TopWorx™ T-Series Valve Controllers

Installation, Operation & Maintenance Manual

 Emerson™
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Table of Contents
Table of Contents ………………………………………………………... 3
Installation on Actuator………………………………………………... 4
Normal and Reverse Acting……………………………………... 4
Mounting.……………………………………………………………... 4
TXP Dimensions and Materials…………………………………….... 5
TXP Flat Top Dimensions and Materials …………………………. 6
TXS Dimensions and Materials………………………………………. 7
TXS Flat Top Dimensions and Materials………………………….. 8
Shaft Detail …………………………………………………………………. 9
Sensors Basic Function ……………………………………………….... 10
Switch Setting ……………………………………………………….. 10
Switch Option L.. ……………………………………………………..11
Switch Option M or K ……………………………………………... 12
Switch Option T ……………………………………………………. 12
Switch Option P or R ………………………………………………. 13
Switch Option E …………………………………………………….. 14
Switch Option 12 …………………………………………………... 15
Switch Option 42/44 and 52/54 ………………………………. 16
Switch Option 0X …………………………………………………... 17-19
Switch Option AS/AM: AS-i ……………………………………... 20
Switch Option PB/PM: Profibus ……………………………….. 21-22
Integrated Pneumatic Pilot …………………………………….. 23
Integrated Pneumatic Control Valves …………………….... 24
Maintenance ………………………………………………………………. 24
Approvals & Certifications ………………………………………..….. 25
Safety Functions………………………………………………………….. 26
Safe Use ……………………………………………………………….. 27
Recommended Operating Temperatures…………………. 27
Warranty …………………………………………………………….... 30

3
Installation on Actuator
Normal and Reverse Acting
Normal acting is full clockwise (CW) when the process valve is closed and counter-clockwise (CCW) when the process valve is open. Reverse
acting is full CW when the process valve is open and CCW when the process valve is closed.

Indicator dome assemblies are designed to accommodate both Normal and Reverse Acting units. When the unit is Reverse Acting, the
indicator dome assembly will have to be rotated.

The image to the right shows a TopWorx™ 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.

Installation on Actuator
Mounting
TopWorx™ has numerous mounting bracket kits available to meet your specific application,
whether rotary or linear. Consult your local distributor or factory representative for ordering
information. The illustration shows a direct Namur mount on a quarter turn valve. Refer to
your mounting kit documentation for specific mounting instructions.

Installation Notes
1. Remove the upper housing of the unit to allow access to the target cam assembly.

2. Hold the unit above the mounting surface in the orientation in which you intend to mount.
Rotate the shaft to align the tang with the actuator slot. In some cases it may be necessary to
rotate the target cam on the shaft to allow assembly. For most units the target cam is secured
with a compression spring. Simply grasp the cam, push down, and realign the cam as re-
quired. On some units the target cam is secured with a snap ring. On these units the removal
of the shaft from the base assembly will be required to change the orientation. Once removed
from the base assembly, remove the snap ring securing the target cam and rotate as required.

3. Use caution not to allow undue axial (thrust) load on the shaft.

4. 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. Refer to the Proof Testing section for
proper safety function setup.

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

6. 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 outdoors or when installed.

7. 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.

4
Dimensions and Materials: TopWorx™ TXP

MATERIALS OF CONSTRUCTION

Cast A360 aluminum with chromate

conversion coating inside & out, epoxy
Enclosure
coated exterior rated for 1,000 hrs salt
spray per ASTM B117

VALVE OPTIONAL
304 Stainless Steel standard
Fasteners
SEE INTEGRATED 316 Stainless Steel optional
PNEUMATIC CONTROL
VALVES SECTION 304 Stainless Steel standard
Shaft
316 Stainless Steel optional

Shaft Bushing ASTM C83600 Bronze

Indicator Dome Polycarbonate, UV F1 rated

Silicone/EPDM (Other materials availa-

Seals
ble upon request)

Fastener Torque Specifications

Enclosure Housing Bolts 8 ft-lbs [10.8 N·m] +/- 10%

Indicator Dome Screws 200 in-oz [141 mN·m] +/- 10%

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

5
Dimensions and Materials: TopWorx™ TXP Flat Top

MATERIALS OF CONSTRUCTION
Cast A360 aluminum with chromate
conversion coating inside & out, epoxy
Enclosure
coated exterior rated for 1,000 hrs salt
VALVE OPTIONAL
spray per ASTM B117
SEE INTEGRATED
304 Stainless Steel standard
PNEUMATIC Fasteners
CONTROL VALVES 316 Stainless Steel optional
SECTION
304 Stainless Steel standard
Shaft
316 Stainless Steel optional
Shaft Bushing ASTM C83600 Bronze
Silicone/EPDM (Other materials availa-
Seals
ble upon request)

Fastener Torque Specifications

Enclosure Housing Bolts 8 ft-lbs [10.8 N·m] +/- 10%
Bottom Mounting Holes 10 ft-lbs [13.6 N·m] +/- 10%

6
Dimensions and Materials: TopWorx™ TXS

MATERIALS OF CONSTRUCTION

Enclosure Stainless steel. 316

304 Stainless Steel standard

Fasteners
316 Stainless Steel optional

304 Stainless Steel standard

VALVE OPTIONAL Shaft
SEE INTEGRATED 316 Stainless Steel optional
PNEUMATIC
CONTROL VALVES Shaft Bushing 316 Stainless Steel
SECTION
Indicator Dome Same as TXP Dome
Buna/EPDM (Other materials available
Seals
upon request)

Fastener Torque Specifications

Enclosure Housing Bolts 8 ft-lbs [10.8 N·m] +/- 10%
Indicator Dome Screws 200 in-oz [i41 m N m] +/- 10%

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

7
Dimensions and Materials: TopWorx™ TXS Flat Top

MATERIALS OF CONSTRUCTION

Enclosure Stainless steel. 316

304 Stainless Steel standard

VALVE OPTIONAL Fasteners
SEE INTEGRATED
316 Stainless Steel optional
PNEUMATIC
CONTROL VALVES 304 Stainless Steel standard
Shaft
SECTION 316 Stainless Steel optional

Shaft Bushing 316 Stainless Steel

Silicone/EPDM (Other materials availa-

Seals
ble upon request)

Fastener Torque Specifications

Enclosure Housing Bolts 8 ft-lbs [10.8 N·m] +/- 10%
Bottom Mounting Holes 10 ft-lbs [13.6 N·m] +/- 10%

8
Dimensions and Materials: Shaft Detail

TXP/TXS NAMUR Shaft

TXP/TXS Linear Shaft

9
Sensors: Basic Function
Each T-Series unit is equipped with 2 or 4 adjustable targets with a usable range between 45° and 90°. For normal acting applications the
targets are color coded red for closed and green for open. The color code would be reversed for reverse acting units. After installing the unit
on the actuator or valve assembly, the targets must be set.

Normal acting
1. Rotate the valve full CW to the closed position.
2. Twist the red target button(s) CW or CCW as required to engage the switch (refer to the specific switch section for testing
and confirmation information about your switch type).
3. Rotate the valve full CCW to the open position.
4. Twist the green target button(s) CW or CCW as required to engage the switch (refer to the specific switch section for test-
ing and confirmation information about your switch type).

Reverse acting
1. Rotate the valve full CW to the open position.
2. Twist the red target button(s) CW or CCW as required to engage the switch (refer to the specific switch section for test-
ing and confirmation information about your switch type).
3. Rotate the valve full CCW to the closed position.
4. Twist the green target button(s) CW or CCW as required to engage the switch (refer to the specific switch section for
testing and confirmation information about your switch type).

Normal-acting open position Normal-acting closed position

- or - - or -
Reverse-acting closed position Reverse-acting open position

CLOSED

Setting Switches
Unlock the green and red targets. Stroke the actuator open
and closed to ensure there is no obstruction in it’s stroke. Once OPEN
the actuator is at the desired position, twist the knob on the
cam until the switch is made and lock the target. The red knob
is for closed and the green knob is for open.

For switching angles less than 45 degrees or more than 90 de-

grees, consult factory for proper configuration.

10
Switch Option L2: GO Switches

GO Switches are dry contact, so they consume no power to

operate and have no voltage drop or leakage current.

Wiring Diagram

ES-00631-R2

Repeatability .002" (.05 mm)

Response Time 8 milliseconds

0.020 to 0.150 (0.5mm to

Differential
3.8mm)

Operating -76° to 221°F

Temperature (-60° to 105°C)
Silver cadmium oxide,
Contact Material
gold flashed
Forms SPDT, Form C
Electrical Ratings 4A@120VAC / 3A@24VDC

Target Material Ferrous metal

Sensing Range Approx. 1/10" (2.5 mm)

Sensing Range
3 5/8" (92mm) (max)
with Target Magnet

Also available from TopWorx™ : The TopWorx™ D-Series with DPDT, Stainless Steel GO Switches.
Call Inside Sales or email [Link]@[Link] for more details

11
Switch Option M2/M4 or K2/K4: SPDT Mechanical Switches PRODUCT SPECIFICATIONS
When installing units with M or K switches a standard voltage ohm OPTION M
meter may be used to set the target cams by looking for continuity
Switch Type Mechanical
between the N/O and
COMMON wires. Sealed No
Circuitry SPDT
Wiring Diagram Termination Quick Connect
Rating 10A@125VAC or 250VAC
Conforming to standards UL: 1054
Contact Resistance 15MΩmax. (initial)
Insulation Resistance 100MΩmin. (at 500V DC)
OPTION K
Switch Type Mechanical
Sealed No
Circuitry SPDT
Termination Quick Connect
Rating 10A@125VAC or 250VAC
Conforming to standards UL: 1054

Switch Option T2: DPDT Mechanical Switches

When installing units with T switches a standard voltage ohm
meter may be used to set the target cams by looking for continuity
between the N/O and COMMON wires.

Wiring Diagram

PRODUCT SPECIFICATIONS
Switch Type Mechanical
Sealed No
Circuitry DPDT
Termination Quick Connect
Rating 8A 125V AC or 250V AC
UL recognized and CSA certified, meets
Conforming to standards
MIL-S-8805
Contact Silver
Terminals End Solder

12
Switch Options P2 or R2/R4: SPDT Reed Proximity Switches
When installing units with P or R switches a standard voltage ohm meter may be used to set the target cams by looking for continuity
between the N/O and COMMON wires.

Wiring Diagrams (R2/P2)

ES-00626-R4

PRODUCT SPECIFICATIONS
P Option
Switching Voltage VDC 120V Max

Carry Current 3 Amp Max

Power Rating 3 - 100 Watt

Contact Material Tungsten

R Option
Switching Voltage DC/AC 30V Max

Carry Current 0.5 Amp Max

Switching Current 0.2 Amp Max

Power Rating 3 Watt

Contact Material Rhodium

13
Switch Option E2/E4: Inductive NAMUR Sensors
Basic inductive sensors
 2mm sensing range
 Flush mountable
 NAMUR output
 Intrinsically safe when connected to
an approved switch isolator

Wiring Diagram: Switch Option E2

PRODUCT SPECIFICATIONS
General specifications
Wiring Diagram: Switch Option E4 Switching element function NAMUR NC
Rated operating distance sn 2 mm
Installation embeddable
Output polarity NAMUR
Assured operating distance sa 0 ... 1.62 mm
Reduction factor rAl 0.25
Reduction factor rCu 0.2
Reduction factor rV2A 0.7
Nominal ratings

Nominal voltage Uo 8V
Switching frequency f 0 ... 1000 Hz
ES-00626-R4
Hysteresis H typ. %

Current consumption
Measuring plate not detected ≥3 mA
Measuring plate detected ≤1 mA
Standard conformity
When installing TopWorx™ products with P&F sensors we EMC in accordance with IEC / EN 60947-5-2:2004
suggest using a commercially available switch tester like DIN EN 60947-5-6
Standards
P&F part number: ST0-03 switch tester. (NAMUR)
Ambient conditions
Ambient temperature -25 ... 100 °C (248 ... 373 K)
Mechanical specifications
Connection type Core cross- 130 mm, PVC cable 0.14
section mm2
Housing material PBT
Sensing face PBT
Protection degree IP67
General information
Use in the hazardous area see instruction manuals
Category 1G; 2G; 1D

14
Switch Option 12: Inductive Sensors

Wiring Diagram

PRODUCT SPECIFICATIONS
BROWN
+V
Item Standard
Switch Option 1 - M12 body 5mm sensing PROXIMITY
SENSOR MAIN
BLACK
CIRCUITS

Differential travel 10% max. of sensing distance

LOAD

Power supply voltage 12 ~ 24 VDC. Ripple (p~p): 10% max. (10 ~ 30 BLUE
0V
(operating voltage range) VDC)
Current consumption
10 mA max.
(DC 3-wire)
Output type PNP

Control output 200 mA max. (32 VDC max.) [see Note 1]

1.0 V max. (under load current of 200 mA with cable
Residual voltage
length of 2m)
Operation mode (with
N/O
sensing object approaching)
Output reverse polarity protection, Power source
Protection circuit circuit reverse polarity protection, Surge suppressor,
Short-circuit protection
Operating: -40°C to 70°C, Storage: -40°C to 85°C
Ambient air temperature
(with no icing or condensation)
±10% max. of sensing distance at 23°C within
Temperature influence temperature range of -25°C to 70°C ±15% max.
(See note 1 below) of sensing distance at 23°C within temperature
range of -40°C to 70°C
Ambient humidity Operating: 35% to 95%, Storage: 35% to 95%
±1% max. of sensing distance in rated voltage
Voltage influence
range ±15%
50 MΩ min. (at 500 VDC) between current carry
Insulation resistance
parts and case
1,000 VAC at 50/60 Hz for 1 min between current
Dielectric strength
carry parts and case
10 to 55 Hz, 1.5mm double amplitude for 2 hours
Vibration resistance
each in X, Y and Z directions
Shock resistance 1,000 m/s2, 10 times each in X, Y and Z directions
IEC60529: IP66, Degree of protection EN60947-5-2:
Standards and listings
EMC
Note 1: When using any model at an ambient temperature between -40°C and -25°C and a power
voltage between 30 and 32 VDC, use a load current of 100 mA max.,

15
Switch Option 42/44 or 52/54: Inductive Sensors

42 Wiring Diagram

44 Wiring Diagram

54 Wiring Diagram

52 Wiring Diagram

Switch Option 42/44 Switch Option 52/54

SUPPLY VOLTAGE 10-30 VDC SUPPLY VOLTAGE 5-60 VDC
LOAD CURRENT (IL) 100 mA max. LOAD CURRENT (IL) 100 mA max.
LEAKAGE CURRENT (OFFSTATE) 0.05 mA typ., 0.1 μA at 25ºC LEAKAGE CURRENT (OFFSTATE) 0.05 mA typ., 0.1 μA at 25ºC
OUTPUT PNP normally open OUTPUT 2 Wire DC normally open
VOLTAGE DROP AT IL (MAX.) ≤3V VOLTAGE DROP AT IL (MAX.) ≤ 5 VDC
HYSTERESIS — HYSTERESIS Typ. 0.2mm
SHORT CIRCUIT AND SHORT CIRCUIT AND
Yes No
OVERLOAD PROTECTION OVERLOAD PROTECTION
REVERSE POLARITY Yes REVERSE POLARITY Yes
FACE MATERIAL PBT FACE MATERIAL Crastin
STANDARDS EN 60947-5-2 STANDARDS IEC / EN 60947-5-2:2004
PROTECTION DEGREE IP67 ENVIRONMENTAL PROTECTION IP67
-14 ºF to +158 ºF -14°F to +185°F
AMBIENT TEMPERATURE AMBIENT TEMPERATURE
(-25.6 ºC to +70 ºC) (-25.6 ºC to +85 ºC)

16
Switch Option 0X: 4-20mA Position Transmitter

Wiring Diagram

ELECTRICAL DATA

Voltage Input Range 8.5 - 34 Volts DC

Standard Output Signal Two wire 4-20mA with out of range indicaƟon

Input Polarity Bi-DirecƟonal

The 2-wire 4-20mA transmiƩer will generate a nomi-

nal 4 – 20mA output for full-range actuaƟon of the
Primary Usage valve. The generaƟng signals below 4mA and above
20mA if the posiƟon sensor indicates an out of range
value.
Any rotaƟon range between 20 and 320 degrees.
Factory set for 20 to 180 degree operaƟon in counter
RotaƟon
clockwise rotaƟon to open and 20 to 90 degree oper-
aƟon in clockwise rotaƟon to open applicaƟons.
Modes OpƟonal linear and rotary modes

Linearity +/- 1%*

Repeatability 0.3%*

Hysteresis 0.5%*
Temperature -40 to 85C
*Indicated linearity, repeatability and hysteresis is for the device only. Installed
specificaƟons will depend on the total mechanical and electrical
system's capability.

17
Switch Option 0X: 4-20mA Position Transmitter
Apply power to
device, LED on Calibration Flow Chart

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 occurred,
LED flashes code 4-5
Device stores set points, LED on
Greater than allowed
rotation has occurred,
LED flashes code 4-6
Is malfunction detected
in stored set points? NO

YES
Internal error, LED

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. In rotary
mode, 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 other user-selectable option is to
calibrate the device without the over and under travel capability (Linear Mode.) See the calibration flow chart in this document for addi-
tional information.
18
Switch Option 0X: 4-20mA Position Transmitter
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

DEADBAND
During calibration, make sure the potentiometer is not rotating through INDICATION
its deadband area. The red dot located on the potentiometer should not
rotate through the area marked with red during the full rotation of the
valve. If it does, reposition the shaft.

19
 MECHANICAL SWITCHES OR
Bus Option AS/AM: AS-i protocol REED SWITCHES

Wiring Diagram ASI BOARD

MOUNTING BRACKET

Openness 800+ products, 150 Vendors

Type of Network Sensor Bus
Physical Media 2-wire cable (flat or round)
Network Topology Bus, Ring, Tree, Star
Maximum Devices
v2.0 31 nodes (or 248 I/O points)
v2.1 62 nodes (or 434 I/O points)
Maximum Distance
Maximum Distance 100 meters
Maximum Distance with repeaters
300 meters
(max. of 2 repeaters can be used)
Communication Methods
Transmission Properties 5 mSec latency max. on fully loaded segment
 Master/Slave with cyclic polling
Primary usage
 Manchester Bit Encoding implemented via Alternating Pulse Modulation (APM)
v2.0 Discrete Signals
v2.1 Discrete Signals (supports 12 bit analog signals accessed over 5 cycles)
 Limited to 200mA per device power consumption
Power & Communications on same pair
 Requires AS-i specific power supply on communications bus for de-coupling
 Devices can be supplied from bus (<200mA)
 Additional power can be supplied by AS-i power bus cable having multiple power supplies
Device Power Supply
(required for higher power outputs)
 Supply shall be powered by a limited-voltage power supply
Wiring Types
Round: Normal 2 wire cable. #16AWG (1.5mm)
Flat: 2 wire flat AS-i cable (1.5mm conductors) Yellow for communications / Black for additional power
Grounding aspects Ungrounded communications bus
Shielding Unshielded wire
Terminators No terminators required
Device Addressing Automatic when connected one at a time to the segment or with Handheld Addressing Unit
Governing Body ATO (AS-i Trade Organization)
Website [Link]

Data bit Bit Function Input Output

D0 Input I1 / Output O1 Closed limit Red Solenoid switch 1
D1 Input I2 / Output O2 Open Limit Green Solenoid switch 2
D2 Input I3 / Output O3 N/A Solenoid switch 3

AS-I Bit-Settings D3 Input I4 Fault signal (optional) N/A

Parameter bit Bit Function Configuration Code
P0 not used Extended ID code 1 7
P1 not used IO code 7
P2 not used Extended ID code 2 E
P3 not used Parameter 8
Watchdog on ID code A

20
Bus Option PB/PM: Profibus Protocol MECHANICAL SWITCHES OR
REED SWITCHES

PB/PM Wiring Diagram

ASI BOARD

MOUNTING BRACKET

Type of Network Device Bus

Physical Media Twisted pair, fiber

Network Topology Bus, Ring, Star

max. 126 stations on one bus
(maximum of 244 bytes input
Maximum Devices
and output data possible for
each slave)
Maximum Distance
93.75Kbps and less – 1200 meters
500Kbps – 400 meters
DP
1.5Mbps – 200 meters
12Mbps – 100 meters

Max Distance with repeater

9,500 meters with repeaters
(max. of 9 repeaters can be used)

Communication Methods Peer-to-peer, multicast or cyclic master-slave (uses token passing sequence)
Primary usage Used for Discrete and Analog for PLC, Variable Speed Drives, Remote I/O communications

Power and Communications Power is supplied separately from communications bus (can be supplied on a parallel power bus)

Devices are powered separately from communications bus. A 5A maximum fuse muse be placed in series
Device Power Supply
with the input power terminals.
Wiring Types Shielded twisted pair #22 AWG
Device Addressing Handheld/Software only

Governing Body PROFIBUS International (PI)

Web Site [Link]

(Continued next page.)

21
Switch Option PB/PM: Profibus Protocol (Continued)
Technical Data

Power requirements Line Parameters Line Type A Line Type B

PROFIDP 4I20 V1.2 24VDC +- 10% Impedance 135 to 165 100 to 130
Max I = 530mA
(solenoid/s activated) Capacitance per unit length (pF / m) <30 <60
Idle I = 24mA
Loop resistance (/ km) 110 ---

Core Diameter (mm) 0.64 >0.53

Core cross section (mm2) >0.34 >0.22

Profibus info Recommended Line Lengths

ID 09ED HEX Transmission rate (kBaud) 9.6 19.2 93.75 187.5 500 1200 1500

GSD file [Link] Line type A 1200 1200 1200 1000 400 200 100

Transmission Speed 12Mbaud Line type B 1200 1200 1200 600 200 - -

Software Parameters
OUTPUT BYTE 1 Fail Closed Fail Open Dual Coil INPUT BYTE 1
BITS BITS

7 n/a n/a n/a n/a 7 n/a n/a

6 n/a n/a n/a n/a 6 n/a n/a
5 n/a n/a n/a n/a 5 n/a n/a

4 n/a n/a n/a n/a 4 n/a n/a

3 n/a n/a n/a n/a 3 SPARE Input 4
2 n/a n/a n/a n/a 2 SPARE Input 3

1 Output 2 n/a n/a High Closed 1 High Closed Input 2

0 Output 1 High Open High Closed High Open 0 High Open Input 1
Low Closed Low Open

Diagnostic BYTE 1 Profibus Board

BITS
7 n/a

6 n/a
5 n/a

4 n/a

3 n/a

2 Hard Wired high

1 Hard Wired high

0 Hard Wired high

22
Integrated Pneumatic Pilots
The 15 mm pilot valve has been designed and developed by TopWorx™ as a logical evolution of the traditional product range manufactured
for the pneumatic market. The 15 mm solenoid valve is designed for those applications, more and more common on the actual market,
where besides high performances in terms of pressure and flow, minimum dimension, very low power consumption and high reliability even
at high cycling rates are specified.

All the 15mm pilot valves feature:

 Heat-resistant bobbin molded with 30%
glass-filled polyester (PBT)
 Class H 200°C copper wire according INTEGRATED
to IEC 317-8
 Encapsulation with specially designed,
high-quality, glass-filled polyamide (PA66)
 Stainless steel guiding tube
 Plunger and core made of magnetic
stainless steel specially designed for INTEGRATED
solenoid applications

Contact factory for technical pilot valve information

23
Integrated Pneumatic Control Valve Hookup Procedures A flow control may be used in Port 3, but should NEVER BE USED in
Prior to connecting the supply air to the spool valve, flush the Port 5. Any blockage or restriction may cause an internal pressure
system to remove any debris or contaminates. Galvanized pipe build-up inside the enclosure and pose a safety issue.
can easily flake and contaminate the system and therefore is not
recommended. A 40 micron point of use filter at every device is Spool Valve Specifications
recommended. Medium Dried, filtered air (40 micron)

Max Operating
2-Way Spool Valves Pressure
100psi (0.7 MPa) (6.89Bar)
The TopWorx™ open/closed spool valve is a 5 port, 2-way valve
Min. Operating
driven by an internally mounted pilot valve. The spool valve supply Pressure
30psi (0.21 MPa) (2.06Bar)
port and work ports are marked as follows: Ambient
Temperature Refer to Product Nameplate Marking
Range
Flow Coefficient 1.0Cv

Protection Degree Type 4, 4X, IP67

Port Size 1/4" NPT or BSP for 1.0Cv valve

Available in Hardcoat Anodized
Valve Body Aluminum TF061 or 304 Stainless Steel or 316 Stain-
less Steel
Valve Seals Buna-N/EPDM

Maintenance
No maintenance is required. The bearing's internal diameter
should be checked after 1 million cycles for wear. Require
dimension should be between 10.00 to 10.05mm. In the
event of wear, return the unit to the manufacturer for replace-
ment. Switch setting can be checked periodically.

Aggressive substances: e.g. acidic liquids or gases that may

attack metals or solvents that may affect polymeric materials.
If the equipment is likely to come into contact with aggressive
substances, then it is the responsibility of the user to take
suitable precautions that prevent it from being adversely affected,
thus ensuring that the type of protection provided by the equip-
ment is not compromised.

Suitable precautions: e.g. regular checks as part of routine inspec-

tions or establishing from the material’s datasheets that it is
resistant to specific chemicals. If in doubt, contact TopWorx™ for
assistance.

Area Classifications
Explosion Proof Protection Method
Explosion proof protection is accomplished by using long flange
and bearing surfaces with small clearances that do not allow
flames from explosions to escape the enclosure. In the event that
the flange surface or bearing areas become damaged, the protec-
tion method will fail and allow potentially explosive vapor to
Highly Recommended ignite. Gaps between flanged surfaces, once torqued, should not
TopWorx™ highly recommends Locktite 567 brand thread sealant. exceed .0015” [.038mm].
Do not use a hard setting pipe compound. If Teflon thread seal tape
is used, start the wrap on the second thread from the leading Intrinsically Safe Protection Method
thread of the fitting. This will prevent tape shreds from contaminat- For installation parameters, refer to the product nameplate.
ing the spool valve seals.
Non-Incendive Protection Method
Breathers (AL-M30) should be installed in the exhaust ports, when Non incendive units are designed with circuitry in which any arc or
NPT threads are used, to keep debris from falling into the spool thermal effect produced, under intended operating conditions of
valve and damaging the seals. This must be addressed prior to in- the equipment, is not capable of igniting the flammable gas,
stallation, or storage. vapor or dust-air mixtures.

24
Certifications & Approvals
TopWorx™ is proud to be certified for use in the following markets:

ATEX – European Union TopWorx™ products carry a wide range of certification markings:
Class I, Div 1 – Intrinsically Safe and Explosion-proof
IEC – Europe and other World Areas, includ- Class I, Div 2 – Non-incendive
ing Australia & New Zealand Class III – Dust Ignition Proof
Ex ia IIC – Zone0/Zone1 – Intrinsically Safe
US and Canada Ex d IIC & IIB+H2 – Zone1 – Flameproof
Ex nAnC IIC – Zone2 – Non-arcing/Non-sparking

Brazil Consult factory for copies of our certifications, which will include all
product specifications such as ambient temperature ranges, gas/
dust group coverage, intrinsic safety parameters and special condi-
tions for safe use.
Russia

China

PESO India

Korea

Proof Testing
Sira Test & certification Ltd has conducted a Failure Mode, Effect and Diagnostic Analysis (FMEDA) of the T-Series Discrete Valve Controller
against the requirements of IEC61508-2. The SIL ratings described below are only applicable to products manufactured in the U.S.A.

25
T-Series Safety Functions
The safety functions of the T-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 perform its safety
function.
 To admit pneumatic pressure to the spool valve by energizing the solenoid valve allowing the actuator to perform its safety func-
tion.

The actuator and valve may be configured to fail safe in a normally open (N/O) or normally closed (N/C) configuration depending on the
process under control. The T-Series Discrete Valve 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 T-Series Discrete Valve Controller is configured with the safety function to admit 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 dangerous failure (see Tables on
pages 29 and 30).

Hardware Functional Description

The T-Series Discrete Valve Controller implements the safety functions as a sub-system as defined according to IEC 61508-2 clause [Link]
Note 1. Furthermore, with reference to IEC 61508-2 clause [Link].2/3, the full assembly can be classified as a “Type A” sub-system. A com-
plete functional block diagram of the T-Series Discrete Valve Controller can be shown in the Tables on pages 29 and 30.

No fault (normal) conditions

a) Under normal operating conditions the T-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 T-Series Discrete Valve Controller does not have any online fault diagnostics, however if the T-Series Discrete Valve Controller develops
a fault which reverts the valve to its fail safe state then the sensor module will acknowledge this change in the 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 detectable failure (λ SD) and is considered as such in the FMEDA. If the T-Series Discrete Valve
Controller develop a fault which latches the valve in its current, potentially dangerous, state then this form of failure will only be acknowl-
edged 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 failure event has occurred and therefore this kind of failure is a dangerous undetectable failure (λ DD) and is considered
as such in the FMEDA.

The utilization of the PVST by the T-Series Discrete Valve Controller will reveal any covert undetected dangerous failures and therefore in-
crease 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

It should be realized that the electronics in the T-Series Discrete Valve Controller are performing positional feedback to the PLC and operator
which is not considered online diagnostics. Diagnostic coverage is assessed in the FMEDA according to utilizing PVST to reveal covert unde-
tected dangerous failures. This diagnostic coverage is only applicable at the point of PVST and not for normal operations.

Please visit our website to download a copy of the Sira Functional Safety Assessment Report for the T-Series Discrete
Valve Controller at [Link]

26
Safe Use
Special Conditions of Safe Use (All installations)
Clean only with a damp cloth to prevent possibility of electrostatic discharge.

For Explosion Proof installations, the internal ground connection shall be used and the external ground connection, if supplied in addition,
is supplemental bonding allowed where local authorities permit, or is required.

When installing with a third party listed nipple-mount solenoid, it is the responsibility of the installer to provide fittings, and apparatus,
suitable for the area classification in accordance with the National Electrical Code.

All cable entry devices or conduit stopping boxes shall be certified in type of explosion protection ‘d’, suitable for the conditions of use and
correctly installed.

The IIC enclosures are excluded from use in carbon disulphide atmospheres.

The air pressure to the valve block, when fitted, shall not exceed 7bar.

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

Special Conditions of Safe Use (Flameproof Installations)

 The slotted hexagonal head cover screws are not of standard form; they shall only be replaced with identical screws sourced from the
equipment manufacturer.
 The hexagonal head cover screws are to be replaced only with stainless steel 304, grade A2-70, or 316 grade A4-80 to ISO 35061.
 Cover fasteners are to be tightened to a torque valve of 10.85Nm (8 ft/lbs) minimum.

Special Conditions For Safe Use (Intrinsic Safety)

 The 4-20mA loop circuit and the various additional sub-assemblies (switches, sensors, valves, etc.) shall be treated as separate intrin-
sically safe circuits.
 The entity parameters for simple switches that are not covered by a certificate are Ui = 30 V, Ii = 200 mA and Pi = 0.72 W/switch (T4)
or Pi = 0.34 W/switch (T6). The entity parameters of certified devices fitted shall be obtained from the applicable certificate.

Recommended Operating Temperatures

27
GLOBAL SUPPORT OFFICES

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3300 Fern Valley Road Asia Pacific Pte Ltd - TopWorx Horsfield Way
Louisville, Kentucky 40213 USA c/o ASCO ASIA Bredbury Industrial Estate
+1 502 969 8000 BLK4008, Ang Mo Kio Avenue 10 Stockport SK6 2SU
[Link]@[Link] United Kingdom
#04-17/22, Techplace 1
+44 0161 406 5155
Singapore 569625
[Link]@[Link]
+65 6891 7550
[Link]@[Link]

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Dubai 17033 Modderfontein
United Arab Emirates Gauteng
+971 4 811 8283 South Africa
[Link]@[Link] +27 011 451 3700
[Link]@[Link]

Visit [Link] for comprehensive information on our company,

capabilities, and products – including model numbers, data sheets,
specifications, dimensions, and certifications.

[Link]@[Link]

[Link]

The Emerson logo is a trademark and a service mark of Emerson Electric Co. ©2016 Emerson Electric Co. ©2014 - ©2016 TopWorx , All rights [Link]™, and GO™Switch are trademarks of TopWorx
™. All other marks used in this document are the property of their respective owners. Information contained herein - including product specifications is subject to change without notice.

ES-01856-1 R15