide the target magnet #2 until SW2 activates. Release the target magnet to
lock the position. Push down and slide the target magnet #4 until SW4 activates. Release the target magnet to lock the position.
Step 3: Cycle the valve CLOSED and OPEN several times to ensure proper calibration
For models mounted in perpendicular orientation, the target disk will have to be rotated to realign the target disk to match the
desired orientation.
Step 1: Grasp the target disk and gently lift until the target disk disengages the orientation pin in the shaft.
Step 2: Rotate the disk as needed to realign the targets.
Step 3: Follow steps 1 through 3 for models mounted in Parallel orientation above.
For reverse acting applications (CCW to close), the switch functions will be transposed. Sw 1 (and Sw 3 if in an V4 model)
become open. Sw 2 (and Sw 4 if in an V4 model) become closed.
The “push to set” target disk has been designed to accommodate various applications and rotations. If your application is different from
those outlined here, please consult the factory for further information.
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GO Switch
GO Switch: Options L2/L4/Z2/Z4

Target Arrangement
All Valvetop products are factory set for 90° rotation normal acting on parallel orientation with switch 1 (full clockwise) for the process valve closed
position. When changing orientation the target disk will have to be relocated for your application. All target disks are supplied with 4 slots on 90°
increments allowing the Valvetop unit to be rotated 90°, 180°, or 270° from standard.
TYPICAL L2/Z2 TARGET ARRANGEMENT

MINIMUM USABLE ROTATION 45°
MAXIMUM USABLE ROTATION 125°
TYPICAL L4/Z4 TARGET ARRANGEMENT


Never perform switch calibration while an area is known to be hazardous.
For intrinsically safe models with L2/L4, the unit must be wired in accordance with the control drawing S-K127 and S-K127A.
For intrinsically safe models with Z2/Z4, the unit must be wired in accordance with the control drawing ES-01743-1 and ES-01744-1.
GO Switch calibration may be performed using a Volt-Ohm meter with the Ohm setting across COM and NO. When the switch is active, the
meter will read ≤0.5 Ohms, or the Diode setting may be used simply to indicate continuity. If a 120VAC source is used, an appropriately sized
resistor must be used in series to limit current to a maximum of 1.5 Amperes when circuit rating is unknown or permanent damage may occur.
For L2/Z2 models mounted in parallel orientation (see illustration on page 15)
Step 1: With the valve CLOSED position. Push down and slide the target magnet #1 until SW1 activates.
Release the target magnet to lock the position.
Step 2: Rotate the valve to the OPEN position. Push down and slide the target magnet #3 until SW3 activates.
Step 3: Cycle the valve CLOSED and OPEN several times to ensure proper calibration.
For L4/Z4 models mounted in parallel orientation (see illustration on page 15)
Step 1: With the valve CLOSED position. Push down and slide the target magnet #1 until SW1 activates.
Release the target magnet to lock the position. Push down and slide the target magnet #3 until SW3 activates.
Step 2: Rotate the valve to the OPEN position. Push down and slide the target magnet #2 until SW2 activates.
Release the target magnet to lock the position. Push down and slide the target magnet #4 until SW4 activates.
Step 3: Cycle the valve CLOSED and OPEN several times to ensure proper calibration
For models mounted in perpendicular orientation, the target disk will have to be rotated to realign the target disk to
match the desired orientation.
Step 1: Grasp the target disk and gently lift until the target disk disengages the orientation pin in the shaft.
Step 2: Rotate the disk as needed to realign the targets. Use the images provided on the previous page as a reference.
Step 3: Follow steps 1 through 3 for models mounted in Parallel orientation above.
For reverse acting applications (Counterclockwise to close), the switch functions will be transposed. Sw 1 (and Sw 3 if in an
L4/Z4 model) become open. Sw 2 (and Sw 4 if in an L4/Z4 model) become closed.
The “push to set” target disk has been designed to accommodate various applications and rotations. If your application is different from
those outlined here, please consult the factory for further information.
L2/L4 Specifications Z2/Z4 Specifications

Repeatability .002" (.05 mm) Repeatability .002" (.05 mm)
Response Time 8 milliseconds Response Time 8 milliseconds
Differential 0.020 - .150” (0.5 - 3.8mm) Differential 0.020 - .150” (0.5 - 3.8mm)
Operating Operating
-60° to 221°F (-40° to 105°C) -60° to 221°F (-40° to 105°C)
Temperature Temperature
Contact Material Silver cadmium oxide, gold flashed Palladium silver w/sawtooth surface
Contact Material
configuration
Forms SPDT, Form C
Forms DPDT, Form CC
Ratings 4A@120VAC / 3A@24VDC
Ratings 4A@120VAC / 2A@240VAC / 3A@24VDC
Target Material Ferrous metal
Target Material Ferrous metal
Sensing Range Approx. 1/10" (2.5 mm) Sensing Range Approx. .050 - .080" (1.3 - 2.0 mm)
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GO Switch
Electrical Connections & Wiring Terminal Strip Assembly

Option L2
Switch 1
Green to GND Ground
COM (Black) Terminal 2
NO (Blue) Terminal 3
NC (Red) Terminal 1
Switch 3
Green to GND Ground
COM (Black) Terminal 5
NO (Blue) Terminal 6
NC (Red) Terminal 4
Option L4
Switch 1 Switch 2
Green to GND Ground Green to GND Ground
COM (Black) Terminal 2 COM (Black) Terminal 5
NO (Blue) Terminal 3 NO (Blue) Terminal 6
NC (Red) Terminal 1 NC (Red) Terminal 4
Switch 3 Switch 4
Green to GND Ground Green to GND Ground
COM (Black) Terminal 8 COM (Black) Terminal 11 NOTE: Refer to the wiring diagram
on the inside lid of your product to
NO (Blue) Terminal 9 NO (Blue) Terminal 12 determine actual pin out location.
NC (Red) Terminal 7 NC (Red) Terminal 10
Option Z2
Switch 1
Green to GND Ground
COM (Black) Terminal 2 COM (Black/White) Terminal 5
NO (Blue) Terminal 3 NO (Blue/White) Terminal 6
NC (Red) Terminal 1 NC (Red/White) Terminal 4
Switch 3
Green to GND Ground
COM (Black) Terminal 8 COM (Black/White) Terminal 11
NO (Blue) Terminal 9 NO (Blue/White) Terminal 12
NC (Red) Terminal 7 NC (Red/White) Terminal 10
Option Z4
Switch 1 Switch 2
Green to GND Ground Green to GND Ground Green to GND Ground Green to GND Ground
COM (Black) Terminal 2 COM (Black/White) Terminal 5 COM (Black) Terminal 14 COM (Black/White) Terminal 17
NO (Blue) Terminal 3 NO (Blue/White) Terminal 6 NO (Blue) Terminal 15 NO (Blue/White) Terminal 18
NC (Red) Terminal 1 NC (Red/White) Terminal 4 NC (Red) Terminal 13 NC (Red/White) Terminal 16
Switch 3 Switch 4
Green to GND Ground Green to GND Ground Green to GND Ground Green to GND Ground
COM (Black) Terminal 8 COM (Black/White) Terminal 11 COM (Black) Terminal 20 COM (Black/White) Terminal 23
NO (Blue) Terminal 9 NO (Blue/White) Terminal 12 NO (Blue) Terminal 21 NO (Blue/White) Terminal 24
NC (Red) Terminal 7 NC (Red/White) Terminal 10 NC (Red) Terminal 19 NC (Red/White) Terminal 22
*The above terminations are typical and may vary depending on your configuration. Refer to the wiring diagram located on the inside top housing for a wiring diagram
specific to your configuration.
4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X
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.
Features:
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 20º to 320º. Factory set for 20º to 180º operation in counter clockwise rotation to open and 20º to 90º
operation 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: -40º to 85ºC
Potentiometer Only 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 Features Electrical Data

–Hollow shaft mounting requires no gears -Voltage Input Range: 8.5 - 34 Volts DC
and has no backlash -Standard Output Signal: Two wire 4-20mA
–Direct shaft position feedback with out of range indication
–Capable of 4,000,000 lifetime operations -Input Polarity: Bi-Directional
–Better than 0.3° resolution
–Conductive plastic Potentiometric sensor
for environmental protection
–Temperature Range: -40º to +85ºC
Potentiometer Electrical Data Potentiometer Wiring

-Voltage Input Range: 0-35 Volts Blue
-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
Wiper = Black
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% Red
NOTE: Refer to the wiring diagram

on the inside lid of your product to
determine actual pin out location
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4-20mA Transmitter
Calibration Flow Chart

Apply power to
device, LED on
Is button pressed
and held for at least NO
0.5 seconds?
YES
Is button released Is button released Is button released Is button

before 3 seconds? NO before 5.5 seconds? before 8 seconds? released? NO
NO NO
YES YES YES YES
Calibrate counterclockwise, Calibrate clockwise, device Calibrate counterclockwise, Calibrate clockwise, device
device waits for 4ma set point, waits for 4ma set point, LED device waits for 4ma set point, waits for 4ma set point, LED
LED flashes code 3-1, rotary flashes code 3-2, rotary LED flashes code 5-1, linear flashes code 5-2, linear
User moves valve to 4ma position
Is button pressed
and released? NO
YES
Is the set point within

required range? NO
YES
Device waits for 20ma set point,

LED flashes code 3-3
User moves valve to 20ma position Is the actual reading Start position is too
greater than maximum low or in dead band,
NO LED flashes code 4-3
4ma value?
Is button pressed
YES
and released? NO
Start position is too high,
YES LED flashes code 4-4
Is the set point within Has greater than Has less than Wrong direction of
required range and has at maximum allowed minimum allowed rotation occurred, LED
least 20 degree of rotation rotation occurred? NO rotation occurred? NO flashes code 4-7
been detected?
YES YES Less than allowed
YES
rotation has occured,
Device stores set points, LED on
Greater than allowed
rotation has occurred,
Is malfunction detected
in stored set points? NO
YES
Internal error, LED
flashes code 4-1

Troubleshooting
Error Code and Problem Table
Problem Probable Cause/Solution
Transmitter Module has no current output 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)
Transmitter does not output 4 or 20mA (+/-1%) Unit not calibrated (calibrate)
at desired end of travel Unit is calibrated (recalibrate - if still fails, replace board)
Output is not linear or does not track valve Input signal is not linear
position or rotation - Linkage or drive mechanism is introducing non-linearity
- Unit is not calibrated (calibrate)
Error Code 4-3 Start position is too low or in the dead-band position.
Error Code 4-4 Start Position is too high
Error Code 4-5 Start and stop positions are less than 20º, increase valve
rotation between start and stop positions to greater than 20º.
Error Code 4-6 Rotation has exceeded the 320º limit. Decrease valve rotation
between start and stop positions to less than 320º.
Error Code 4-7 Calibration rotation was in the wrong direction or the
potentiometer passed through the dead-band position.
Error Code 4-1 Internal Error has occurred. Recalibrate, if error continues, replace module.
LED Flash Code Diagram

Flash Codes
( first count – second count ) Interpretations
0-0 Calibrated
3-1 Counter-Clockwise Calibration, Waiting to calibrate the 4mA position, Rotary Mode
3-2 Clockwise Calibration, Waiting to calibrate the 4mA position, Rotary Mode
3-3 Waiting for 20mA Full Open Setting Button Press
4-1 Calibration Required
4-3 Calibration Start Value is Too Low
4-4 Calibration Start Value is Too High
4-5 End Value is Too Close to Start Value
4-6 Maximum Rotation Exceeded
4-7 Wrong Direction of Rotation
5-1 Counter-Clockwise Calibration, Waiting to calibrate the 4mA position, Linear Mode
5-2 Clockwise Calibration, Waiting to calibrate the 4mA position, Linear Mode
Operation of the 4-20mA Current Position Transmitter

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.
Operation of the Stand 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.
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4-20mA Transmitter

D-Series Upgrade Procedure: 4-20mA Position Transmitter
(Use the following installation procedure to upgrade an existing D-Series in the field)
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

2) Install the 4-20mA position transmitter using the supplied or existing mounting bolts (See illustration below)
3) Remove the existing shaft and replace with the new shaft and position sensor kit assembly (See illustration below)
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 o-ring seals on shaft
4) The alignment boss on the bracket (indicated in the Illustration below) 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.
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 the illustration below with
the valve in the closed position.
The potentiometer has been factory set for typical valve rotation ranges from 2º to 180º in counter-clockwise rotation applications from the
4mA position to the 20mA position and from valve rotation ranges from 2º to 90º 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.
Module and Bracket Potentiometer Shaft Assembly
TRANSMITTER MODULE
BRACKET
ALIGNMENT BOSS
4-20mA POSITION
TRANSMITTER
POTENTIOMETER CONNECION METHOD

0X, KX, & MX MODELS:
CONNECTOR PLUGS INTO CIRCUIT BOARD.
0A, 0B, KA, MA, KB, & MB MODELS:

POTENTIOMETER ONLY CONNECTED
ACCORDING TO WIRING DIAGRAM
POTENTIOMETER
1K OR 10K
4-20mA Transmitter with HART: Options LH/MH/KH/EH/ZH/0H

During run mode, the 4-20mA position transmitter will output 4-20mA for valve positions between and including the set points. In the rotary mode,
the module will provide an over or under travel correction if the valve position exceeds the high or low set point within +/-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. In the linear mode, no under or over travel is compensated
for. The device can be set to either linear or rotary mode during calibration using the on board push button switch, or remotely using HART
communications.
DEADBAND
INDICATION
Calibrating End Set Points Locally:

The 4-20 current transmitter can be used for any rotation range between 20 and 320 degrees**.
Option #1: +/- 3% Over and Under Travel at the Set End Points (Rotary):
1) As the shaft rotates, make sure the potentiometer is not rotating through its deadband area. The red dot located on the potentiometer should
not rotate past the area marked with red during the full rotation of the valve. If it does, reposition the shaft.
2) Apply power to unit (LED should be continuously on to indicate the unit has been calibrated or flashing the 4-1 code to indicate the unit has
not been calibrated)
3) Counter-clockwise calibration - Press the button greater than 0.5 seconds and less than 3 seconds 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).
4) Clockwise calibration - Press the button greater than 3 seconds and less than 5.5 seconds 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).
5) Rotate valve to the desired position corresponding to 4mA. (This can be the open or closed position)
6) 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)
7) Rotate valve to the desired position corresponding to 20mA (This will be the position opposite of the position in step 3 or step 4)
8) Press the button to capture the 20mA value (The LED will turn on continuously)
Option #2: No Under and Over Travel at Set End Points (Full Linear):
1) As the shaft rotates, make sure the potentiometer is not rotating through its dead band area. The red dot located on the potentiometer should
not rotate past the area marked with red during the full rotation of the valve. If it does, reposition the shaft.
2) Apply power to unit (LED should be continuously on to indicate the unit has been calibrated or flashing the 4-1 code to indicate the unit has
not been calibrated)
3) Counter-clockwise calibration - Press the button greater than 5.5 seconds and less than 8 seconds 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).
4) Clockwise calibration - Press the button greater than 8 seconds 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).
5) Rotate valve to the desired position corresponding to 4mA. (This can be the open or closed position)
6) 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)
7) Rotate valve to the desired position corresponding to 20mA (This will be the position opposite of the position in step 3 or step 4)
8) Press the button to capture the 20mA value (The LED will turn on continuously)
NOTE:**The potentiometer has been factory set for typical valve rotation ranges from 20 to 180 degrees in counter-clockwise rotation applications
from the 4mA position to the 20mA position and from valve rotation ranges from 20 to 90 degrees 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.
LED LIGHT
PUSHBUTTON
NOTE: Schematics are

for illustration purposes
only. Refer to the wiring
diagram on your product
to determine actual pin
out location
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HART
Calibration Chart
Apply power to device
Factory reset in handheld device
Calibration required,
Is button pressed
and held for at
NO
least 0.5 seconds?
YES
Is button released Is button released Is button released Is button

before 3 seconds? NO before 5.5 seconds? before 8 seconds? released? NO
NO NO
YES YES YES YES
Calibrate counter clockwise, Calibrate clockwise, device Calibrate counterclockwise, Calibrate clockwise, device
device waits for 4ma set point, waits for 4ma set point, LED device waits for 4ma set point, waits for 4ma set point, LED
LED flashes code 3-1, rotary flashes code 3-2, rotary LED flashes code 5-1, linear flashes code 5-2, linear
User moves valve to 4ma position
Is button pressed
and released? NO
YES
Is the set point within

required range? NO
YES
Device waits for 20ma set point,

User moves valve to 20ma position Is the actual reading Start position is too
greater than maximum low or in dead band,
NO LED flashes code 4-3
4ma value?
Is button pressed
YES
and released? NO
Start position is too high,
YES LED flashes code 4-4
Is the set point within Has greater than Has less than Wrong direction of
required range and has at maximum allowed minimum allowed rotation occurred, LED
least 20 degree of rotation rotation occurred? NO rotation occurred? NO flashes code 4-7
been detected?
YES YES Less than allowed
YES
rotation has occured,
Greater than allowed

Calibrated LED on rotation has occurred,
YES
Is calibration in handheld Calibration in handheld device

NO device successful?

Remote HART calibration using the Emerson 375 Field Communicator
1) Make sure that the HART power is not activated before attaching the signal/power wires, wires must be 12 to 24 AWG, to the HART device.
2) If not already connected, connect the device to the two HART signal/power lines. Pin 1 on the terminal block is the positive input and pin 2 is
the negative input. Pin 1 is the first pin on the left of the module and pin 2 is the middle pin (see picture below). Once connected, activate the
HART power/signal from the control system.
PIN#1
Positive Input
3) Connect the Emerson 375 Handheld device to the HART signal lines. Red marked lead to the positive signal
line and the black lead to the negative signal line.
4) Activate the 375.
5) Select the HART Application option from the menu selections.
6) If a warning screen is shown. Disregard and hit “CONTINUE”.
7) If the “Modification has been made to the configuration” screen is shown, hit “OK”.
8) ANYTIME the non-zero status code(s) screen is shown, hit “YES”.
The main menu should now be shown indicating:
- Process Variable
- Device Service
- Review
10) Select the “2. Device Service” option.
11) Select the “5. Calibrate” option.
12) Select “OK” when the “You are to set the valve operation ranges” screen is shown.
13) Select either the “1. Counter clockwise” or “2. Clockwise” options depending on the application.
14) Make sure the potentiometer is not rotating through its deadband area.
15) Follow the on screen instructions. Select “OK” when the valve is at the 4mA setpoint (Is the valve fully closed?)
16) After the first set point is saved, rotate the valve to the 20mA position.
17) Select “OK”.
18) The set points are now calibrated.
19) If error occurs, the screen will display the error type and abort.
20) Re-calibrate if an error occurs and again make sure the potentiometer is not rotating through its deadband area.
For More Information
To download more information concerning the Valvetop D-Series Valve Controller with HART, visit us online:
http://www.topworx.com/downloads/data.html or call 502-969-8000 and reference # ES-01299-1.
1 PV
1 Process Variable 2 PV Loop current
3 Status DAC trim corrupted
Valve cal corrupted
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1 Warm reset 1 PV LRV

2 Factory reset 2 PV URV
3 Range values 3 PV unit
4 PV LSL
4 Calibrated
2 Device Service 5 PV USL
5 Calibrate
6 D/A trim
7 Loop test
8 Valve mode 1 Tag
9 Device info 2 Descriptor
3 Message
4 Date
5 Poll addr 1 Poll address
6 Long tag 2 Loop current mode
1 Offline 7 Software rev
HART Application 2 Online 8 Hardware rev
HART DD Menu Tree (Emerson 375 Field Communicator)
3 Utility
4 HART Diagnostics
FOUNDATION Fieldbus
™
Application
375 Main Menu 1 PV LRV
Settings 2 PV URV
3 PV USL
Listen For PC 4 PV LSL
3 Review 5 PV Min span
6 PV Unit
ScratchPad 7 Valve mode
8 Calibrated
9 Software rev
10 Hardware rev
HART

Troubleshooting
LED Flash Code Diagram

Flash Codes
( first count – second count ) Interpretations
0-0 Calibrated
3-1 Counter-Clockwise Calibration, Waiting to calibrate the 4mA position, Rotary Mode
3-2 Clockwise Calibration, Waiting to calibrate the 4mA position, Rotary Mode
3-3 Waiting for 20mA Full Open Setting Button Press
4-1 Calibration Required
4-3 Calibration Start Value is Too Low
4-4 Calibration Start Value is Too High
4-5 End Value is Too Close to Start Value
4-6 Maximum Rotation Exceeded
4-7 Wrong Direction of Rotation
5-1 Counter-Clockwise Calibration, Waiting to calibrate the 4mA position, Linear Mode
5-2 Clockwise Calibration, Waiting to calibrate the 4mA position, Linear Mode
LED Error Codes

Problem Probable Cause/Solution
Transmitter Module has no current output 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)
Transmitter does not output 4 or 20mA Unit not calibrated (calibrate)

(+/-1%) at desired end of travel Unit is calibrated (recalibrate - if still fails, replace board)
Output is not linear or does not track Input signal is not linear
valve position or rotation - Linkage or drive mechanism is introducing non-linearity
- Unit is not calibrated (calibrate)
Error Code 4-3 Start position is too low or in the dead-band position.
Error Code 4-4 Start Position is too high
Error Code 4-5 Start and stop positions are less than 20º, increase valve rotation between start and
stop positions to greater than 20º.
Error Code 4-6 Rotation has exceeded the 320º limit. Decrease valve rotation between start and stop
positions to less than 320º.
Error Code 4-7 Calibration rotation was in the wrong direction or the potentiometer passed through
the dead-band position.
Error Code 4-1 Internal Error has occurred. Recalibrate, if error continues, replace module.
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FOUNDATION Fieldbus
Foundation Fieldbus
Optional Piezo Pilot Valve FF Communication Module
Button Board
FF Bus Connection
+ Signal
Shield
- Signal
Ground Strap
Optional Potentiometer Connector
Terminal Board to Optional Valve

Position Switches and Piezo Pilot Valve
D2-FF Assembly: “Inside the Box”

Main Shaft FF Communication Module
Target Wheel Target Magnet
OPEN Limit Switch (Optional) CLOSED Limit Switch (Optional)
Potentiometer (Optional)
Piezo Pilot Valve (Optional)
Pneumatic Manifold (Optional)
Spool Valve
Fail Closed Spool Valve Replacement Assemblies Fail Last Position Spool Valve Replacement Assemblies
PART # DESCRIPTION PART # DESCRIPTION
AV-BFCVA20 Std Alum Spool Valve Assy w/Buna seals AV-BFLPVA20 Std Alum Spool Valve Assy w/Buna seals
AV-BFCVS20 Std 304SS Spool Valve Assy w/Buna seals AV-BFLPVS20 Std 304SS Spool Valve Assy w/Buna seals
AV-BFCV620 Std 316SS Spool Valve Assy w/Buna seals AV-BFLPV620 Std 316SS Spool Valve Assy w/Buna seals
Operation
This section of the manual provides operational information for configuring, control and monitoring the device locally or remotely through the
FOUNDATION Fieldbus Host Control System.
Operation Mode and Function Block Assignments

Automatic (Auto) and Out of Service (OOS) mode are available for all the function blocks in FOUNDATION Fieldbus Host Control System.
To operate device using function block, first set the required Function Block mode to OOS, then set the required channel number according to
Table 1. After downloading the Function Block to system, set the Function Block mode to AUTO.
Note: For DI block, if “Open Indicator Input” is chosen, FIELD_VAL_D parameter will indicate Open/Close status. If “Close Indicator Input” is
chosen, FIELD_VAL_D parameter will indicate reversed Open/Close status.
Table 1 Function Block Assignments

Function Block Signal Channel Unit
DO Command to open or close 1 None
DI Output command readback 2 None
Open indicator input 3 None
Close indicator input 4 None
AI Instrument temperature 5 ºC
Analog position 6 %
Table 2 LED Functionality
LED Label Off On Blink Flash
Device is calibrated Reversing valve is Calibration is required

STATUS No power
and full functioning in process or error has occurred
Calibrating closed Closed GO switch is

CLOSE Not in closed position In closed position
position is in process triggered during calibration
Open GO switch
Calibrating open
OPEN Not in open position In open position is triggered during
position is in process
calibration
NOTE: LED duty cycle is shown on the right.
on LED=
off Flashing
Flashing: LED is on for 5% of every second.
Blinking: LED is on for 50% of every second. on LED=
off Flashing
Time
Table 3 Button Board Functionality
Activity Function
REVERSE button pressed Reverse valve
OPEN button pressed once Start to calibrate open position
OPEN button pressed again Confirm current position as open position
CLOSE button pressed once Start to calibrate closed position
CLOSE button pressed again Confirm current position as closed position
(Continued on next page)

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FOUNDATION Fieldbus
Operation (Cont.)
Table 4 Calibration Statuses
Status Description
Calibration needed Device is not calibrated or calibration for the other end position is needed.
Running Device calibration is in process
Timed Out Device calibration timed out (maximum 5 minutes)
Both triggered Both Go switches are triggered simultaneously
Range error Less than minimum allowed rotation range (minimum 20 degrees)
In deadband End position is too high/low or in deadband
No sensor detected No sensor is detected during calibration
Successful Device is calibrated
Device Calibration (Required Configuration)

Device can be calibrated either locally using buttons or remotely using bus command. A summary for LED and button board functionalities is
provided in Table 2 and 3.
Calibrating End Positions Locally

Perform Calibration
a. This operation is only available if Transducer Block is in OOS mode and the button board is active. If Transducer Block is in Auto
mode, change the mode to OOS. If the button board is disabled, set “Buttonboard Enable” parameter to “Active in OOS”.
b. STATUS LED will flash if device is not calibrated. To start calibration procedure, identify the current shaft position by sight, press
(greater than 50ms and less than 5min) either the CLOSE or OPEN button according to the position to start the calibration.
c. If CLOSE button is pressed, CLOSE LED will blink to indicate that calibration is in process, perform the following according to sensor
type to calibrate the closed end position (note that either CLOSE or OPEN position can be calibrated first):
Option #1: GO switch only case: Move magnet to trigger the closed switch (the
GO switch labeled as closed position switch). CLOSE LED will flash to indicate the Deadband
Indication
switch is triggered.
Option #2: Potentiometer only case: Make sure the potentiometer is not in deadband
(the red dot should not fall into the red line area).
Option #3: Both GO switch and potentiometer case: Move magnet to trigger the closed
switch (the GO switch labeled as closed position switch). CLOSE LED will flash to indicate
the switch is triggered. Make sure the potentiometer is not in deadband (the red dot should
not fall into the red line area).
* Press the CLOSE button AGAIN to confirm the position. CLOSE LED will become solid on.
d. Press the REVERSE button (greater than 50ms and less than 5min) to move valve to the other position. If there is a potentiometer,
as the shaft rotates, make sure the potentiometer is not rotating through its deadband area. STATUS LED will blink for 3 seconds to
indicate the reverse action. Note: The REVERSE button is not operational in units without integral pilot valves supplied by TopWorx.
For those applications, the valve will have to be moved manually or with existing controls.
e. Press the OPEN button and perform the following according to sensor type to calibrate the open end position (note that these steps
are similar to the calibration for the closed end position):
Option #1: GO switch only case: Move magnet to trigger the open switch (the GO switch labeled as open position switch).
OPEN LED will flash to indicate the switch is triggered.
Option #2: Potentiometer only case: Make sure the potentiometer is not in deadband.
Option #3: Both GO switch and potentiometer case: Move magnet to trigger the open switch (the GO Switch labeled as
open position switch). OPEN LED will flash to indicate the switch is triggered. Make sure the potentiometer is not in deadband.
* Press the OPEN button AGAIN to confirm the position. OPEN LED will become solid on.
f. STATUS LED will become solid on if the calibration procedure is successful. It will flash if the calibration is failed. The calibration
status will be shown in “Calibration Status”. Please see Table 4 for the list of calibration statuses.
Note that either end position can be re-calibrated/re-adjusted if the other end position is already calibrated. That is, after initial calibration, either
position can be recalibrated individually without calibrating the other position.
Calibrating End Positions Remotely

Calibration remotely using bus command can be done through guided method or manual setup.
Perform Guided Calibration through Method (Recommended)
Click the method “Device Setup” or “Calibrate” on screen and follow the instructions for calibration.
Perform Calibration by Setting Parameters
a. This operation is only available if the Transducer Block is in OOS mode. If Transducer Block is in Auto mode, change the
mode to OOS.

Operation (Cont.)
b. STATUS LED will flash if device is not calibrated. To start calibration procedure, select the “Set to current position” from either the
“Open End Position” or the “Close End Position” parameter. The corresponding OPEN or CLOSE LED will blink to indicate that cali-
bration is in process.
c. For calibrating the “Close End Position”, perform the following according to sensor type to calibrate the closed end position (note that
either the “Open End Position” or the “Close End Position” can be calibrated first):
Option #1: GO switch only case: Move magnet to trigger the closed switch (the GO switch labeled as closed position switch).
CLOSE LED will flash to indicate the switch is triggered.
Option #2: Potentiometer only case: Make sure the potentiometer is not in deadband (the red dot should not fall into the red
line area).
Option #3: Both GO switch and potentiometer case: Move magnet to trigger the closed switch (the GO Switch labeled as
closed position switch). CLOSE LED will flash to indicate the switch is triggered. Make sure the potentiometer is not in deadband
(the red dot should not fall into the red line area).
* The status for “Close End Position” will automatically change back to “No Action Required” if the action is performed.
d. Select the “Reverse” from the “Reverse Valve Position” parameter. If there is a potentiometer, as the shaft rotates, make sure the
potentiometer is not rotating through its deadband area. STATUS LED will blink for 3 seconds to indicate the reverse action.
Note: The REVERSE button and "Reverse Valve Position" is not operational in units without integral pilot valves supplied by
TopWorx. For those applications, the valve will have to be moved manually or with existing controls.
e. Select the “Set to current position” from the “Open End Position”. (note that these steps are similar to the calibration for the closed
end position):
Option #1: GO switch only case: Move magnet to trigger the open switch (the GO switch labeled as open position switch).
OPEN LED will flash to indicate the switch is triggered.
Option #2: Potentiometer only case: Make sure the potentiometer is not in deadband.
Option #3: Both GO switch and potentiometer case: Move magnet to trigger the open switch (the GO switch labeled as open
position switch). OPEN LED will flash to indicate the switch is triggered. Make sure the potentiometer is not in deadband.
* The status for “Open End Position” will automatically change back to “No Action Required” if the action is performed.
f. STATUS LED will become solid on if the calibration procedure is successful. It will flash if the calibration failed. The calibration status
will be shown in “Calibration Status”. Please see Table 4 for the list of status.
*Note that either end position can be re-calibrated/re-adjusted if the other end position is already calibrated.
End Position Deadband Adjustment

If there is a potentiometer, the end position deadband is determined by the value for “Open/Close Stop Offset” parameter. This value is adjustable.
Its default value is 10% and the allowable range is 5% to 40%. For example, with the default value, if the open position is at 100 degree and the
closed position is at 50 degree, then if actual value position is within 50±(100-50)×10%=45~55 degree, the “Close State” is “True”, and the “Open
State” is “False”.
Reverse Valve Position

Valve position can be reversed locally by pressing the REVERSE button on the button board if it is enabled. It can also be done remotely by select-
ing the “Reverse” from the “Reverse Valve” parameter when device is in OOS mode. The value for “Reverse Valve” will automatically change back to
“No action” (default value) if the action is performed. STATUS LED will blink for 3 seconds to indicate the reverse action. Note: The REVERSE
button is not operational in units without integral pilot valves supplied by TopWorx. For applications, the valve will have to be moved manually or with
existing controls.
Flash LED
To identify a device in the plant, put Transducer Block into OOS mode and select the “Flash LED” for the “Flash LED” parameter. Status LED on the
unit will blink for 5 minutes. After 5 minutes, status for “Flash LED” will automatically change back to “Finished” (default value).
Shutdown Configuration
Shutdown configuration controls the behavior of the valve in case of an internal communications failure in the electrical module. This is independent
of the FF communication on the bus line. The “shutdown action” parameter is also re-used as the default position (initial status) for a device encoun-
tered a power loss.
Parameters and functions
a. Shutdown enable (SHUTD_ENABLE parameter):
Enable, auto recovery: If there is an internal failure, valve will move to certain position according to the setting of parameter
SHUTDOWN_ACTION. When the internal failure is solved, the valve will automatically go to its current setpoint position.
Enable, manual recovery: If there is an internal failure, valve will move to certain position according to the setting of parameter
SHUTDOWN_ACTION. When the internal failure is solved, the valve will NOT automatically go to its current setpoint position unless
SHUTD_RESET parameter is manually selected as “reset”.
Disable: Shutdown functionality is not operational; the valve will stay in its last position after an internal failure.
b. Shutdown action (SHUTD_ACTION parameter):
Open: When performing shutdown operation or starting up after a power loss, valve will go to open position.
Close: When performing shutdown operation or starting up after a power loss, valve will go to close position.
Hold: When performing shutdown operation or starting up after a power loss, valve will stay in original position.
Note: The shutdown action is not operational in units without integral pilot valves supplied by TopWorx. For those applications, the
valve will have to be moved manually or with existing controls.
c. Shutdown delay (SHUTD_DELAY_TIME parameter):
The time waited to perform shutdown operation after the internal failure occurs. The default value is 5 seconds. The allowable range
is from 2 to 255 seconds.
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FOUNDATION Fieldbus
Operation (Cont.)
d. Shutdown reset (SHUTD_RESET parameter):
Inactive: Shutdown reset function is not active. If “manual recovery” is selected for SHUTD_ENABLE parameter and there is an
internal error, after the internal failure is solved, the valve will NOT automatically go to its current setpoint position. Device stays in
shutdown status.
Reset: Shutdown reset function is active. If “manual recovery” is selected for SHUTD_ENABLE parameter and there is an internal
error, after the internal failure is solved, shutdown status will be reset, and the valve will automatically go to its current setpoint
position. When this reset is completed, the SHUTD_STATUS parameter will be “Device is operational” and the SHUTD_RESET
parameter will return to “inactive”.
e. Shutdown status (SHUTD_STATUS parameter):
Device operational: there is no internal error.
Device shutdown: there is internal error.
Examples
a. For internal communications failure
The factory default shutdown configuration settings are as following:
Shutdown enable: Enable, Manual Recovery
Shutdown action: Close
Shutdown delay: 5 seconds
Shutdown reset: Inactive
If there is an internal failure, after 5 seconds, valve will move to close position according to the setting of parameter
SHUTDOWN_ACTION. When the internal failure is solved, the valve will NOT automatically go to its current setpoint position
unless SHUTD_RESET parameter is manually selected as “reset”.
b. For power lose
If the “shutdown action” is “Open”, when power is re-applied to device after a power loss, before valve receives the bus command
(for example, the SP_D from DO function block), valve will go to open position.
If the “shutdown action” is “Hold”, when power is re-applied to device after a power loss, before valve receives the bus command
(for example, the SP_D from DO function block), valve will stay in the previous position, that is, the position that power is off.
Buttonboard Enable
Local operation through push buttons is only available when the button board is active. The factory default value for “Buttonboard Enable” parameter
is “Active in OOS”. When device is in OOS mode, the button board can be enabled by setting the “Buttonboard Enable” parameter to “Active in
OOS” or disabled by setting it to “Never active”.
Valve Position Indication

The “Analog position” parameter will indicate current valve position in percentage (the display range for AI block: -200% to +199%, the display range
for TB block: 0%~100%) if there is a potentiometer and the calibration is successful, otherwise, the value is 0. The percentage is calculated as the
distance in degrees from current position to close position versus the full open to close distance in degrees. The “Final Discrete Position” parameter
will indicate current valve position as “Closed”, “Open”, “Opening” or “Closing”. Device will indicate “Closed” or “Open” according to the discrete
position. The assigned position from DO block is indicated by “DO Command” parameter as “Close” or “Open”.
Position Sensor Type Indication

The “Position Sensor Type” parameter will indicate the sensor type detected by the device during calibration. This parameter will indicate “GO switch
only”, “Potentiometer only”, or “Both GO switch and potentiometer” if sensor type is detected. Otherwise, it will indicate “Not assigned” (default value).
Temperature Indication
Temperature is measured every 100 millisecond by the sensor on the circuit board and indicated as degree C by “Temperature” parameter. The
allowed temperature range is -25 to +65 degree C. An alarm will be triggered if temperature is out of range (Please see the Alert section for more
details). The maximum/minimum measured temperature is recorded in the device. It can be viewed through the command in base record.
Device Cycle Count, Adjustment and Control

The parameter “Cycle Count” (this parameter is read only) indicates the total end position cycles. The parameter “Adjusted Count” indicates the end
position cycles after adjustment. If valve position changes from close to open and back to close, the value for both parameters will be increased by
one. Users can set “Adjusted Count” to any non-negative value and the adjusted cycle count will start to increase based on this set value. Users
can set a limit for them using the “Cycle Count Limit” and “Adjusted Count Limit” parameters. The default limit is 1000000 cycles. The allowed input
value for “Cycle Count Limit” must be greater than the current cycle count and less than 4294967296. The allowed input value for “Adjusted Count
Limit” must be greater than the current adjusted cycle count and less than 4294967296. An alarm will be triggered if the count is out of range limit
(Please see the Alert section for more details).
Timers
There are 3 timers available in this device:
Time in position: the time in seconds that device is in current position since the last movement. It is automatically reset to zero when the power is
switched off.
Open travel time: the time between when pilot valve position is changed due to request and when the open end position is reached. It is indicated
in seconds with accuracy in 10 milliseconds.
Close travel time: the time between when pilot valve position is changed due to request and when the close end position is reached. It is indicated
in seconds with accuracy in 10 milliseconds.

Operation (Cont.)
These values are important in determining abnormal events that recently occurred. For example, a temporary drop in pressure or a sticky process
valve (valve that has been left in the same position for a long time without cycling) will affect the performance of the last operation of the valve, but
does not necessarily mean the mechanical device is worn out. The average open/close travel time (in seconds) of the last 30 strokes is calculated
and indicated in parameter “Average Time”. Process valve/actuators typically wear out at a constant steadily pace. A good indication of wear will be
the average travel times since the change is slow, but constant. Users can set an upper limit for “Time in position” using the “Time in Position Hi
Limit” parameter. The default value is 864000 seconds (10 days). The allowed input value must be less than 4294967296. Users can also set the
low/high limits for the open/close travel time and the average open/close travel time using their “Travel Lo Limit” and “Travel Hi Limit” parameters.
The default value is 0 for the low limit and 300 seconds for the high limit. The allowed input value must be less than 65536. An alarm will be trig-
gered if any time value is out of range limit (Please see the Alert section for more details).
Field Diagnostic Alerts/Plantweb Alerts

List of Alerts
Check: The Check condition is true if any transducer block has a normal mode other than Out of Service and the actual mode is
not AUTO.
Calibration Failed: Device has not been calibrated or the calibration has failed. Please refer to Table 4 Calibration Statuses for
the reason of failure.
Bad Temperature Sensor: Temperature sensor is malfunctioning. Temperature value is not reliable.
System Temperature Exceeded: Maximum/minimum temperature exceeds the value set in the limit.
Software Error: Controller card memory error occurs.
Travel Deviation:
a. Valve/actuator moves to an undesired position. For example, the device energizes an output to OPEN a spring return
actuator. The position feedback indicates the device has reached the OPEN position. Afterwards, air pressure is lost and the
actuator moves back to the CLOSED position (spring-return). The position feedback sensor will indicate the actuator is in the
CLOSED position although a command to CLOSE the actuator has never been issued. In this situation a Travel Deviation
alert will be generated indicating the actuator was in a desired position, but moved to an undesired position.
b. Valve/actuator doesn’t move to a desired position. For example, the device energizes an output to OPEN a spring return
actuator. But the air pressure is lost so the actuator doesn’t move. After 5 minutes, the position feedback indicates the
device still has not reached the OPEN position. Travel Deviation alert will be generated indicating the actuator can not move
to a desired position.
Shutdown is Set: Device shutdown is operating due to an internal communications failure in the electrical module.
Buttonboard Failure: Button board is malfunctioning.
Open/Short Circuit: There is an open circuit for the main Piezo or there is a short circuit for any Piezos. If there is an open circuit
or the main Piezo, only this alert is triggered. Device will automatically operate as normal once there is no open circuit for the
main Piezo. If there is a short circuit for any Piezos, device will power off both Piezos. Device will return to normal Piezo operation
only if no short circuit is detected after a power cycle.
Adjusted Cycle Count Exceeded: Adjusted cycle count has exceeded the value set in the limit.
Control Module Life Cycle Exceeded: Cycle count has exceeded the value set in the limit.
Time in Position Limit Exceeded: Time value has exceeded the value set in the limit.
Open Travel Time Limit Exceeded: Time value has exceeded the value set in the limit.
Close Travel Time Limit Exceeded: Time value has exceeded the value set in the limit.
Internal I/O Failure: Internal communications are lost; device will act according to shutdown configuration.
NV Memory Failure: Non-volatile EEPROM data corruption was detected on the Fieldbus electronics board. Default values were
loaded into the faulty block. If the failure reoccurs it may indicate a faulty EEPROM memory chip.
Electronics Failure: The device has detected a fault with an electrical component on the Fieldbus electronics module assembly.
Note: The Travel Deviation and Open/Short Circuit Alerts are not monitored in units without integral pilot valves supplied by
TopWorx. For those applications, the valve will have to be moved manually or with existing controls.
Alert handling
Both field diagnostics and PlantWeb alerts are supported in this device. Although these alerts have default settings (see table
5), these can be changed by the customer to match their requirements.
For field diagnostic alerts, there are four levels of alerts available:
a. Failed Alerts
A Failure Alert indicates a failure within a device that will make the device or some part of the device non-operational. This
implies that the device is in need of repair and must be fixed immediately.
This alert has the following five parameters:
FD_FAIL_MAP: Enables or disables conditions to be detected as active for this alarm category. Thus the same condition
may be active in all, some, or none of the alarm categories.
FD_FAIL_MASK: allows the user to suppress any single or multiple conditions that are active, in this category, from being
broadcast to the host through the alarm parameter.
FD_FAIL_PRI: Designates the priority.
FD_FAIL_ACTIVE: Reflects the error conditions that are being detected as active as selected for this category. Multiple
conditions may be shown.
FD_FAIL_ALM: To report the particular failed condition to the host system.

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FOUNDATION Fieldbus
Operation (Cont.)
b. Off Spec Alerts
An Off Spec Alert indicates a condition within a device that is out of the range of the specification. The alert is used to notify
the host that the device has detected a condition within the device that is not critical, will not cause a failure if left unat-
tended but should be reported to the host for awareness and possible action.
FD_OFFSPEC_MAP: Enables or disables conditions to be detected as active for this alarm category. Thus the same condi-
tion may be active in all, some, or none of the alarm categories.
FD_OFFSPEC_MASK: allows the user to suppress any single or multiple conditions that are active, in this category, from
being broadcast to the host through the alarm parameter.
FD_OFFSPEC_PRI: Designates the priority.
FD_OFFSPEC_ACTIVE: Reflects the error conditions that are being detected as active as selected for this category. Multiple
FD_OFFSPEC_ALM: To report the particular failed condition to the host system.
c. Maintenance Alerts
A Maintenance Alert indicates a condition within a device that, if not attended to in the near future (the type of alert defines
the time period for “Near Future”) will make the device or some part of the device non-operational. This implies that the de-
vice is in need of repair and must be fixed as soon as possible.
FD_MAINT_MAP: Enables or disables conditions to be detected as active for this alarm category. Thus the same condition
may be active in all, some, or none of the alarm categories.
FD_MAINT_MASK: allows the user to suppress any single or multiple conditions that are active, in this category, from being
FD_MAINT_PRI: Designates the priority.
FD_MAINT_ACTIVE: Reflects the error conditions that are being detected as active as selected for this category. Multiple
FD_MAINT_ALM: To report the particular failed condition to the host system.
d. Check Alerts
A Check Alert indicates output signal temporarily invalid (e.g. frozen) due to on-going work on the device. This alert has
the following five parameters:
FD_CHECK_MAP: Enables or disables conditions to be detected as active for this alarm category.
Thus the same condition may be active in all, some, or none of the alarm categories.
FD_CHECK_MASK: allows the user to suppress any single or multiple conditions that are active, in this category, from being
FD_CHECK_PRI: Designates the priority.
FD_CHECK_ACTIVE: Reflects the error conditions that are being detected as active as selected for this category. Multiple
FD_CHECK_ALM: To report the particular failed condition to the host system.
For Plantweb alerts, there are three levels of alerts available:
a. Failed Alerts
A Failure Alert indicates a failure within a device that will make the device or some part of the device non-operational. This
implies that the device is in need of repair and must be fixed immediately.
FAILED_ENABLE: Enable the indication and reporting.
FAILED_MASK: Suppress reporting.
FAILED_PRI: Designates the priority.
FAILED_ACTIVE: Displays which of the conditions within the alert is active.
FAILED_ALM: To report the particular failed condition to the host system.
b. Maintenance Alerts
A Maintenance Alert indicates a condition within a device that, if not attended to in the near future (the type of alert defines
the time period for “Near Future”) will make the device or some part of the device non-operational. This implies that the de-
vice is in need of repair and must be fixed as soon as possible.
MAINT_ENABLE: Enable the indication and reporting.
MAINT_MASK: Suppress reporting.
MAINT_PRI: Designates the priority.
MAINT_ACTIVE: Displays which of the conditions within the alert is active.
MAINT_ALM: To report the particular failed condition to the host system.
c. Advisory Alerts
An Advisory Alert indicates a condition within a device that is informational in nature. The alert is used to notify the host that
the device has detected a condition within the device that is not critical, will not cause a failure if left unattended but
should be reported to the host for awareness and possible action.
ADVISE_ENABLE:Enable the indication and reporting.
ADVISE_MASK: Suppress reporting.
ADVISE_PRI: Designates the priority.
ADVISE_ACTIVE: Displays which of the conditions within the alert is active.
ADVISE_ALM: To report the particular failed condition to the host system.

Operation (Cont.)
Alert parameter description
a. Alerts – Enable/Map
These parameters are used to enable the indication and reporting of each corresponding alert. When an alert is disabled, the
device shall not detect that particular alert; it shall not be indicated in the xxxx_ACTIVE parameters or be reported via respec-
tively alerts. If an alert enable parameter is changed to “disabled” while the alert is active, it shall clear the alert and re-
evaluate the alert.
b. Alerts - Mask
These parameters will mask any of the failed conditions listed in respectively alerts.
Setting a bit to true will cause the corresponding alert to be indicated in the xxxx_ACTIVE parameters but not reported to the
host via the alerts. If an alert mask is changed while the alert is active, the alert is cleared and all the conditions are reevaluat-
ed.
c. Alerts - Priority
This designates the priority of the alerts. The default is 2 and the recommended value is between 10 and 15.
d. Alerts - Active
These parameters display which of the conditions is active. When a device detects a condition has become active, it shall set
the corresponding bit in the xxxx_ACTIVE parameters. If it is not suppressed/masked, it will be reported using the associated
alert parameter. These parameters are read only.
e. Alerts - Alarm
These parameters are used to report the particular condition to the host. These parameters are read only.
Recommended Actions and Default Settings for Alerts

Please see the Table 5 below for the recommended actions and default settings for all alerts.
Table 5 Recommended Actions and Default Setting/Mapping for Alerts (Note that no alert is masked in factory default settings)
Default Enabled Alert
Field Diagnostic Plantweb

Alerts Recommended Actions
Failed Off Spec Maint. Check Failed Maint. Advisory
Check Check transducer block mode.  

Calibration required or failed, check
calibration status for reasons, check
Calibration Failed  
air pressure, check valve system, re-
calibrate valve controller.
Temperature sensor is not functioning,
Bad Temperature Sensor  
replace valve controller when possible.
Temperatures too high/low, take cor-
System Temperature
rective actions to bring temperature  
Exceeded
within specified range.
Software error detected, cycle power,
Software Error if problem persists, replace valve con-  
troller when possible.
Lost position, check air pressure,
check shaft assembly and position,
Travel Deviation  
check open/close go switch and/or
potentiometer connection if available.
Internal communications problem,
check shutdown configuration for re-
Shutdown is Set  
start, if problem persists after restart,
replace valve controller when possible.
Button board is not functioning correct-
Buttonboard Failure ly, replace valve controller when possi-  
ble.
Output to pilot valve disabled because
of open/short circuit, check pilot valve
connection. Replace malfunctioning
Open or Short Circuit  
Piezo. When short circuit issue is
resolved, device must be power cy-
cled.
Adjusted Cycle Count Adjusted cycle counter exceeded limit,
 
Exceeded re-assign limit or re-adjust cycle count.

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FOUNDATION Fieldbus
Operation (Cont.)
Table 5 Recommended Actions and Default Setting/Mapping for Alerts (Cont.) (Note that no alert is masked in factory default
settings)
Default Enabled Alert
Field Diagnostic Plantweb

Alerts Recommended Actions
Failed Off Spec Maint. Check Failed Maint. Advisory
Valve controller life cycle exceeded

Control Module Life Cycle limit, replace valve controller. Recom-
 
Exceeded mend complete switchbox replace-
ment.
Time in position exceeded, check

Time in Position Limit Ex-
control system configuration, and  
ceeded
check valve and valve actuator.
Open travel timer exceeded, check air

pressure, check shaft assembly and
Open Travel Time Limit Ex-
position, check open/close go switch  
ceeded
and/or potentiometer connection if
available.
Close travel timer exceeded, check air
pressure, check shaft assembly and
Close Travel Time Limit Ex-
position, check open/close go switch  
ceeded
and/or potentiometer connection if
available.
Internal communications are lost;
valve controller will act according to
Internal I/O Failure shutdown configuration. If problem  
persists, replace valve controller when
possible.
Non-volatile EEPROM data corruption
was detected on the Fieldbus Elec-
tronics Board. Default values were
loaded into the faulty block.
1. Check the device configuration for
changes in the block parameter val-
NV Memory Failure ues.  
2. Reset the processer to clear the
error.
3. Download a Device Configuration.
NOTE: If the failure reoccurs it may
indicate a faulty EEPROM memory
chip.
The valve controller has detected a
fault with an electrical component on
Electronics Failure  
the Fieldbus Electronics Module As-
sembly. Replace the valve controller.

Operation (Cont.)
Restart Methods
You can restart the module via different mechanisms. Depending on which restart option is used; the communication links, static parameters, etc.
may be affected. However, due to the effect that a restart can have on the module, and therefore the process, restarting the module should be used
cautiously.
Restart using bus command
There are several Restart options as described bellow. This can be done via parameter RESTART in the Resource block. The following is
a brief description for each of the restart options:
a. Resource
Performing a “Resource”-restart resets the dynamic variables in the Function Blocks but has no observable effect on the module.
However, the dynamic variable within the module are reset and this could cause a “bump” in your process.
b. Defaults
Performing a “Restart with Defaults” should be done with care. This restart sets the static parameters of the function blocks in the
module to their default state. It also disconnects all links within the module. After performing a “Restart with Defaults”, a “Restart
Processor” should be performed.
c. Processor
Performing a “Restart Processor” has the same effect as removing power from the module and re-applying power. This is typically
used to restart the module if device shutdown is set due to internal communication lost caused by incorrect power application.
d. Valve Controller Processor
Performing a “Valve Controller Processor”-Restart has the same effect as removing power from the module and re-applying power.
This is typically used to restart the control part of the module.
e. Valve Controller Defaults
Performing a “Valve Controller Defaults”-restart should be done with care. This restart sets the calibration to default. It will erase the
calibration information. It has the same effect as “restart locally using buttons” in the following subsection.
f. Restore Factory Default Blocks
Performing “Restore Factory Default Blocks” restores default blocks i.e. manufacturer pre-instantiated blocks. It will clear complete
NV memory of device and this will result in NV Memory Failure error. To clear this error in device, a “Restart Processor” should
be performed.
Restart locally using buttons
To set valve controller to factory default locally using buttons: power off device, push both OPEN and CLOSE buttons, power on device,
release buttons when status LED is on.
Device Options
Enable/disable field diagnostics alerts simulation
This method will enable/disable field diagnostics alerts simulation.
Enable/disable access to the TB base record parameter
This method will enable/disable access to the Transducer Block base record parameter.
Base Record Methods

Get current real position: get position in percentage.
Get open endpoint: Get open endpoint in degrees. Due to 18 degrees dead band, the range is from 0 to 341.
Get close endpoint: Get close endpoint in degrees.
Get minimum temperature ever in degree C.
Get maximum temperature ever in degree C.
DD Version Info
This method will show the build number, date and info for the device description files.
To download more information concerning the Valvetop D-Series Valve Controller with Foundation Fieldbus,
visit us online: http://www.topworx.com/downloads/data.html Or call 502-969-8000 and
reference # ES-02512-1

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FOUNDATION Fieldbus
AS-I Sensor Communication Module (SCM) : Option AS
Option AS: SCM Calibration

Calibration
Switch Never perform the switch calibration procedure where area is known
to be hazardous.
CLOSE ASI OPEN
Step 1
Once pneumatic hookup and wiring has been completed close the
valve using the SCM-ASI on-board calibration switch. If no AS-i
AS-i
+ASI-
Close network connection is available, you may connect a 24VDC power

Terminals LEDs supply to the ASI terminals as previously described.
- D3 +
Open
Solenoid AUX Input Step 2
Outputs
Inputs
Terminals With the valve in the CLOSED position, disengage the BOTTOM cam
Terminals
- D2 +
from the splined hub and rotate Clockwise until the Red LED lights.
TopWorx
SCM-ASi 2.1
Release the cam to re-engage the splined hub.
Step 3
Note: Internal mount pilot in the DXP/DXS is 0.6W. For any externally mounted,
Open the valve by sliding the calibration switch to the OPEN position.
or customer supplied, solenoid valve 4 watt maximum power consumption is
allowed. A 170 mA max surge current limitation is required to prevent activation
of the short circuit protection. Step 4
Once the valve is in the OPEN position, disengage the TOP cam from
AS-i Specifications the splined hub and rotate Counter-clockwise until the Green LED
lights. Release the cam to re-engage the splined hub.
Device ID A Free Profile
Device I/O B 2 Inputs / 2 Outputs
Step 5
Inputs Cycle the valve CLOSED and OPEN several times using the
D2 Open Limit Switch 0 Switch Open calibration switch to verify both limit switches are maintaining
D3 Closed Limit Switch 1 Switch Closed their set points.
Outputs
D1 Solenoid #1 (Close) 0 De-energize Solenoid Step 6
D0 Solenoid #2 (Open) 1 Energize Solenoid Finally, slide the calibration switch to the ASI position. The
AS-i network will now have full control of the valve once the
Output Power SCM-ASI has been addressed.
Current & 40mA + open solenoid current
Output Power and closed solenoid current
Max solenoid current = 160mA
per output NOTE: When upgrading a TopWorx AS-i module with a new
Max power = 4 watts per output) TopWorx AS-i 2.1 module, make sure the input and output data
bit positions are updated as indicated above.
Voltage 20 to 30VDC
Wiring
Step 1
For internally-mounted or external pilot device(s), wire the ‘+’ and ‘-’ leads to the terminals marked D0 (open) and D1 (closed). The internally-
mounted pilot has an LED indicator for power verification.
Note: For an externally mounted solenoid valve, 4 watt maximum power consumption is allowed. A 160 mA surge current limit is required to
prevent activation of the short circuit protection circuit.
Step 2
Connect the AS-i communication wires to the terminals marked AS-i ‘+’ and AS-i ‘-’ .
Note: For calibration of the switches, a 24 VDC power supply may be used instead of an ASI Controller. If an ASI Controller is not
available, wire +24 VDC to ASI+, and GND to ASI-. The calibration switch will still be able to actuate the valve.
Additional Instruction for wiring an external switch input.

For externally mounted auxiliary input limit switches, wire switches to terminals marked -D2+ for open switch and -D3+ for closed limit switch.
NOTE: Refer to the wiring diagram on the inside lid of your product to determine actual pin out location.

To download more information concerning the Valvetop D-Series Valve Controller with AS-i, visit us online:
http://www.topworx.com/downloads/data.html Or call 502-969-8000 and reference # ES-02512-1.

Reed Switch Sensor Communication Module (SCM) Calibration: Options R2/R4
Option R2: SCM Calibration
Never perform limit switch calibration while an area is

known to be hazardous.
First, be sure you have an air supply connected, and the appro-
priate spool valve to actuator connections. Set the air supply
Secondary or Dual between 80 and 100psi.
Pilot Spool Valve
To I/O
Terminals
Logic
Signal IN Step 1
For standard explosion-proof units: Using a 24VDC regulated
To I/O
Voltage IN for
power supply, connect (+) to COM and (-) to NO terminals.
Pilot Valve Control Limit current to the internal limit switches below maximum
To I/O
current ratings.
Logic
Signal IN
To Pilot Valve Caution: Many power supplies do not have current
To I/O
limiting; therefore, ALWAYS use a load resistor with a
value of 200 to 2500 Ohms in series with the COM or
NO legs of the circuit or damage may occur.
Option R4: SCM Step 2

With the valve in the CLOSED position, disengage the lower
cam from the splined Hub and rotate clockwise until the Red
LED lights. Release the cam to re-engage the splined Hub,
making sure it is seated on the splines. This sets the CLOSED
limit switch.
Secondary or Dual Step 3

To I/O Pilot Spool Valve Cycle the valve to the OPEN position using the attached control
Terminals
equipment.
Logic
Signal IN
Step 4
To I/O While the valve is in the OPEN position, disengage the upper
Voltage IN for
Pilot Valve Control
cam from the splined Hub and rotate the upper cam counter-
To I/O clockwise until the Green LED lights. Release the cam to
Logic re-engage the splined Hub, making sure to seat the cam on
Signal IN the splines. This sets the OPEN limit switch.
To Pilot Valve
To I/O Step 5
Cycle valve several times to insure limit switches maintain cali-
bration. Check that the target assembly is secure to the actua-
tor pinion, and all air connections are tight.
NOTE: Continuity may be verified using a continuity

light or by using an Ohmmeter in series with the NO
Electrical Ratings connection.
SCM R2/R4 200mA@120VAC (25W MAX)
NOTE: Refer to the wiring diagram on the inside lid of your product
to determine wiring configuration and actual pin out location.
**Install per control drawing #ES-01743-1
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Reed SCM
ESD (Emergency Shut Down) Sensor Communication Module (SCM): Option ES
Electrical Ratings
Option ES: SCM
Current/Voltage
Open/Closed 0.25A@24VDC w/5V drop
Indication 0.25A@120VAC w/5V drop
Module Voltage 18-28VDC
Module Current 50mA (MAX)
Pilot Current (Standard) 20mA
800mA@24VDC MAX
PST Feedback Relays
250mA@125VAC MAX
800mA@24VDC MAX
CALIBRATION Pilot MAX Valve Rating
SWITCH 250mA@125VAC MAX
ALARM COM
PSI
Suggested Calibration Set-Up:

PASS/FAIL
DIAGNOS-
RELAY
24VDC(+) COM
COM
{
PARTIAL
LOAD
STROKE TEST
FEEDBACK **Same for both open
24VDC(-) NO indication and closed
200(4W) to indication output
2500(1/4W)Ohms
Diagnostic Relay and Pass/Fail Relay Outputs:

ESD Conventional Enclosure Assembly The diagnostic relay outputs the status flash code as shown in the
Message Table. (see pg.38)
PILOT COIL
1300ms 500ms
MODEL 35 GO SWITCH TO SET
PARTIAL STROKE POSITION
500ms
ESD MODULE CONTAINS (2) REED

The Pulse Train will repeat 3 times. In order to use this diagnostic
RELAYS FOR FULL OPEN/CLOSED
INDICATION PLUS ESD TIMER CIRCUIT
relay output, control logic should count the number of positive
transitions in order to get the message number. Clear the count
register in the logic when you see a logic low (open) for more than
INTEGRAL 5/2 VALVE
one second. The Pulse Train can be reset anytime by activating
the Calibration Switch or the PST/Calibration Activation Input.
Pass/Fail Relay:
The Pass/Fail Relay indicates whether the PST passed or failed.
OPTIONAL EXTERNAL BUTTON SWITCH In this example the relay is closed (high) from the last successful
WITH LOCKING SHIELD FOR INITIATING
THE PARTIAL STROKE PROCEDURE Partial Stroke Test.
PAD LOCK PROVIDED

BY END USER
When the PST switch is pressed for less than 5 seconds the test
begins and the Pass/Fail Relay opens (low). The Pass/Fail Relay
closes again once the unit completes and passes the Partial Stroke
Test.

ESD Conventional Instruction and Operation
Operation:
Before operation, the ESD must be calibrated (see Calibration below). After calibration, a partial stroke test may be performed (see Partial Stroke
Test below). The partial stroke time tolerance range can be selected as 20%, 30% or 40% (see Partial Stroke Time Tolerance Range Selection
below). A single switch (on board and external) is used to perform the calibration, the partial stroke test and the tolerance range selection. These
operations can be initiated from the control room with no need to shut down the entire plant. Non-volatile memory stores the calibration value and
the selected tolerance range value allowing for retention, even in the event of loss of power. The LED, both onboard and in the control room, flash-
es unique visual indicators to signal pass/fail of tests and possible maintenance issues (please see ESD Conventional Flow Chart pg.42 and
Message Table for ESD Conventional pg.41 for more details).
Partial Stroke Time Tolerance Range Selection:

1. The default partial stroke time tolerance range is set to 20%. This value can be selected as 20%, 30% or 40% anytime.
The value will be recorded in the EEPROM (memory) of the micro controller.
2. Press and hold the push button for ten to fifteen seconds to set the partial stroke time tolerance range to 20%.
If the value is saved to memory successfully, the LED and diagnostic relay will flash message code 5-1.
3. Press and hold the push button for within fifteen to twenty seconds to set the partial stroke time tolerance range to 30%.
4. Press and hold the push button for more than twenty seconds to set the partial stroke time tolerance range to 40%.
5. If there is a writing value to memory failure, the LED and diagnostic relay will flash message code 6-6.
The Pass/Fail relay will be turned OFF.
Hardware Configuration:
1. Ensure that the valve is in the CLOSED position.
2. Refer to the drawing at right which shows the correct orientation of the
GO Switch target and sensor cams for FAIL CLOSED valves which are
normal acting (see page 3).
3. If the unit conforms to this configuration, you may proceed to calibration.
If not, complete Hardware Configuration steps 4-7
4. Lift the target against the springload and rotate it such that the magnet is
counterclockwise from the GO Switch
5. Slide the magnet in the target wheel so as to position it approximately
one inch from the edge of the GO Switch
6. Press down on the lower cam and rotate it such that it is squarely aligned
to the front of the electronics module. The red light on the module should come on
7. Lift up on the upper cam and rotate it such that it is 90º clockwise from the electron-
ics module.
Calibration:
1. Before performing calibration, make certain the valve is fully open, and the target button is set to the proper partial position. NOTE: If the
valve is not fully open, the test will abort and the LED and diagnostic relay will flash message code 7-7 indicating that the valve
is not fully open. The Pass/Fail relay will be turned OFF.
2. Press and hold the push button on board for five to ten seconds.
3. The activation relay will be turned ON to initiate valve closing.
4. The valve will move until the GO Switch detects the partial stroke position.
5. The GO Switch will send feedback indicating that the pre-determined position is reached.
6. The time required to move the valve from the “fully open position” to the “partially open position” is the partial stroke time of the valve.
The acceptable time ranges are from fifty milliseconds to eight seconds. This “partial stroke calibration time” will be recorded in the
EEPROM (memory) of the micro controller. EEPROM will retain the value until your next calibration.
7. If the calibration is successful, the Pass/Fail relay will be turned ON and both the LED and diagnostic relay will flash message code 3-3.
8. After the LED flashes code for three times, both the LED and diagnostic relay will be steady, signifying that the calibration is complete.
Reset of the flashing LED and the diagnostic relay may be performed at anytime while the LED is flashing by pressing the calibration
button.
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ESD

ESD Conventional Instruction and Operation
Partial Stroke Test:
1. Before performing the Partial Stroke Test (PST), make certain the valve is fully open. NOTE: If the valve is not fully open, the test will
abort and the LED and diagnostic relay will flash message code 7-7 indicating that the valve is not fully open. The Pass/Fail relay
will be turned OFF.
2. If using the onboard module push button, press the button and hold it for more than half a second and less than five seconds.
If using the optional external Partial Stroke Test Switch, push firmly once.
3. The activation relay will be turned ON to initiate valve closing.
4. The valve will move until the GO Switch detects the partial stroke position.
5. The time required to move the valve up to the partial stroke position will be compared against the “partial stroke calibration time” value stored
in EEPROM (memory). The acceptable time ranges from "(1-tolerance range value) x partial stroke calibration time" to "(1+tolerance range
value) x partial stroke calibration time". For example, if the partial stroke calibration time is 6 seconds and the tolerance range value is 20%,
the acceptable PST time ranges are from 4.8 to 20 seconds.
6. If the time required for moving the valve to the Partial Stroke position exceeds the acceptable range of the “partial stroke calibration time”, the
test will be aborted, indicating valve failure. The Pass/Fail relay will remain OFF and both the LED and diagnostic relay will flash
message code 5-5 if the valve has moved. If the valve has not moved, the Pass/Fail relay will remain OFF and both the LED and
diagnostic relay will flash code 4-4. CAUTION: Before recalibration, make sure failure type is addressed (see table below).
7. If the time required is within the acceptable range, the Pass/Fail relay will be turned ON and both the LED and Diagnostic Relay will flash
message code 2-2 .
8. After the LED flashes code for three times, both the LED and diagnostic relay will be steady, signifying that the Partial Stroke Test
is complete.
Note: Partial Stroke Time Tolerance Range Selection, Calibration or Partial Stroke Test cannot be performed when the LED is flashing. Before
re-running the test, please wait for the LED to become steady or clear it by pressing the button.
Message Table for ESD Conventional

LED Status Diagnostic Relay
Problem Cause / Solution
Flash Code Message
Solid ON Unit operating correctly No action required
1-1 Device not calibrated Need to perform the calibration procedure before the partial stroke test
2-2 Partial stroke test passed No action required

with 20% tolerance range
3-3 Calibration completed No action required
4-4 Valve has not moved during Possible causes include:

partial stroke test 1) The valve is stuck
2) The shaft is broken
5-1 Partial stroke time tolerance No action required
range is set to 20%
range is set to 30%

range is set to 40%
5-5 Partial stroke test failed The valve did not reach the partial stroke position within the allotted time. Possible causes include:
1) The valve is stuck or sluggish
2) The GO Switch target for the partial stroke position is set incorrectly
3) The shaft is broken
6-6 Module memory error Contact factory
7-7 Valve is not fully open Unit cannot calibrate or run a partial stroke test without the valve starting in the open position.
Check the following:
1) Air supply to actuator
2) Solenoid is powered
3) If valve is fully open, adjust the open switch cam to indicate the open position
Continuous Hardware failure Contact factory

fast
flashing

Calibration Flow Chart
Apply power
LED displays memory error

No continuous fast flashing
Is memory ok?
Pass/fail relay state 0
Yes
No
Is device calibrated?
Yes
Is button pressed and held for No

at least 0.5 seconds?
Yes
Is button Is button Is button Is button

No No No No Is button No
released before released before released before released before
released?
5 seconds? 10 seconds? 15 seconds? 20 seconds?
Yes Yes Yes Yes

Yes
Begin partial stroke test Begin partial stroke calibration

Yes
Set partial stroke time
No No tolerance range to 20%
Is valve fully open? Valve opens Is valve fully open?
Yes Yes
No
Write uncalibrated status to memory Set partial stroke time
Is device calibrated? tolerance range to 30%
Yes
Is writing status value to No
No memory successful?
Is stored calibrated
value for partial stroke time Yes
within range? Is writing
No Set partial stroke time
Valve closes tolerance
Yes No
range value to tolerance range to 40%
Valve closes memory
Is maximum Is partial successful?
No No
allowed time stroke position
(8s)passed? reached? Yes
Is partial stroke No Is calibrated Yes
position reached? Yes
time passed?
Yes No
Is minimum
allowed time (50ms)
passed?
Is minimum allowed No Is writing Is writing
Valve opens Yes tolerance tolerance
time (50ms) passed? Valve opens range value to No range value to
Yes Valve opens memory memory
successful? successful?
No
Has valve moved?
Yes Yes
Is writing No
Valve opens Yes calibrated value
to memory
successful?
Yes
LED displays LED displays LED displays LED displays LED displays
valve is not valve closing valve has not valve is not valve closing
calibrated code time failure code moved code fully open code time failure code LED displays writing LED displays writing
1-1 Pass/fail 5-5 Pass/fail 4-4 Pass/fail 7-7 Pass/fail 5-5 Pass/fail error code 6-6 Pass/ error code 6-6 Pass/
relay state 0 relay state 0 relay state 0 relay state 0 fail relay state 0 fail relay state 0
LED displays LED displays

partial stroke test calibration LED displays LED displays LED displays
complete code 2-2 complete code range set to range set to range set to
for all tolerance range 3-3 Pass/fail 20% complete 30% complete 40% complete
Pass/fail relay state 1 relay state 1 code 5-1 code 5-2 code 5-3
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ESD
Troubleshooting
Proof Testing
The user is required to carry out ‘proof testing’ at specified intervals in order to verify the absence of any failures and hence meet the required
PFDave. (This is normally done for the entire safety function in order to exercise every device in the safety-instrumented system. Proof tests are
described in IEC 61511-1, clause 16).
PFD = Probability of Failure in the Dangerous model.
PFDave is obtained by arithmetic average over the time interval “T” and depends on the failure rate (symbol ‘’) of the chosen ESD valve and it’s
actuator. (See the formula below)
T= 3 x PFDave
(1.2 x 10-6 + VALVE + ACTUATOR ) x 2.738 x 10-6
As a guide, the following table gives proof test intervals for the Topworx ESD valve controller together with the selected valve and actuator failure
rates in order to achieve 50% of the total PFDave required for SIL3 (5 x 10-4).
25000
VALVE + ACTUATOR Proof test interval
(per hour) (hours)
20000
1 x 10-4 2,327
HOURS
1 x 10-5 6,994 15000

-6
1 x 10 15,780
1 x 10 -7
20,528 10000
The proof test procedure should verify the ESD valve 5000
controller allows the ESD valve to function 100% on
command, and that any failures related to the valve,
actuator or partial stroke test function are revealed. 0 1x10-4 1x10-5 1x10-6 1x10-7
Failure Rate λ
To download more information concerning the Valvetop D-Series ESD Valve Controller,
including a copy of the Sira Functional Safety Assessment Report visit us online at
http://www.topworx.com/downloads/data.html
or call 502-969-8000 and reference # ES-00936-1.
DeviceNet Sensor Communication Module (SCM): Option DN

Basic DeviceNet I/O Operation Step 4: While the valve is in the OPEN position, disengage the top cam
from the splined Hub and rotate Counterclockwise until the Green LED
The DeviceNet Sensor-Communications Module (known hereafter as SCM-DN) lights. Release the cam to re-engage the splined Hub. Be sure the cam
operates as a combined discrete input and output device on the DeviceNet is seated on the Hub.
network. It is a slave (server) device that can be allocated by the system
implementer to one specific master (client). There are several parameters that Step 5: Cycle the valve CLOSED and OPEN a few times using the
may be modified by the user. These are collected in a block of data called the calibration switch to verify both limit switches are maintaining their set
Parameter Object (See Configuration Parameters Table, pg. 42). They may points.
be left as defaulted, depending upon your application.
Step 6: Finally, slide the calibration switch to the DeviceNet position.
The Polled I/O feature follows the conventional method of a client requesting The DeviceNet network will now have full control of the valve once the
data from and/or sending data to one server at a time. This requires both a SCM-DN has been addressed.
command message from the client and a response message from each server
for every set of I/O. To improve throughput on the network Change-of-State
and Cyclic I/O functions have been defined by the DeviceNet protocol. These How to Install and Establish DeviceNet Communications
functions are supported by the SCM-DN. The discrete data returned in the poll Step 1: Connect the DeviceNet cable to the round 5-pin round mini or
response to the client will contain both valve contact input and valve command micro connector according to DeviceNet cable wiring specifications, or
output status data. wire directly to the terminals on the SCM-DN.
Polled I/O Step 2: Make sure that the DeviceNet network is terminated properly.
The client can poll (read) the input and command the output status from the
Step 3: Set the baud rate and address of the SCM-DN if different from
SCM-DN and can energize or de-energize the discrete outputs on the SCM-DN.
The status LEDs report the actual state of the valve; i.e. the red led is lit when default (See Baud Rate Selection Table, pg. 42).
the valve is closed, and the green led is lit when the valve is open.
Step 4: Make sure that there is power on the DeviceNet network and
that it is plugged into a Master device.
The client controls the valve outputs by sending a poll command to the SCM-
DN. If no data is sent to the SCM-DN during a poll, then the outputs are put into
Step 5: Wire the DeviceNet cable to the SCM-DN.
the “idle” state and their actions are then governed by the Idle Action and Idle
Value attributes of the Parameter Object (See Configuration Parameters Table,
Step 6: In fixed baud rate mode, the SCM-DN will undergo its initializa-
pg. 42).
tion sequence, flashing both LEDs. After approximately 4 seconds, the
Both idle and fault operations are implemented for the valve output points. The Module Status LED (labeled “MS”) will go on solid green and the
outputs can be set individually to hold last state or to implement user-defined Network LED will flash green.
states upon receipt of an “idle” command or upon a “fault” condition. You can
Step 7: In autobaud mode, the SCM-DN the Module Status LED
implement these actions via the Parameter Object (See Configuration
Parameters Table, pg. 42). will continue to blink until the SCM-DN recognizes valid traffic on
the DeviceNet link and syncs to a specific baud rate.
Cyclic and Change-of-State I/O Step 8: The green Network Status LED (labeled “NS”) will go on solid
Both the Cyclic and Change-Of-State (COS) are activated by allocating a
once the Master recognizes the unit on the link and allocates the
connection for one or the other using the allocate service of the DeviceNet
connection (commissions it).
Object (class 3), and setting the EPR (Expected Packet Rate) for that
connection. The value for the EPR is used to set the various communication Step 9: The SCM-DN is now operating on the network.
timers.
The Cyclic connection initiates a transmission every time the connection timer How to Configure the DeviceNet Node Address and Baud Rate
expires. The cyclic connection can only send data from the SCM-DN to it’s Step 1: The address and baud rate can be set using the 6-position DIP
assigned client. The polled and cyclic connections are not exclusive, so both switch blocks, SW1 and SW2 (as seen on the SCM-DN Illustration
can exist at the same time. The manner in which cyclic connection reports its pg.42).
data is the same as the polled connection.
Step 2: Switches 1 and 2 on SW2 define the baud rate selection as
The Change of State (COS) connection is the same as the cyclic connection shown in the Baud Rate Selection Table, pg. 42.
except that as well as triggering communications on the expiration of the timer,
the COS connection also initiates a transfer on a change of the valve’s status. Step 3: Switches 1 through 6 on SW1 define the address selection as
The COS connection is mutually exclusive with the cyclic connection, but can shown in the Address Selection Table, pg. 42.
coexist with the polled connection. The COS connection operation is very
useful in conserving bandwidth, and provides the client with the most current Step 4: Switch setting changes will NOT take effect until the device is
data as fast or faster than a poll connection. The COS connection automatically reset with either a RESET command or a power cycle.
turns on the COS mechanism when the connection is created.
Quick Start for DeviceNet How to Configure the Network Communications Protocol
Limit Switch Calibration Step 1: Switches 3, 4 and 5 on SW2 define which link is selected –
Never perform switch calibration while area is known to be hazardous. DeviceNet or Modbus – as shown in the Communications Protocol
Selection Table, pg 42.
Step 1: Once pneumatic hookup and wiring has been completed close the
valve using the SCM-DN on-board calibration switch. If no DeviceNet network Step 2: For DeviceNet set all 3 switches OFF or 0.
connection is available, you may connect to a 24VDC power supply.
Step 3: If you change the switches, the new selection will not become
Step 2: Place the calibration switch in the closed position. With the valve in the effective until the unit is power cycled or a Reset command is received
CLOSED position, disengage the bottom cam from the splined Hub and rotate by the SCM-DN.
Clockwise until the Red LED lights. Release the cam to re-engage the splined
Hub. Be sure the cam is seated on the Hub. Step 4: Switch 6 of SW2 selects the Modbus protocol for ASCII or RTU
as shown in the Modbus Protocol Table, pg 42.
Step 3: Open the valve by sliding the calibration switch to the OPEN position.
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DeviceNet
DeviceNet Sensor Communication Module (SCM): Option DN

MODULE/NETWORK
STATUS LEDS CALIBRATION SW
DEVICENET
MODBUS SCM-DN
MS/TX NS/RX
OPEN The network shield is not terminated. Connections to the

AUTO
pilot valve and relay contacts are all made internal to the
+OUTPUTS
CLOSE
AUX- AUX+
ALARM enclosure.
RESET
CLOSED OPEN
OPEN CLOSE SIG+ SIG- COM
*
(VALVE STATE LEDS)
DNET
V+
000
1
BAUDRATE
V- CANL CANH
ASCII/RTU
MODBUS*
FRAMING
ADDRESS
0
O 1 2 3 4 5 6 O 1 2 3 4 5 6
N N
Address Selection Baud Rate Selection Communications Protocol Selection

ADDRESS Switch Position DeviceNet DeviceNet Modbus DIP Switch Position
DIP Switch Position
Baud Rate SW 2,3 SW 2,4 SW 2,5
SW 1,1 SW 1,2 SW 1,3 SW 1,4 SW 1,5 SW 1,6
SW 2,1 SW 2,2 DeviceNet N/A OFF OFF OFF
Node
Switch Position Values N/A 7,N,2 OFF OFF ON
Address 125k OFF OFF
32 16 8 4 2 1 250k OFF ON N/A 7,E,1 OFF ON OFF
N/A 7,O,1 OFF ON ON
0 OFF OFF OFF OFF OFF OFF 500k ON OFF
N/A 8,N,1 ON OFF OFF
1 OFF OFF OFF OFF OFF ON Autobaud ON ON N/A 8,N,2 ON OFF ON
2 OFF OFF OFF OFF ON OFF N/A 8,E,1 ON ON OFF
3 OFF OFF OFF OFF ON ON N/A 8,O,1 ON ON ON
4 OFF OFF OFF ON OFF OFF Modbus Protocol
5 OFF OFF OFF ON OFF ON Modbus Protocol DIP Sw Position
... SW 2,6
62 ON ON ON ON ON OFF ASCII OFF
63 ON ON ON ON ON ON RTU ON
Configuration Parameters (Class 15)

Instance Parameter Name Values Default Setting Default Value Description
1 Max Open Time 0 to 65535 Disabled 0 Max time allowed for valve to Open before triggering an alarm
2 Max Close Time 0 to 65535 Disabled 0 Max time allowed for valve to Close before triggering an alarm
3 Cycle Count Limit 0 to 4294967295 Disabled 0 Max number of cycles allowed before triggering an alarm
4 Analog High Limit 0 to 255 Disabled 255 Highest analog value before triggering an alarm
5 Analog Low Limit 0 to 255 Disabled 0 Lowest analog value before triggering an alarm
0 = Use fault value
6 DNet Fault Action 0 or 1 Use Fault Value 0
1 = Hold last state
0 = OFF
1 = Open
7 DNet Fault Value 0 thru 3 OFF 0
2 = Close
3 = No change
0 = Use fault value
8 DNet Idle Action 0 or 1 Use Fault Value 0
1 = Hold last state
0 = OFF
1 = Open
9 DNet Idle Value 0 thru 3 OFF 0
2 = Close
3 = No change
1 = Status & Alarm bytes
2 = Status & Alarm bytes = last Open & Close Times
10 Assembly Config 1 to 4 Standard Assembly 1
3 = Status & Alarm bytes + Cycle Count
4 = Status & Alarm bytes + last Open/Close Times + Cycle Count

To download complete information concerning the Valvetop D-Series Valve Controller with DeviceNet, visit us online:
http://www.topworx.com/downloads/data.html or call 502-969-8000 and reference # S-K128.
Pneumatic Hookup Procedures

Spool Valve Specifications
Prior to connecting the supply air to the spool valve, flush the system to Medium Dried, filtered air (40 micron)
remove any debris or contaminates. Galvanized pipe can easily flake and
Max Operating
contaminate the system and therefore is not recommended. A 40 micron Pressure
100psi (0.69 MPa) (6.89Bar)
point of use filter at every device is recommended.
Min. Operating
30psi (0.21 MPa) (2.07Bar)
Pressure
Max Consumption
4-Way Spool Valves Rate
600 cc/min @ 80psi
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 Ambient
Refer to Product Nameplate Marking
follows: Temperature Range
Flow Coefficient 1.2Cv or 3.0Cv
Environment Rating Type 4, 4X, IP67
1/2” NPT for 3.0Cv valve

Port Size
1/4" NPT for 1.2Cv valve
Available in Latching/Non-Latching
Manual Override
Push Type & Palm Actuator Type
Available in Hardcoat Anodized

Exhaust of Port 4 Supply Exhaust
Exhaust of Port 2 of Port 4 Supply Exhaust of Port 2 Valve Body
(when actuator opens) (when
(when actuator actuator opens)
closes) (when actuator closes) Aluminum, 304, or 316 Stainless Steel
TOP VIEW TOP VIEW

Spool Seals: Buna-N
5 1 3 5 1 3 Valve Body Seals available in
Pilot Valve Pilot Valve Pilot Valve Pilot Valve
Valve Seals
Internally Internally Internally Internally Buna-N, Silicone, EPDM & Viton.
mounted mounted Mounted Mounted
4 2 4 2
Port to Port to
Port to Port to
Actuator Close Actuator
Actuator OpenClose Actuator Open
***Never Plug, Block or Restrict Port VIEW
BOTTOM 5*** BOTTOM VIEW
***NEVER PLUG, OR BLOCK, PORT 5*** ***NEVER PLUG, OR BLOCK, PORT 5***
Always install vents Always install vents

Supply
or speed controls
Supply
or speed controls Supply Don’t forget!
TopWorx has a complete line of
5 1 3 55 11 33 5 1 3 breathers, flow controls, regulators
and filters.
4 2 44 22 4 2
Port to Close Port to Open Plug

Port to Close Port to
Port to Open
Open /Close Plug Port to Open Check out www.topworx.com or call
DOUBLE ACTING ACTUATORS DOUBLE
SPRING ACTING
RETURNACTUATORS
ACTUATORS SPRING RETURN ACTUATORS us at 502.969.8000 for more details
Highly Recommended 1 5 1 3
5 3
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 4leading
2 thread of the fitting. This
4 will
2
FAIL CLOSED FAIL CLOSED
prevent tape shreds from contaminating the spool valve seals.
5 1 3 5 1 3 DID YOU KNOW?
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 ad-
TopWorx manufactures the globally-
dressed prior to installation, or storage.
4 2 4 2 known GO Switch Leverless Limit
FAIL LAST POSITION FAIL LAST POSITION
Switch, which comprises a full line of
A flow control may be used in Port 3, but should NEVER BE USED in5 Port 1
5 3 1 3 harsh environment sensors. If your
5. Any blockage or restriction may cause an internal pressure build-up in- application is very cold, very hot, under
side the enclosure and pose a safety issue.
4 2 4 2 water or in a caustic atmosphere, then
BLOCK CENTER BLOCK CENTER
GO Switch has the answer.
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Pilots & Spool Valves
Spool Valves and Pilots

Pilot Device Assembly
SINGLE PILOT ASSEMBLY Pilot
Assembly
Manifold
YELLOW Urethane 10-32 Metal Plug
Tubing (Work)
24V, 110V, 220V, or
Intrinsically Safe Pilot Device
(no plug connector on I.S. Pilots)
(x1) for Fail Closed apps
(x2) for Fail Last Position &
Block Center apps 4- 40 x .25"
SEM screw 10-32 Metal
TORQUE Barb Fitting
100 IN-OZ TORQUE 60 IN-OZ
Bracket
ORIFICE TO BE USED
RED
4-40x.25 (x2) IN EXPLOSION PROOF
Urethane
Bracket APPLICATIONS ONLY
Tubing Orifice
(Supply) Assembly
SINGLE I.S. PILOT ASSEMBLY F7 F9 USE IN ALL APPLICATIONS
I.S. Pilot (EXCLUDING M,K,H,L2 SWITCH OPTIONS)
Assembly 10-32 Metal
Barb Fitting F18 F21 M, K, & H SWITCH OPTIONS
RED F17 F16 USE IN L2 OPTION ONLY

10-32 Metal Plug
Urethane
Tubing
(Supply)
10-32 Metal
Barb Fitting
TORQUE 60 IN-OZ DUAL PILOT ASSEMBLY
YELLOW Urethane
4- 40 x .25" Coil 1 Pilot Tubing (Work)
SEM screw Assembly
TORQUE
100 IN-OZ RED Urethane
Tubing (Supply) 10-32 Metal Plug
YELLOW Urethane 10-32 Metal

Tubing (Work) Barb Fitting
Bracket TORQUE 60 IN-OZ
Coil 2
4- 40 x .25"
SEM screw
TORQUE
10-32 Metal 100 IN-OZ
DUAL I.S. PILOT ASSEMBLY Barbed
Barb Fitting
Bracket “Y” Fitting
I.S. Pilot RED Barbed
Assembly Urethane “Y” Fitting RED Urethane
Tubing Tubing (Supply)
(Supply) YELLOW Urethane
YELLOW Urethane Tubing
(Work) Tubing (Work)
ORIFICE TO
RED Urethane BE USED IN
Tubing (Supply) EXPLOSION Orifice
PROOF Assembly
APPLICATIONS
ONLY
10-32 Metal
Barb Fitting
4- 40 x .25" TORQUE 60 IN-OZ
SEM screw
TORQUE
100 IN-OZ
Bracket
10-32 Metal Plug
Spool Valve Assembly
Push
Button
Flame Arrestor O-Ring (x5)

Push Button Override
M5 x 25mm SHCS (x4)

(4mm hex wrench)
Spool valve with Spool Valve with Spool Valve

dual manual override Single Manual Override Without Manual Override
Proof Testing for D-Series Valvetop
Sira Test & certification Ltd has conducted a Failure Mode, Effect and Diagnostic Analysis
(FMEDA) of the D-Series Discrete Valve Controller against the requirements of IEC61508-2.
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D-Series Safety Functions
The safety functions of the D-Series Discrete Valve Controller are defined as:
 To relieve pneumatic pressure to the spool valve by de-energizing the solenoid valve allowing the actuator to per-
form its safety function.
 To admit pneumatic pressure to the spool valve by energizing the solenoid valve allowing the actuator to perform
its safety function.
The actuator and valve may be configured to fail safe in a normally open (N/O) or normally closed (N/C) configuring
depending on the process under control. The D-Series controller requires an air supply in some form which must be
assessed by the end user to ensure the required SIL is achieved. E.g. If the D-Series controller is configured with
the safety function to relieve pneumatic pressure to the actuator in order for it to revert to its fail safe state then a
failure of the air supply will be a safe failure.
The D-Series Discrete Valve Controller could benefit from an increase in availability by incorporating the GO magnetic
proximity switches at the Partial Valve Stroke Test (PVST) position and utilize a PVST command into the PLC which
will perform a PVST either automatically or by an operator at no longer than the prescribed intervals with the opera-
tor taking the appropriate action in the event of a failure being detected by PVST.
Hardware Functional Description

The D-Series Discrete Valve Controller implements the safety functions as a sub-system as defined according to IEC
61508-2 clause 7.4.2.11 Note 1. Furthermore, with reference to IEC 61508-2 clause 7.4.4.1.2/3, the full assembly can
be classified as a “Type A” sub-system.
No fault (normal) conditions

a) Under normal operating conditions the D-Series Discrete Valve Controller will maintain the Normally Open (N/
O) actuator / valve in the closed position or the Normally Closed (N/C) actuator / valve in the open position.
b) The bus networking device may relay valve positional data to the operator during normal operating conditions
but this device is not responsible for implementing the safety function.
Self diagnosed fault conditions

The D-Series Discrete Valve Controller does not have any online fault diagnostics however if the D-Series Discrete
Valve Controller develops a fault which reverts the valve to its fail safe state then the sensor module will knowledge
this change in valve position through the integrated shaft which is coupled to the valve. The bus networking device
can then notify the operator of a valve position change without being requested. This kind of failure is a safe detecta-
ble failure (λSD) and is considered as such in the FMEDA.
If the D-Series Discrete Valve Controller develops a fault which latches the valve in its current, potentially dangerous,
state then this form of failure will only be acknowledged during proof test, PVST or when a demand is placed on the
element. The bus networking device can only notify the operator of no valve movement after the failure event has
occurred and therefore this kind of failure is a dangerous undetectable failure (λDD) and is considered as such in the
FMEDA.
The utilization of PVST by the D-Series Discrete Valve Controller will reveal any covert undetected dangerous failures
and therefore increase the availability of the device. The use of PVST as a diagnostic tool will enable the following
actions:
 Detect the valve position.
 Detect valve movement.
 Measure the time to travel from open to partial stroke position.
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To download more information concerning the Valvetop D-Series Valve Controller,

including a copy of the Sira Functional Safety Assessment Report visit us online at
http://www.topworx.com/downloads/data.html
Or call 502-969-8000
Safe Use
User instructions (in compliance with ATEX 94/9/EC Directive, Annex II, 1.0.6)
Instructions for safe selection, installation, use, maintenance and repair

1) The equipment may be used in zones 0, 1 or 2.
2) The equipment may be used in the presence of flammable gases and vapors with apparatus groups IIC or IIB or IIA and with temperature
classes T1 or T2 or T3 or T4 or T5 or T6.
3) The equipment is certified for use in ambient temperatures in the range of -50°C to +60°C and should not be used outside this range.
(NOTE: Ambient temperature range may change according to protection method)
4) The equipment is to be installed by suitably trained personnel in
accordance with the applicable code of practice (typically IEC 60079-14)
5) Under certain extreme circumstances, the plastic cover over the valve position indicator may generate an ignition-capable level of electro-
static charge. Therefore, particularly in the event of an installation in zone 0, the equipment shall not be installed in a location where the
external conditions are conducive to the build-up of electrostatic charge, e.g. wind-blown dust, etc. Additionally the equipment shall only
be cleaned with a damp cloth.
6) Periodic inspection of the equipment and system should be performed by suitably trained personnel in accordance with the applicable
code of practice (typically IEC 60079-17) to ensure it is maintained in a satisfactory condition.
7) The equipment does not require assembly or dismantling.
8) The equipment is not intended to be repaired by the user. Repair of the equipment is to be carried out by the manufacturer, or their ap-
proved agents, in accordance with the applicable code of practice.
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 according to protection type and suitable for the conditions of use and cor-
rectly installed.
The IIC enclosures are excluded from use in carbon disulphide atmospheres.
The air pressure to the valve block, when fitted, shall not exceed 6.9bar.
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.
TopWorx Valvetop D-Series Replacement Part Number List

35 Series GO Switches Pilot Replacement Kits
35-13319M Option L2/L4 - SPDT AV-S24VPMRK 24vdc pilot/manifold replacement kit
35-83358M Option Z2/Z4 - DPDT Stainless Steel AV-S110VPMRK 110vac pilot/manifold replacement kit
Switch / Module Replacement Kits AV-SP20PMRK Piezo pilot/manifold replacement kit
SCM-FF Foundation Fieldbus module Spool Valve Replacement Assemblies

Fail Closed / No Override
SCM-AS AS-Interface module
AV-BFCVA20 Std Alum Spool Valve Assembly w/ Buna seals
SCM-DN DeviceNet module
AV-BFCVS20 Std 304SS Spool Valve Assembly w/ Buna seals
AV-MSW1 (M) SPDT mechanical switch replacement
AV-BFCV620 Std 316SS Spool Valve Assembly w/ Buna seals
AV-E1 (E) P+F NJ2-V3-N sensor replacement
Spool Valve Replacement Assemblies
AV-TSW1 (T) DPDT mechanical switch replacement Fail Last Position / No Override
AV-420TMRK 4-20mA transmitter replacement assembly w/ potentiometer AV-BFLPVA20 Std Alum Spool Valve Assembly w/ Buna seals
Indicator / Dome Replacement Kits AV-BFLPVS20 Std 304SS Spool Valve Assembly w/ Buna seals
AV-GB002 90º, Green/Open, Red/Closed, Buna O-Ring AV-BFLPV620 Std 316SS Spool Valve Assembly w/ Buna seals
AV-YB002 90º, Yellow/Open, Black/Closed, Buna O-Ring Spool Valve Replacement Assemblies
Block Center / No Override
AV-BB002 90º, Black/Open, Yellow/Closed, Buna O-Ring
AV-BBCVA20 Std Alum Spool Valve Assembly w/ Buna seals
AV-4B002 45º, Green/Open, Red/Closed, Buna O-Ring
AV-BBCVS20 Std 304SS Spool Valve Assembly w/ Buna seals
Shaft Replacement Kits
Mechanical Switches (M2 or T2) AV-BBCV620 Std 316SS Spool Valve Assembly w/ Buna seals
Standard shaft
AV-SSB201
Buna-N O-Rings & (2) cam Assembly w/ Hardware
NAMUR Shaft Consult Factory

AV-NSB201
Buna-N O-Rings & (2) cam Assembly w/ Hardware To order replacement parts or for information
Shaft Replacement Kits concerning parts or spool valve options not listed call
GO Switches (L2 - Manufactured after July 1, 2007) TopWorx at 502-969-8000
Standard shaft
AV-SSB205
Buna-N O-Rings & (2) Target Assembly w/ Hardware
NAMUR shaft
AV-SNB205
Buna-N O-Rings & (2) Target Assembly w/ Hardware
Shaft Replacement Kits

SCMs with Reed Switches (R2)
NAMUR Shaft
AV-NSB202
Standard Shaft
AV-SSB202
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Warranty
Warranty
Valvetop DXP Certifications

www.topworx.com ™
Certifications & Approvals
Recommended Operating Temperatures

Flameproof (DXP and DXS Only)
Option Switch Description Valvetop with NO Solenoid Valvetop WITH Solenoid
M Mechanical switch - SPDT -40°C to +80°C -20°C to +60°C
K Mech. switch w/Au contact -40°C to +80°C -20°C to +60°C
L 35 GO Switch SPDT -60°C to +80°C -20°C to +60°C
Z 35 GO Switch DPDT -60°C to +80°C -20°C to +60°C
R Reed Switch SPDT -40°C to +80°C -20°C to +60°C
T Mechanical switch DPDT -40°C to +80°C -20°C to +60°C
8 Mechanical switch DPDT -40°C to +80°C -20°C to +60°C
PS Reed cube with LED -40°C to +80°C -20°C to +60°C
PN Reed cube w/no LED -40°C to +80°C -20°C to +60°C
AS Asi -40°C to +80°C -20°C to +60°C
DN DeviceNet -40°C to +80°C -20°C to +60°C
FF Foundation Fieldbus -40°C to +80°C -20°C to +60°C
FF Foundation Fieldbus Cold Temp not available -30°C to +60°C
MB Mod Bus -40°C to +80°C -20°C to +60°C
_X 4-20mA Transmitter -40°C to +80°C -20°C to +60°C
_H 4-20 Xmitter with HART -40°C to +80°C -20°C to +60°C
0A 1k potentiometer -40°C to +80°C -20°C to +60°C
0B 10k potentiometer -40°C to +80°C -20°C to +60°C
PEPPERL+FUCHS SWITCH OPTIONS - STANDARD

E NJ2-V3-N -25°C to +80°C -20°C to +60°C
F NJ2-12GK-N -25°C to +80°C -20°C to +60°C
B NJ2-12GK-SN -40°C to +80°C -20°C to +60°C
C NJ2-11-N -25°C to +80°C -20°C to +60°C
J NJ2-11-SN -40°C to +80°C -20°C to +60°C
7 NJ2-12GM40-E2 -25°C to +70°C -20°C to +60°C
V NJ3-18GK-S1N -25°C to +80°C -20°C to +60°C
3 NJ5-30GK-S1N -25°C to +80°C -20°C to +60°C
PEPPERL+FUCHS SWITCH OPTIONS - CUSTOM

<N001> NCB5-18GM40-NO-V1 -25°C to +80°C -20°C to +60°C
<N002> NJ4-12GM-N -25°C to +80°C -20°C to +60°C
<N003> SJ3.5-N -25°C to +80°C -20°C to +60°C
<N004> SJ3.5-SN -40°C to +80°C -20°C to +60°C
<N005> NCN4-12GM35-NO -25°C to +80°C -20°C to +60°C
<N006> NJ2-12GK-SN -40°C to +80°C -20°C to +60°C
<N007> SJ3.5-S1N -25°C to +80°C -20°C to +60°C
<N010> NJ5-11-N-G -25°C to +80°C -20°C to +60°C
<N011> NJ2-11-N-G -25°C to +80°C -20°C to +60°C
<N012> NJ3-18GK-S1N -25°C to +80°C -20°C to +60°C
<N013> NJ5-18GK-N -25°C to +80°C -20°C to +60°C
<N014> SC3.5G-N0 -25°C to +80°C -20°C to +60°C
<N015> NJ2-12GM-N -25°C to +80°C -20°C to +60°C
<N016> NJ5-18GM-N -25°C to +80°C -20°C to +60°C
<N017> NJ2-12GK-N -25°C to +80°C -20°C to +60°C
<N018> NCB5-18GM40-NO -25°C to +80°C -20°C to +60°C
<N019> NJ2-12GM40-E2 -25°C to +80°C -20°C to +60°C
<N020> NCB2-12GM35-N0 -25°C to +80°C -20°C to +60°C
<N021> SJ3.5-N-BU -25°C to +80°C -20°C to +60°C
<N022> NBN4-12GM40-Z0 -25°C to +80°C -20°C to +60°C
<N023> NJ2-11-SN-G -40°C to +80°C -20°C to +60°C
<N024> NBB5-18GM40-Z0 -25°C to +70°C -20°C to +60°C
<N025> NCB2-12GM40-Z0 -25°C to +70°C -20°C to +60°C
<N026> NJ4-12GK-N -25°C to +80°C -20°C to +60°C
Recommended Operating Temperatures - continued
Intrinsically Safe
DXP/DXS DXR
Option Switch Description Valvetop w/o Solenoid Valvetop w/Solenoid Valvetop w/o Solenoid Valvetop w/Solenoid
M Mechanical switch - SPDT -40°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
K Mech. switch w/Au contact -40°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
L 35 GO Switch SPDT -60°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
Z 35 GO Switch DPDT -60°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
R Reed Switch SPDT -30°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
T Mechanical switch DPDT not available not available not available not available
8 Mechanical switch DPDT -20°C to +50°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
PS Reed cube with LED not available not available not available not available
PN Reed cube w/no LED -30°C to +55°C -10°C to +50°C not available not available
AS Asi not available not available not available not available
DN DeviceNet not available not available not available not available
FF Foundation Fieldbus -40°C to +80°C -20°C to +80°C -20°C to +80°C -20°C to +80°C
FF Foundation Fieldbus Cold Temp not available -30°C to +80°C not available -30°C to +80°C
MB Mod Bus not available not available not available not available
_X 4-20mA Transmitter not available not available not available not available
_H 4-20 Xmitter with HART -40°C to +55°C -10°C to +50°C -40°C to +55°C -10°C to +50°C
0A 1k potentiometer -40°C to +55°C -10°C to +50°C not available not available
0B 10k potentiometer -40°C to +55°C -10°C to +50°C not available not available
PEPPERL+FUCHS SWITCH OPTIONS - STANDARD

E NJ2-V3-N -25°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
F NJ2-12GK-N -25°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
B NJ2-12GK-SN -40°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
C NJ2-11-N -25°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
J NJ2-11-SN -40°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
7 NJ2-12GM40-E2 -25°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
V NJ3-18GK-S1N -25°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
3 NJ5-30GK-S1N -25°C to +55°C -10°C to +50°C -20°C to +53°C -10°C to +50°C
PEPPERL+FUCHS SWITCH OPTIONS - CUSTOM

<N001> NCB5-18GM40-NO-V1 -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N002> NJ4-12GM-N -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N003> SJ3.5-N -25°C to +60°C -25°C to +60°C -20°C to +53°C -10°C to +50°C
<N004> SJ3.5-SN -50C to +40°C -40°C to +40°C -20°C to +53°C -10°C to +50°C
<N005> NCN4-12GM35-NO -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N006> NJ2-12GK-SN -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N007> SJ3.5-S1N -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N010> NJ5-11-N-G -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N011> NJ2-11-N-G -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N012> NJ3-18GK-S1N -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N013> NJ5-18GK-N -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N014> SC3.5G-N0 -25°C to +60°C -25°C to +60°C -20°C to +53°C -10°C to +50°C
<N018> NCB5-18GM40-NO -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N019> NJ2-12GM40-E2 not available not available not available not available
<N020> NCB2-12GM35-N0 -25°C to +40°C -25°C to +40°C -20°C to +53°C -10°C to +50°C
<N021> SJ3.5-N-BU -25°C to +60°C -25°C to +60°C -20°C to +53°C -10°C to +50°C
<N022> NBN4-12GM40-Z0 not available not available not available not available
<N023> NJ2-11-SN-G -40°C to +40°C -40°C to +40°C -20°C to +53°C -10°C to +50°C
<N024> NBB5-18GM40-Z0 not available not available not available not available
<N025> NCB2-12GM40-Z0 not available not available not available not available
www.topworx.com ™
Notes:
Notes:
www.topworx.com ™
Notes:
™
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. © 2013 Emerson Electric Co.
© 2013 TopWorx, All rights reserved. TopWorx, Valvetop, GO Switch, and Leverless Limit Switch are all trademarks
of TopWorx. All other marks are the property of their respective owners. Information herein – including product
specifications – is subject to change without notice.
ES-01857-1 R11
CP RANGE
COMPACT PNEUMATIC ACTUATORS
INSTALLATION
AND
MAINTENANCE
MANUAL
TABLE OF CONTENTS CP RANGE
INSTALLATION AND MAINTENANCE
SECTION CONTENT PAGE
1 Introduction 3
2 Installation 3
3 Maintenance 5
4 Grease Specification 6
5 Cylinder Seal Replacement 7
6 Fault Detection 8
7 Drawing / Parts List 9
Page 2 of 10 PUB013-003-00
Issue 03/08
INTRODUCTION CP RANGE
1.0 Introduction
This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid Systems CP
range actuators. Users are responsible to follow the instructions in this manual as well as any additional documentation that
has been supplied regarding the actuator or accessories supplied by Rotork Fluid Systems. Should further information or
guidance relating to the safe use of CP Range actuators be required, it will be provided on request. Users are also responsible to
be familiar with and follow any relevant legislation or statutory provisions regarding health and safety.
It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or
on the equipment are properly trained for the work they are performing and are also aware of their responsibilities relating to
health and safety in the workplace. It is extremely important that precautions are taken to avoid spark or static discharge in any
areas of potentially explosive atmosphere.
All Rotork Fluid Systems actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test
certificates and replacement documentation are available upon request. The latest general information regarding any Rotork
product is available on our website www.rotork.com.
INSTALLATION
2.0 Installation
2.1 Electrical Considerations
2.1.1 Any electrical connections required are the responsibilty of the user. Connection documentation is supplied with the actuator.
Refer to the applicable wiring diagram to identify functions of terminals. Verify that the electrical supply characteristics are
compatible with the supplied actuator control components.
2.1.2 Only appropriate certified explosion-proof entry reducers, glands or conduit may be used if the unit is installed in a hazardous
area. Remove any plastic transit plugs. Make cable entries appropriate to the cable type and size. Ensure that threaded
adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with a steel or brass plug. In
hazardous areas an appropriately certified threaded blanking plug must be used.
2.1.3 Access to live electrical conductors is forbidden in hazardous areas unless done under a special permit to work. Otherwise, all
power should be isolated and the unit moved to a non-hazardous area for repair or attention.
2.1.4 The actuator and control components must be protected from electrical spikes, surges, and lightning strikes as well as
magnetic or electro-magnetic fields. This is the responsibility of the user.
2.2 Motive Power Supply (pneumatic, hydraulic)
2.2.1 Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as indicated on the nameplate.
2.2.2 Verify that medium composition (e.g., filtration, hydration) correspond to that for with the actuator was manufactured.
Rotork Fluid Systems must be contacted to verify compatibility of any proposed changes to supply medium.
2.2.3 Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e.g., natural gas).
Note: Depending upon control circuit design, pneumatically powered actuators may exhaust the power supply gas to
atmosphere in the course of normal operation. This may present an unacceptable hazard in some applications. Consult Rotork
Fluid Systems if in doubt as to the suitability of the equipment supplied for your application.
Page 3 of 10 PUB013-003-00
Issue 03/08
INSTALLATION CP RANGE
2.3 Maximum Allowable Temperature
2.3.1 The maximum temperature allowable for standard build actuators is 100°C (212°F). Other maximum temperature build
options are available. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the
nameplate is not exceeded and also, in the case of sites where a potentially explosive atmosphere may exist, that the surface
temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere.
2.3.2 Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply gas will affect actuator
temperature. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures.
The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment
per the guidelines set forth in EN 1127-1 par 6.4.2.
2.4 Operating Environment
2.4.1 The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the
safe use of, or the protection afforded by the actuator. Where appropriate, the user must ensure the actuator is suitably
protected against its operating environment including, but not limited to, lightning strikes, vibration sources and vehicular
movement.
2.4.2 If the unit has a nameplate indicating that it is suitable for installation in potentially explosive atmosphere (hazardous area), it
must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the
nameplate.
2.5 Mechanical Considerations
2.5.1 It is recommended that before lifting an actuator onto a valve, great care is taken to ascertain the position of the valve and
orientate the actuator accordingly.
2.5.2 Rotork actuators can be mounted on valves in almost any desired position. It is usual however to align the centerline of the
cylinder to the centerline of the associated pipe work.
Note: Certain accessory and control components e.g., filter drains, hydraulic reservoirs; require proper orientation with
respect to gravity to function properly. Contact Rotork Fluid Systems if in doubt.
2.5.3 Ensure all fasteners are adequately tighten to avoid loosening during the course of operation, taking into account vibration
induced by the dynamics of the pipeline.
2.54 All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris. Ensure
tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the
dynamics of the pipeline.
2.5.5 When the actuator has been bolted to the flange or adapter, the position of the stop bolts should be checked to ensure full
opening and closing of the valve. If these end of travel positions are not correct, the stop bolts may be adjusted by first
loosening the fixing nut and then screwing the bolts in or out until desired end position is obtained. Stroke the yoke away from
the stop bolt when adjusting, then return it to check position. When the correct positioning is obtained, re-tighten the fixing
nut.
2.5.6 Certain valves incorporate their own stops. In these cases it is recommended that the actuator stop bolt positions coincide
with the valve stop positions.
2.5.7 Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required.
2.5.8 Once in position, the actuator should operate the valve with a smooth continuous action.If uneven operation occurs, the
pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. Flow may be restricted by
undersize pipe or fittings. These could throttle the flow thus reducing the pressure and volume at the actuator and causing
intermittent motion. Further fault detection procedures are outlined in Section 6.
Page 4 of 10 PUB013-003-00
Issue 03/08
MAINTENANCE CP RANGE
3.0 Maintenance
3.1 Rotork actuators are designed to work for long periods of time in the most severe conditions. However, a preventative
approach to maintenance helps prevent costly down time and can actually reduce the cost of ownership. Rotork can provide
an actuator maintenance contract tailored to meet each customer’s individual requirements.
3.2 Any personnel working with or on the equipment must be properly trained for the work they are performing and be aware of
their responsibilities relating to health and safety in the workplace.
3.3 No inspection or repair should be undertaken unless it conforms to any applicable hazardous area certification requirements.
Under no circumstances should any modification or alteration be carried out on the unit as this could invalidate the
certification.
3.4 Before performing maintenance, the actuator should be isolated from remote control signals and the pneumatic/hydraulic
power supply. The system should be then be relieved of any internal pressure prior to disassembly.
3.5 Improper operation, adjustment or maintenance of the actuator and controls may, depending on the application, release
potentially explosive gas and or dangerous liquids.
3.6 After maintenance has been performed and re-assembly completed, follow the inspection guidelines as outlined section 3.6.
3.7 Periodic Inspection
3.7.1 Ensure that the actuator correctly operates the valve within the required cycle time. The actuator should be cycled several
times with all the existing controls e.g., remote control, local control and manual override; particularly if the actuator is not
frequently operated.
3.6.2 Verify that the power gas supply pressure value is within the required range.
3.7.3 Visually inspect external components of the actuator for physical damage.
3.7.4 Check pneumatic/hydraulic connections for leakage. Tighten pipe fittings as required.
3.7.5 Remove dust and dirt build-up from all actuator surfaces. They can inhibit cooling thus raising the temperature of the
actuator above the maximum allowable limit.
3.7.6 Inspect actuator paint work for damaged to ensure continued corrosion protection. Touch-up as required to applicable paint
specification.
Page 5 of 10 PUB013-003-00
Issue 03/08
GREASE AND HYDRAULIC OIL CP RANGE
4.0 Grease and Hydraulic Oil Specifications
4.1 Grease Specification
Manufacturer: Mobil
Trade name: Mobiltemp 78
Colour: Gray/black
Soap type: Inorganic
Oil type: Mineral
Consistency (NLGI GRADE)-ASTM D217: 1
Worked penetration at 25°C-ASTM D217: 295/325 dmm
Dropping point - ASTM D2265 260°C
Viscosity of base oil at 40°C-ASTM D445: 485 cSt
Note: This is the standard grease specification for Rotork Fluid Systems actuators. If an alternative was specified and/or
supplied, it is noted in job specific documentation, which is available upon request.
4.2 Hydraulic Oil Specification
Manufacturer: Mobil
Trade name: DTE 11
Viscosity at 40°C: 16.5 cSt
Viscosity index ASTM: 168
ISO Grade: 16
Pour point: -42°C
Specific weight at 15°C: 0.85 kg/dm3
Equivalent to: Statoil - Hydraway HVX-A15
Note: This is the standard hydraulic oil specification for Rotork Fluid Systems actuators. If an alternative was specified
and/or supplied, it is noted in job specific documentation, which is available upon request.
Page 6 of 10 PUB013-003-00
Issue 03/08
CYLINDER SEAL REPLACEMENT CP RANGE
5.0 Cylinder Seal Replacement

When the cylinder seals must be replaced, either due to a leak or as part of a preventative maintenance programme,
follow the procedure outlined below (reference drawing on page 9).
5.1 Disassembly
5.1.1 Ensure that the power gas supply to the actuator is shut off. For spring-return actuators, the actuator must be positioned
so that the spring is fully extended.
5.1.2 Disconnect power gas supply line from the end flange (item 4).
5.1.3 Unscrew the tie rods (item 24).
5.1.4 Remove the end flange (item 4) and the o-ring (item 14*) from the end flange.
5.1.5 Remove the cylinder tube (item 7) and o-ring (item 14*) that is between the cylinder tube and spring container (item 30)
on spring-return actuators or, on double-acting actuators is between the cylinder tube and housing (item 21).
5.1.6 For spring-return actuators, verify that the actuator is positioned so that the spring is fully extended as instructed in
step 5.1.1.
Note: When the spring is fully extended some spring force remains against the piston.
5.1.7A Double-acting actuators only: Unscrew the piston fixing bolt (item 10) and remove it and washer (item 8).
5.1.7B Spring-return actuators only: Begin to unscrew the piston fixing bolt (item 10). Ensure that the piston is free and sliding
on the shaft as the fixing bolt is unscrewed so that all spring force is released before the fixing bolt is disengaged. Also
ensure that threaded bushing (item 18C) remains fixed inside the axial bar (item 18B). Remove piston fixing bolt (item 10)
and washer (item 8).
5.1.8 Remove the piston (item 5).
5.1.9 Remove the o-rings outside (item 6) and inside (item 9) the piston.
5.2 Reassembly RECOMMENDED TIGHTENING TORQUE

BOLT SIZE NM FT. LBS
M8 20 15
5.2.1 Carefully clean the o-ring grooves and all sealing surfaces.
M10 40 30
M12 55 40
5.2.2 Lubricate all the new o-rings with clean grease and place them in the
M14 110 81
proper locations. M16 220 162
M20 430 317
5.2.3 The assembly procedure is the direct reverse of the disassembly procedure. RECOMMENDED TIGHTENING TORQUE EXCEPTIONS
ACTUATOR TIE RODS (AND CYL FLG TO HOUSING CP065 ONLY)
5.2.4 Reconnect power gas supply lines to the actuator. M16 (CP055) 130 96
M16 (CP065) 180 133
5.2.5 Cycle the actuator several times. It’s movement should be smooth and ACTUATOR HOUSING TO VALVE OR ADAPTER FLANGE
M10 (CP045) 45 33
continuous. If not, refer to Section 6, Fault Detection.
M12 (CP055) 85 63
M20 (CP065) 300 221
* On double-acting actuators item 14 is used in two locations: on both end
of the cylinder tube sealing against the end flange and the housing. On
spring-return actuators item 14 is used in three locations: between the end
flange and cylinder tube, between the cylinder tube and spring can, and
between the spring can and the housing.
Page 7 of 10 PUB013-003-00
Issue 03/08
FAULT DETECTION CP RANGE
6.0 Fault Detection

In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the maintenance technician.
This table is designed to cover as wide a range of Rotork Fluid Systems actuators as possible. Reference to equipment not
supplied should be ignored.
SYMPTOM CAUSE REMEDY
6.1 Erratic movement 6.1.1 Irregular supply of operating 6.1.1.1 Check operating medium for consistent
medium. supply pressure and correct as necessary.
6.1.2 Inadequate lubrication. 6.1.2.1 Dismantle, re-lubricate and reassemble.
6.1.3 Worn parts. 6.1.3.1 Dismantle. Visually inspect for significant

wear. Actuator replacement may be required.
6.1.4 Defective valve. 6.1.4.1 Consult the valve manufacturer's

documentation.
6.2 Short stroke 6.2.1 Incorrectly set stops 6.2.1.1 Check the position of the travel stops and
(valve and /or actuator). readjust as necessary.
6.2.2 Hardened grease. 6.2.2.1 Dismantle, remove any hard grease,

re-lubricate and reassemble.
6.2.3 Debris left in the cylinder or 6.2.3.1 Disassemble cylinder assembly to remove
housing during maintenance. debris. Reassemble cylinder assemble as
necessary.

documentation.
6.3 Apparent lack of power 6.3.1 Inadequate supply pressure. 6.3.1.1 Ensure supply pressure is above the minimum
operating pressure of the actuator and that
output torque produced at supply pressure
exceeds valve torque demand.
6.3.2 Incorrect speed control settings. 6.3.2.1 Adjust speed controls to increase flow.
6.3.3 Exhaust port blocked. 6.3.3.1 Remove and clean the exhaust port
silencers and replace.
6.3.4 Pipe work blocked, crushed 6.3.4.1 Examine the pipe work for blockages,
or leaking. crushed pipe or leakage. Clear or replace
as necessary.
6.3.5 Defective controls. 6.3.5.1 Examine the controls, refurbish or renew

as necessary. Refer to component
manufacturer's documentation.
6.3.6 Defective piston seal. 6.3.6.1 Dismantle the cylinder assembly, remove
the defective piston seal. Fit new seal and
reassemble.
6.3.7 Defective rod seal. 6.3.7.1 Dismantle the cylinder assembly, remove
the defective rod seal. Fit new seal and
reassemble.
6.3.8 High valve torque or valve seized. 6.3.8.1 Consult the valve manufacturers
documentation.
Page 8 of 10 PUB013-003-00
Issue 03/08
DRAWING / PARTS LIST CP RANGE
15
11
DOUBLE-ACTING
29
13
12
21
25 1
14
SPRING-RETURN 7
19
14
26
27
16
23
22
3 17
18A
2
9
14
4 28
24 8 5 30
10 6 18B
18C PARTS FOR SPRING-RETURN ONLY

31
ITEM DESCRIPTION MATERIAL QTY ITEM DESCRIPTION MATERIAL QTY

1 Stop Screw – Housing Carbon Steel 1 17 Spring Pin Spring Steel 1
2 Stop Nut Carbon Steel 2 18A Axial Bar – Double-Acting Alloy Steel (Nit-ox® treated) 1
3 O-ring Buna-N 2 18B Axial Bar – Spring-Return Alloy Steel (Nit-ox® treated) 1
4 End Flange Ductile Iron 1 18C Bushing – threaded Alloy Steel 1
5 Piston Carbon Steel 1 19 Bushing Steel/Bronze/Teflon 1
6 O-ring Buna-N 1 20 Housing Plug (not shown) Carbon Steel 1
7 Cylinder Tube Carbon Steel (Nit-ox® treated) 1 21 Housing Carbon Steel 1
8 Washer Carbon Steel 1 22 Stop Screw – End Flange Carbon Steel 1
9 O-ring Buna-N 1 23 Yoke Ductile Iron 1
10 Piston Retaining Bolt Alloy Steel 1 24 Tie Rod Alloy Steel 4
11 Retaining Ring Spring Steel 1 25 Adapter Plate Ductile Iron 1
12 Key Carbon Steel 1 26 Washer Carbon Steel 2
13 Spring Spring Steel 1 27 Bushing Steel/Bronze/Teflon 2
14 O-Ring Buna-N 28 Yoke Pin Alloy Steel (Nit-ox® treated) 1
15 O-ring Buna-N 4 29 Output Shaft Alloy Steel (Nit-ox® treated) 1
16 Bushing Steel/Bronze/Teflon 1 30 Spring Container Carbon Steel 1
31 Spring Spring Steel 1
Quantity (2) for double-acting, (3) for spring-return.

Spring-return actuators only.
Page 9 of 10 PUB013-003-00
Issue 03/08
Corporate Headquarters
A full listing of our worldwide Rotork plc Electric Actuators and Control Systems
sales and service network is tel

fax
+44 (0)1225 733200
+44 (0)1225 333467 Fluid Power Actuators and Control Systems
available on our website. email [email protected]
Gearboxes and Gear Operators
Precision Control Instruments
www.rotork.com Projects, Services and Retrofit
All Rotork Fluid Systems actuators are manufactured under a third party accredited ISO 9001
quality assurance programme. As we are continually developing our products, their design is
subject to change without notice.
PUB011-004-00
The name Rotork is a registered trademark. Rotork recognises all registered trademarks.
Issue 04/08 Published and produced in the UK by Rotork Fluid Systems. ROWMH1112
GP RANGE
PNEUMATIC SCOTCH YOKE ACTUATORS
INSTALLATION
AND
MAINTENANCE
MANUAL
CONTENTS GP RANGE
SECTION CONTENT PAGE
1 Introduction 3
2 Installation 3
3 Maintenance 5
4 Grease and Hydraulic Oil Specifications 6
5 Cylinder Seal Replacement 7
6 Fault Detection 8
7 Actuator Drawing / Parts List 9
Appendix
A Stop Bolt Adjustment 10
B MB1 Switchbox Setting Procedure 11
Page 2 of 12 PUB011-004-00
Issue 04/08
INTRODUCTION GP RANGE
1.0 Introduction
This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid Systems GP
range actuators. Users are responsible to follow the instructions in this manual as well as any additional documentation that
has been supplied regarding the actuator or accessories supplied by Rotork Fluid Systems. Should further information or
guidance relating to the safe use of GP range actuators be required, it will be provided on request. Users are also responsible to
be familiar with and follow any relevant legislation or statutory provisions regarding health and safety.
It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or
on the equipment are properly trained for the work they are performing and are also aware of their responsibilities relating to
health and safety in the workplace. It is extremely important that precautions are taken to avoid spark or static discharge in any
areas of potentially explosive atmosphere.
All Rotork Fluid Systems actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test
certificates and replacement documentation are available upon request. The latest general information regarding any Rotork
product is available on our website www.rotork.com.
INSTALLATION
2.0 Installation
2.1 Electrical Considerations
2.1.1 Any electrical connections required are the responsibility of the user. Connection documentation is supplied with the actuator.
Refer to the applicable wiring diagram to identify functions of terminals. Verify that the electrical supply characteristics are
compatible with the supplied actuator control components.
2.1.2 Only appropriate certified explosion-proof entry reducers, glands or conduit may be used if the unit is installed in a hazardous
area. Remove any plastic transit plugs. Make cable entries appropriate to the cable type and size. Ensure that threaded
adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with a steel or brass plug. In
hazardous areas an appropriately certified threaded blanking plug must be used.
2.1.3 Access to live electrical conductors is forbidden in hazardous areas unless done under a special permit to work. Otherwise, all
power should be isolated and the unit moved to a non-hazardous area for repair or attention.
2.1.4 The actuator and control components must be protected from electrical spikes, surges, and lightning strikes as well as
magnetic or electro-magnetic fields. This is the responsibility of the user.
2.2 Motive Power Supply (pneumatic, hydraulic)
2.2.1 Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as indicated on the nameplate.
2.2.2 Verify that medium composition (e.g., filtration, hydration) correspond to that for with the actuator was manufactured.
Rotork Fluid System must be contacted to verify compatibility of any proposed changes to supply medium.
2.2.3 Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e.g., natural gas).
Note: Depending upon control circuit design, pneumatically powered actuators may exhaust the power supply gas to
atmosphere in the course of normal operation. This may present an unacceptable hazard in some applications. Consult Rotork
Fluid Systems if in doubt as to the suitability of the equipment supplied for your application.
Page 3 of 12 PUB011-004-00
Issue 04/08
INSTALLATION GP RANGE
2.3 Maximum Allowable Temperature
2.3.1 The maximum temperature allowable for standard build actuators is 100°C (212°F).Other maximum temperature build
options are available. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the
nameplate is not exceeded and also, in the case of sites where a potentially explosive atmosphere may exist, that the surface
temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere.
2.3.2 Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply gas will affect actuator
temperature. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures.
The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment
per the guidelines set forth in EN 1127-1 par 6.4.2.
2.4 Operating Environment
2.4.1 The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the
safe use of, or the protection afforded by the actuator. Where appropriate, the user must ensure the actuator is suitably
protected against its operating environment including, but not limited to, lightning strikes, vibration sources and vehicular
movement.
2.4.2 If the unit has a nameplate indicating that it is suitable for installation in potentially explosive atmosphere (hazardous area), it
must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the
nameplate.
2.5 Mechanical Considerations
2.5.1 It is recommended that before lifting an actuator onto a valve, great care is taken to ascertain the position of the valve and
orientate the actuator accordingly.
2.5.2 Rotork actuators can be mounted on valves in almost any desired position. It is usual however to align the centerline of the
cylinder to the centerline of the associated pipe work.
Note: Certain accessory and control components e.g., filter drains, hydraulic reservoirs; require proper orientation with
respect to gravity to function properly. Contact Rotork Fluid Systems if in doubt.
2.5.3 Ensure all fasteners are adequately tighten to avoid loosening during the course of operation, taking into account vibration
induced by the dynamics of the pipeline.
2.54 All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris. Ensure
tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the
dynamics of the pipeline.
2.5.5 When the actuator has been bolted to the flange or adapter, the position of the stop bolts should be checked to ensure full
opening and closing of the valve. If these end of travel positions are not correct, the stop bolts may be adjusted by first
loosening the fixing nut and then screwing the bolts in or out until desired end position is obtained. Stroke the yoke away from
the stop bolt when adjusting, then return it to check position. When the correct positioning is obtained, re-tighten the fixing
nut.
2.5.6 Certain valves incorporate their own stops. In these cases it is recommended that the actuator stop bolt positions coincide
with the valve stop positions.
2.5.7 Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required.
2.5.8 Once in position, the actuator should operate the valve with a smooth continuous action. If uneven operation occurs, the
pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. Flow may be restricted by
undersize pipe or fittings. These could throttle the flow thus reducing the pressure and volume at the actuator and causing
intermittent motion. Further fault detection procedures are outlined in Section 6.
Page 4 of 12 PUB011-004-00
Issue 04/08
MAINTENANCE GP RANGE
3.0 Maintenance
3.1 Rotork actuators are designed to work for long periods of time in the most severe conditions. However, a preventative
approach to maintenance helps prevent costly down time and can actually reduce the cost of ownership. Rotork can provide
an actuator maintenance contract tailored to meet each customer’s individual requirements.
3.2 Any personnel working with or on the equipment must be properly trained for the work they are performing and be aware of
their responsibilities relating to health and safety in the workplace.
3.3 No inspection or repair should be undertaken unless it conforms to any applicable hazardous area certification requirements.
Under no circumstances should any modification or alteration be carried out on the unit as this could invalidate the
certification.
3.4 Before performing maintenance, the actuator should be isolated from remote control signals and the pneumatic/hydraulic
power supply. The system should be then be relieved of any internal pressure prior to disassembly.
3.5 Improper operation, adjustment or maintenance of the actuator and controls may, depending on the application, release
potentially explosive gas and or dangerous liquids.
3.6 After maintenance has been performed and re-assembly completed, follow the inspection guidelines as outlined section 3.6.
3.7 Periodic Inspection
3.7.1 Ensure that the actuator correctly operates the valve within the required cycle time. The actuator should be cycled several
times with all the existing controls e.g., remote control, local control and manual override; particularly if the actuator is not
frequently operated.
3.7.2 Verify that the power gas supply pressure value is within the required range.
3.7.3 Visually inspect external components of the actuator for physical damage.
3.7.4 Check pneumatic/hydraulic connections for leakage. Tighten pipe fittings as required.
3.7.5 Remove dust and dirt build-up from all actuator surfaces. They can inhibit cooling thus raising the temperature of the
actuator above the maximum allowable limit.
3.7.6 Inspect actuator paint work for damaged to ensure continued corrosion protection. Touch-up as required to applicable paint
specification.
Page 5 of 12 PUB011-004-00
Issue 04/08
GREASE AND HYDRAULIC OIL GP RANGE
4.0 Grease and Hydraulic Oil Specifications
4.1 Grease Specification
Manufacturer: Mobil
Trade name: Mobiltemp 78
Colour: Gray/black QUANTITY OF GREASE IN HOUSING

CENTRE BODY SIZE QTY (kg/lb)
Soap type: Inorganic 065, 085, 100 0.3/0.66
130 0.4/0.88
Oil type: Mineral
160, 161, 200, 201 0.5/1.10
Consistency (NLGI GRADE)-ASTM D217: 1 270, 271 0.8/1.76

350 1.2/2.64
Worked penetration at 25°C-ASTM D217: 295/325 dmm
Dropping point - ASTM D2265: 260°C
Note: This is the standard grease specification for Rotork Fluid Systems actuators. If an alternative was specified and/or
supplied, it is noted in job specific documentation, which is available upon request.
4.2 Hydraulic Oil Specification
Manufacturer: Mobil
Trade name: DTE 11
Viscosity index ASTM: 168
ISO Grade: 16
Pour point: -42°C
Specific weight at 15°C: 0.85 kg/dm3
Equivalent to: Statoil - Hydraway HVX-A15
Note: This is the standard hydraulic oil specification for Rotork Fluid Systems actuators. If an alternative was specified
and/or supplied, it is noted in job specific documentation, which is available upon request.
Page 6 of 12 PUB011-004-00
Issue 04/08
CYLINDER SEAL REPLACEMENT GP RANGE
5.0 Cylinder Seal Replacement
5.1 Disassembly
5.1.1 Disconnect pneumatic and electrical supply connections. For spring return actuators, ensure that the actuator is in the failed
position (i.e., at end of the spring stroke).
5.1.2 Remove stop bolt nut (33).
5.1.3 Loosen stop nut (31) and remove stop bolt (32).
5.1.4 Remove tie rod nuts (34) from the tie rods (22).
5.1.5 Remove bottom flange (21).
5.1.6 Remove cylinder tube (19).
5.1.7 Remove housing cover bolts (16), center body cover (15) and cover gasket (14).
5.1.8 Remove piston retaining nut (35) and separate piston (23), shoulder washer (30), and o-ring (36) from piston rod (20).
5.1.9 Remove o-ring (25) and sliding ring (24) from piston (23).
5.1.10 Remove piston rod (20) by unscrewing it from the guide block (4).
5.1.11 Remove flange retaining bolts (13) and remove head flange (18).
5.1.12 Remove head flange and bottom flange o-rings (26).
5.1.13 Remove bolts (38) and shaft seal retaining flange (37) from the head flange (18).
5.1.14 Remove o-ring (28) and shaft seal (29).
5.1.15 Clean all sealing surfaces.
5.1.16 Coat new o-rings, seals and gaskets with grease.
5.2 Assembly
5.2.1 To reassemble the actuator, follow the disassembly procedure in reverse order.
5.2.2 Reconnect power gas supply lines to the actuator.
5.2.3 Cycle the actuator several times. Movement should be smooth and continuous. If not, refer to Section 6, Fault Detection.
RECOMMENDED TIGHTENING TORQUE

BOLT SIZE NM FT. LBS
M6 8.5 6
M8 20 15
M10 40 30
M12 55 40
M14 110 81
M16 220 162
M20 430 317
M22 425 313
M24 585 431
M27 785 579
M30 1,250 921
M33 1,400 1,030
M36 1,750 1,290
Page 7 of 12 PUB011-004-00
Issue 04/08
FAULT DETECTION GP RANGE
6.0 Fault Detection

In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the maintenance technician.
This table is designed to cover as wide a range of Rotork Fluid Systems actuators as possible. Reference to equipment not
supplied should be ignored.
SYMPTOM CAUSE REMEDY
6.1 Erratic movement 6.1.1 Irregular supply of operating 6.1.1.1 Check operating medium for consistent
medium. supply pressure and correct as necessary.
6.1.2 Inadequate lubrication. 6.1.2.1 Dismantle, re-lubricate and reassemble.
6.1.3 Worn parts. 6.1.3.1 Dismantle. Visually inspect for significant

wear. Actuator replacement may be required.

documentation.
6.2 Short stroke 6.2.1 Incorrectly set stops 6.2.1.1 Check the position of the travel stops and
(valve and /or actuator). readjust as necessary.
6.2.2 Hardened grease. 6.2.2.1 Dismantle, remove any hard grease,

re-lubricate and reassemble.
6.2.3 Debris left in the cylinder or 6.2.3.1 Disassemble cylinder assembly to remove
housing during maintenance. debris. Reassemble cylinder assemble as
necessary.

documentation.
6.3 Apparent lack of power 6.3.1 Inadequate supply pressure. 6.3.1.1 Ensure supply pressure is above the minimum
operating pressure of the actuator and that
output torque produced at supply pressure
exceeds valve torque demand.
6.3.2 Incorrect speed control settings. 6.3.2.1 Adjust speed controls to increase flow.
6.3.3 Exhaust port blocked. 6.3.3.1 Remove and clean the exhaust port
silencers and replace.
6.3.4 Pipe work blocked, crushed 6.3.4.1 Examine the pipe work for blockages,
or leaking. crushed pipe or leakage. Clear or replace
as necessary.
6.3.5 Defective controls. 6.3.5.1 Examine the controls, refurbish or renew

as necessary. Refer to component
manufacturer's documentation.
6.3.6 Defective piston seal. 6.3.6.1 Dismantle the cylinder assembly, remove
the defective piston seal. Fit new seal and
reassemble.
6.3.7 Defective rod seal. 6.3.7.1 Dismantle the cylinder assembly, remove
the defective rod seal. Fit new seal and
reassemble.
6.3.8 High valve torque or valve seized. 6.3.8.1 Consult the valve manufacturers
documentation.
Page 8 of 12 PUB011-004-00
Issue 04/08
DRAWING / PARTS LIST GP RANGE
48 46 44 42 2 3 18 19 22 39 31 33
49 47 45 43 41 1 6 20 23 21 32
50 51 5 26 30 24 34 40
13 4 36 25 26 35 28
CENTRE BODY ASSEMBLY

17 14 16 4 27 38
ITEM DESCRIPTION MATERIAL QTY
51 15 7 8 29
1 Centre body Carbon Steel or Ductile Iron 1
2 Guide Bar Alloy Steel - Chrome Plated 1
Centre body cross-section
3 Safety Valve Brass/Stainless Steel 1
4 Guide Block Carbon Steel 1
10 12 37
5 Yoke Carbon Steel or Ductile Iron 1
13 7 9 11 3 17
6 Guide Block Shaft Bushing Steel/Bronze/PTFE 2
7 O-ring NBR 2 55 53
8 Upper Bushing Bronze 1 54 52
9 Lower Bushing Bronze 1
10 Sliding Block Bronze 2
11 Bar Pin Alloy Steel 1
12 Retaining Ring Spring Steel 2
13 Flange Retaining Bolt Carbon Steel -
57
14 Cover Gasket Vaporflex/SA 1
56
15 Cover Carbon Steel 1
16 Cover Mounting Bolt Carbon Steel Typical fabricated carbon steel centre body and yoke illustrated.
Some models have a cast, ductile iron centre body and yoke.
17 Flange Gasket Vaporflex/SA 2
PNEUMATIC CYLINDER ASSEMBLY SPRING CARTRIDGE ASSEMBLY

ITEM DESCRIPTION MATERIAL QTY ITEM DESCRIPTION MATERIAL QTY
18 Head Flange Carbon Steel 1 41 Head Flange Carbon Steel 1
19 Cylinder Tube Carbon Steel - Nickel Plated 1 42 Driving Flange Carbon Steel 1
20 Piston Rod Carbon Steel - Chrome Plated 1 43 Connecting Rod Carbon Steel - Chrome Plated 1
21 Bottom Flange Carbon Steel 1 44 Bushing Steel/Bronze/PTFE 1
22 Tie Rod Alloy Steel - 45 Spring Canister Carbon Steel 1
23 Piston Carbon Steel 1 46 Spring Spring Steel 1
24 Sliding Ring PTFE/Graphite - 47 Stop Bolt Carbon Steel 2
25 O-ring NBR - 48 Bottom Flange Carbon Steel 1
26 O-ring NBR 2 49 Protection Plug Carbon Steel 1
27 Shaft Bushing Steel/Bronze/PTFE 1 50 O-ring NBR 1
28 Seal Washer Carbon Steel/NBR 2 51 Shaft Bushing Steel/Bronze/PTFE 1
29 Seal Washer NBR/PTFE/Graphite 1
30 Shoulder Washer Alloy Steel 1
CLOSURE ASSEMBLY
31 Stop Bolt Fixing Nut Carbon Steel 1
ITEM DESCRIPTION MATERIAL QTY
32 Stop Bolt Alloy Steel 1
52 Flange Carbon Steel 1
33 Stop Bolt Cap Nut Carbon Steel 1
53 Flange Nut Carbon Steel 4
34 Tie Rod Nut Carbon Steel -
54 Seal Washer Carbon Steel/NBR 2
35 Piston Retaining Nut Carbon Steel 1
55 Stop Bolt Alloy Steel 1
36 O-ring NBR 1
56 Stop Bolt Cap Nut Carbon Steel 1
37 Seal Retaining Flange Stainless Steel 1
57 Stop Bolt Fixing Nut Carbon Steel 1
38 Seal Retaining Flange Bolt Stainless Steel 2
39 Bushing Carbon Steel 1 Quantity varies with size of the actuator.
40 O-ring NBR 1 Included in centre body seal kit.
Included in pneumatic cylinder seal kit.
Page 9 of 12 PUB011-004-00
Issue 04/08
APPENDIX A - Stop Bolt Adjustment GP RANGE
1.0 Overview 1.3 Jackscrew

(See figure 3)
All RFS G Range actuators (ie., GP, GH, GO and HPG) incorporate adjustable stops
to limit the degree of travel in both directions. Steps are outlined below for Note: The jackscrew is not designed
to function as a travel stop.
adjustment of the three stop configurations: pneumatic/hydraulic cylinder, spring
Stroking the actuator against
cartridge and, jackscrew. the jackscrew may damage it.
Actuators may be damaged by improper adjustment procedure. Strictly follow 1.3.1 Remove stop bolt cover.
the instructions as outlined below with particular attention to the warnings is
1.3.2 Loosen stop nut.
steps 1.1.3, 1.2.2, 1.3 and 1.3.3.
1.3.3 Turn jackscrew fully in to
1.1 Pneumatic/Hydraulic 1.2 Spring Canister compress spring and remove
Cylinder (See figure 1) (See figure 2) any load from the stop. Failure
to do so may result in damage
1.1.1 Remove stop bolt cover. 1.2.1 Remove the spring stop cap. to the actuator!
1.1.2 Loosen stop nut. 1.2.2 Depressurize the cylinder to On fail close actuators, this is
allow the spring to relax. done by turning the
1.1.3 Apply pressure to outboard Failure to do so may result in handwheel anti-clockwise.
side of cylinder to remove load damage to the actuator!
from stop bolt. Failure to do so On fail open actuators, this is
may result in damage to the 1.2.3 Adjust the spring stop in/out as done by turning the
actuator! desired. handwheel clockwise.
1.1.4 Adjust stop bolt in/out as 1.2.4 Pressurize to outboard side of 1.3.4 Adjust stop bolt in/out as
desired. power cylinder sufficiently to desired.
induce a complete stroke of
1.1.5 Remove pressure from cylinder the actuator and then check 1.3.5 Back jackscrew out (opposite
to verify stop position. the stop position. direction of as determined in
1.3.3) until seated against stop
1.1.6 Repeat steps 1.1.3 - 1.1.5 as 1.2.5 Repeat steps 1.2.2 - 1.2.4 as screw to verify stop position.
necessary to achieve desired necessary to achieve desired
degree of travel. degree of travel. 1.3.6 Repeat steps 1.3.3 - 1.3.5 as
necessary to achieve desired
1.1.7 Once desired position is 1.2.6 Once the desired position is degree of travel.
achieved, tighten stop nut, achieved, replace spring stop
ensuring sealing washer is cap. 1.3.7 Once desired position is
properly centered on the shaft achieved, tighten stop nut,
and fitted in the machined ensuring sealing washer is
recess in the flange. properly centered on the shaft
and fitted in the machined
1.1.8 Re-install stop cover, ensuring recess.
SPRING STOP
sealing washer is properly
SPRING STOP CAP
centered on the shaft and 1.3.8 Re-install stop cover, ensuring
fitted in the machined recess in sealing washer is properly
the stop cover. centered on the shaft and
fitted in the machined recess in
the stop cover.
figure 2
STOP SCREW
SEALING WASHER
STOP NUT STOP SCREW
SEALING WASHER SEALING WASHER
STOP BOLT COVER STOP NUT
SEALING WASHER
STOP BOLT COVER
figure 1
figure 3
Page 10 of 12 PUB011-004-00
Issue 04/08
APPENDIX B - MB1 Switch Adjustment GP RANGE
1.0 MB1 Limit Switch Adjustment

The MB1 is a Rotork Fluid Systems designed and manufactured switch enclosure suitable for use in harsh and/or hazardous
environments. It is available with either dry contact or proximity type switches. Consult the applicable job specific wiring
diagram for termination details. Contact Rotork Fluid Systems switch options and certification details.
1.1 Setting Dry Contact Switches 1.2 Setting Proximity Type Contact Switches
1.1.1 Loosen the four screws (1) and remove the cover (2). 1.2.1 Loosen the four screws (1) and remove the cover (2).
1.1.2 Setting the CLOSE limit switch.
1.2.2 Setting the CLOSE limit switch.
1.1.2.1 Place the actuator/valve in the fully CLOSED position.
1.2.2.1 Place the actuator/valve in the fully CLOSED position.
1.1.2.2 Locate the proper switch cam.
1.1.2.3 Loosen the setscrew (5) and rotate the cam (4) until
the switch operates. Tighten the setscrew. The 1.2.2.3 Loosen the setscrew (5) and rotate the cam (4) until
switch is now set. it is on the same axis as the switch and re-tighten the
setscrews.
1.1.3 Setting the OPEN limit switch.
1.2.2.4 Loosen the fixing nuts on the switch. Position the
1.1.3.1 Place the actuator/valve in the fully OPEN position. switch the proper distance from the cam to activate
the switch. Re-tighten the fixing and lock nuts. The
1.1.3.2 Locate the proper switch cam. switch is now set.
Loosen the setscrew (5) and rotate the cam (4) until
the switch operates. Tighten the setscrew. The 1.2.3 Setting the OPEN limit switch.
switch is now set.
1.2.3.1 Place the actuator/valve in the fully OPEN position.
1.1.4 Replace the cover (2) and tighten the four screws (1).
1.2.3.3 Loosen the setscrew (5) and rotate the cam (4) until
it is on the same axis as the switch and re-tighten the
setscrew.
1.2.3.4 Loosen fixing nuts on the switch. Position the switch

the proper distance from the cam to activate the
switch. Re-tighten the fixing and lock nuts.The
switch is now set.
1.2.4 Replace the cover (2) and tighten the four screws (1).
ITEM DESCRIPTION
1 Screw
2 Cover
3 Microswitch
4 Cam
5 Dowel
Page 11 of 12 PUB011-004-00
Issue 04/08
Corporate Headquarters
A full listing of our worldwide Rotork plc Electric Actuators and Control Systems
sales and service network is tel

fax
+44 (0)1225 733200
+44 (0)1225 333467 Fluid Power Actuators and Control Systems
available on our website. email [email protected]
Gearboxes and Gear Operators
Precision Control Instruments
www.rotork.com Projects, Services and Retrofit
All Rotork Fluid Systems actuators are manufactured under a third party accredited ISO 9001
quality assurance programme. As we are continually developing our products, their design is
subject to change without notice.
PUB011-004-00
The name Rotork is a registered trademark. Rotork recognises all registered trademarks.
Issue 04/08 Published and produced in the UK by Rotork Fluid Systems. ROWMH1112

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Installation, Operation and

Maintenance Instructions for

1 Handling of Valve Actuator Assembly

Installation, Operation and maintenance

3 Control Panel - operating instructions

Installation And Maintenance Manual – CP Range

Installation And Maintenance Manual – GP Range

out safely and following the local safety regulations

Method to lift a Typical valve assembly

REV. DATE MODIFICATION DETAILS PREPARED CHECKED APPROVED

6.5 Flanged End Connections

6.7 Bolting Arrangement

7.4 Electrical Actuators

7.5 Pneumatic Actuators

7.6 Operator Accessories

8.0 In-line Maintenance

9.2 Packing Replacement

11.0 Trouble Shooting Guide

Leaks through gland a. Packing loosened a. Tighten Gland nuts (9.1)

TABLE I – Retainer bolt tightening torque in Nm

TABLE II - Gland tightening torque in Nm (Max)

1) Refer drawing LT3A2260 for pneumatic circuit diagram.

2) Refer drawing LT3A2263 for electrical circuit diagram.

3) Ensure the air filter regulator set pressure is 4 kg/cm2(g).

8) Press close button in the LCS to close the ROSOV.

Air failure: ROSOV will close

Electrical failure: ROSOV will close

WI-ROSOV-IOCL-Rev.1 (Applicable for Batch – 2)

DRAWING DESSIN ZEICHNUNG DRAWING DESSIN ZEICHNUNG

IT ¬ Disponibile nel Kit parti di ricambio DE BESCHREIBUNG

SCG327A617V / 618V / 657V / 658V C117641V combinatie 15. Handbediening, adapterknop

The image to the left shows a Valvetop unit mounted parallel to

The image to the right shows a Valvetop mounted perpendicular

Dimensions and Materials: Valvetop DXP

304 Stainless Steel standard

Shaft Bushing Oilite Bronze

Indicator Dome Polycarbonate, UV F1 rated

O-ring seals available in: Buna,

Fastener Torque Specifications

Dimensions and Materials: Valvetop DXP - Flameproof Ex d IIC

304 Stainless Steel standard

Shaft Bushing Oilite Bronze

Indicator Dome Polycarbonate, UV F1 rated

O-ring seals available in: Buna,

Fastener Torque Specifications

Dimensions and Materials: Valvetop DXS

Enclosure Cast 316 Stainless Steel

304 Stainless Steel standard

304 Stainless Steel standard

Shaft Bushing N/A

Indicator Dome Polycarbonate, UV F1 rated

O-ring seals available in:

Fastener Torque Specifications

Dimensions and Materials: Valvetop DXR

Fastener Torque Specifications

Mechanical Switches: Options M2/M4/M6/K2/K4/K6/T2

Mechanical Switch Assembly

Switch Option M2/K2/T2 Switch Option M4/K4 Switch Option M6/K6

Mechanical Switches: Options M2/M4/M6/K2/K4/K6/T2

Wiring Diagrams and Charts