Valvetop ® D-Series with GO ® Switches

Installation, Operation & Maintenance Manual

Table of Contents

2 Switchbox Orientation
3 Mounting
4 DXP Dimensional Drawing
5 DXP - IIC Dimensional Drawing
6 DXS Dimensional Drawing
7 DXR Dimensional Drawing
8 Shaft Detail
9 Enclosure/Indicator Assembly
10 Switch Orientation
11 Switch Calibration
12 Spool Valves & Pilots
13 Spool Valves & Pilots
14 Wiring & Safe Use
15 Certifications & Approvals
16 Warranty

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D-Series with GO Switch Installation, Operation & Maintenance 502.969.8000

Installation on Actuator

Orientations, Normal and Reverse Acting

Normal acting is full CW when the process valve is closed and CCW when the process valve is open. Reverse acting
is full CW when the process valve is open and CCW when the process valve is closed.

90° indicator dome assemblies are design to accommodate any mounting arrangement and can be adjusted up to
9° off axis if needed. 45° indicator dome assemblies can only accommodate normal acting applications that are
mounted parallel ±9°. Consult your local distributor or factory representative for 45° reverse acting or mounted
perpendicular applications.

Illustration #1

The image to the left shows a Valvetop unit mounted

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

Illustration #2

The image to the right shows a Valvetop mounted

perpendicular to the process valve in the closed
position. The green arrow at the top shows the
“normal acting” direction of travel to open the valve.
Notice that the indicator dome has been rotated 90°
compared to the unit above.

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Installation on Actuator (continued)

Mounting

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

Illustration #3: Mounting Assembly

Installation Notes

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

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

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

3. Always use sound mechanical practices when torquing down any

hardware or making pneumatic connections. Refer to the Integrated
Pneumatic Control Valves section for detailed information on
pneumatic connections.

4. This product comes shipped with 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.

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.

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D-Series with GO Switch Installation, Operation & Maintenance 502.969.8000

Dimensions and Materials: Valvetop DXP

Illustration #4 MATERIALS OF CONSTRUCTION

Cast A360 aluminum with dichro-
mate conversion coating inside &
Enclosure
out, epoxy coated exterior rated for
250 hrs salt spray per ASTM B117
304 Stainless Steel standard
Fasteners
316 Stainless Steel optional

304 Stainless Steel standard

Shaft
316 Stainless Steel optional
Shaft
Oilite Bronze
Bushing
Indicator
Polycarbonate, UV F1 rated
Dome
O-ring seals available in: Buna,
Seals
Silicone, EPDM & Viton

Maximum Fastener Torque Specifications

Enclosure Housing Bolts 8 ft-lbs [10.8 N·m]
Indicator Dome Screws 20 in-oz [141 mN·m]
Bottom Mounting Holes 10 ft-lbs [13.6 N·m]

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Dimensions and Materials: Valvetop DXP - IIC

Illustration #5 MATERIALS OF CONSTRUCTION

Cast A360 aluminum with dichro-

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

304 Stainless Steel standard

Fasteners
316 Stainless Steel optional

304 Stainless Steel standard

Shaft
316 Stainless Steel optional

Shaft Bushing Oilite Bronze

Indicator Dome Polycarbonate, UV F1 rated

O-ring seals available in: Buna,

Seals
Silicone, EPDM & Viton

Maximum Fastener Torque Specifications

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

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

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

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D-Series with GO Switch Installation, Operation & Maintenance 502.969.8000

Dimensions and Materials: Valvetop DXS

Illustration #6
MATERIALS OF CONSTRUCTION

Enclosure Cast 316 Stainless Steel

304 Stainless Steel standard

Fasteners
316 Stainless Steel optional

304 Stainless Steel standard

Shaft
316 Stainless Steel optional

Shaft Bushing N/A

Indicator Dome Polycarbonate, UV F1 rated

O-ring seals available in: Buna,

Seals
Silicone, EPDM & Viton

Maximum Fastener Torque Specifications

Enclosure Housing Bolts 8 ft-lbs [10.8 N·m]
Indicator Dome Screws 20 in-oz [141 mN·m]
Bottom Mounting Holes 10 ft-lbs [13.6 N·m]

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Dimensions and Materials: Valvetop DXR

Illustration #7
MATERIALS OF CONSTRUCTION

Valox® 364
Enclosure Polybutylene
Terephthalate (PBT)

304 Stainless Steel standard

Fasteners
316 Stainless Steel optional

304 Stainless Steel standard

Shaft
316 Stainless Steel optional

Shaft Bushing Delrin® 500P white

Indicator Dome Polycarbonate, UV F1 rated

O-ring seals available in: Buna,

Seals
Silicone, EPDM & Viton

Maximum Fastener Torque Specifications

Enclosure Housing Bolts 10 in-lbs [903 mN·m]
Indicator Dome Screws 20 in-oz [141 mN·m]
Bottom Mounting Holes 8 ft-lbs [13.6 N·m]

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Dimensions and Materials: Shafts

Illustration #8: Shaft Detail

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Illustration #9: Enclosure Assembly

Indicator Assembly
#10
See Illustration #2

Screws are
captive

Shaft Assembly
See Illustration #7

Pilot Device Options: Sensor

See Illustration Options:
#5 See
#12 Illustration
pg. 10
#6

Internal Ground
Lug
O-ring Seal

External Ground Lug

Valve Options:
#11
See Illustration #4
Conduit Entry

Illustration #10: Indicator Assembly

Indicator Dome,
+ 5O adjustable
Polycarbonate 10-32 Captive screws,
with keyed mask. Stainless (x4)
Several rotation and
form options.

Indicator / Dome Replacement Kits

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

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

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

Available in Buna-N,
AV-4B002 90º, Green/Open, Red/Closed, Buna O-Ring Silicone, EPDM, Viton Color-coded Indicator is
available in several
coordinating rotations and
forms for various valve
types, such as 900 , 1800
and Thru-divert applications.

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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 TARGET ARRANGEMENT

MINIMUM USABLE ROTATION 45°
MAXIMUM USABLE ROTATION 125°

TYPICAL L4 TARGET ARRANGEMENT

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Switch Calibration Procedure

Never perform switch calibration procedure while area is know to be hazardous

For intrinsically safe models, the unit must be wired in accordance with the control drawing S-K094 and
S-K094A.

For standard explosion-proof models, the calibration may be preformed using a Volt-Ohm meter by using
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 models mounted in parallel orientation

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 L4 models mounted in parallel orientation

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. 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 (CCW to close), the switch functions will be transposed. Sw 1 (and Sw 3 if in an
L4 model) become open. Sw 2 (and Sw 4 if in an L4 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.

Terms and Definitions

Process valve: A valve that is being controlled either by actuator or cylinder and the use of a Valvetop product
with or without a control valve.
Control valve: A valve used to power an actuator or cylinder that is in turn used to actuate a process valve.
Clockwise (CW): Rotated in the direction of a clocks normal movement.
Counter clockwise (CCW): Rotated in the opposite direction of a clocks normal movement.
Normal acting: Full CW is when the process valve is closed and CCW is when the process valve is open
Reverse acting: Full CW is when the process valve is open and CCW is when the process valve is closed
Parallel orientation: Process valve flow is parallel to the direction of the side conduit entries of the enclosure.
Perpendicular orientation: Process valve flow is perpendicular to the direction of the side conduit entries of
the enclosure.

GO Switch Replacement Part

35-13319M SPDT 35 Series GO Switch

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D-Series with GO Switch Installation, Operation & Maintenance 502.969.8000

Pneumatic Hookup Procedures

Spool Valve Specifications
Prior to connecting the supply air to the spool valve, flush the
Medium Dried, filtered air (40 micron)
system to remove any debris or contaminates. Galvanized
Max Operating 100psi (0.7 MPa) (6.89Bar)
pipe can easily flake and contaminate the system and there- Pressure
fore is not recommended. A 40 micron point of use filter at
Min. Operating 30psi (0.28 MPa) (2.76Bar)
every device is recommended. Pressure

Ambient Refer to Product Nameplate Marking

4-Way Spool Valves Temperature Range
The TopWorx spool valve is a 5 port, 4-way valve driven by Flow Coefficient 1.2Cv or 3.0Cv (1.0 for ColdTemp™)
an internally mounted pilot valve. The spool valve supply port
and work ports are marked as follows:
Environment Rating Type 4, 4X, IP67

Port Size 1/2” NPT for 3.0Cv valve

1/4" NPT for 1.2Cv valve

Manual Override Available in Latching/Non-Latching

Push Type & Palm Actuator Type

Valve Body Available in Hardcoat Anodized

Aluminum, 304, or 316 Stainless Steel

Valve Seals Spool Seals: Buna-N

Valve Body Seals available in
Buna-N, Silicone, EPDM & Viton.
ColdTemp™ Spools are lap-joint
technology containing no seals.

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

Always install vents

Don’t forget!
or speed controls Supply
Supply

TopWorx has a complete line of

3
5 1 3 5 1
breathers, flow controls, regulators
and filters.
4 2 4 2

Port to Close Port to Open Plug Port to Open /Close Check out [Link] or call
DOUBLE ACTING ACTUATORS SPRING RETURN ACTUATORS us at 502.969.8000 for more details

Highly Recommended
TopWorx highly recommends Locktite 567 brand thread seal-
ant. Do not use a hard setting pipe compound. If Teflon
thread seal tape is used, start the wrap on the second thread DID YOU KNOW?
from the leading thread of the fitting. This will prevent tape TopWorx manufactures the globally-
known GO Switch Leverless Limit
shreds from contaminating the spool valve seals.
Switch, which comprises a full line of
harsh environment sensors. If your
Breathers (AL-M31) should be installed in the exhaust ports application is very cold, very hot, under
to keep debris from falling into the spool valve and damaging water or in a caustic atmosphere, then
the seals. This must be addressed prior to installation, or GO Switch has the answer.
storage.

A flow control may be used in Port 3, but should NEVER BE

USED in Port 5. Any blockage or restriction may cause an
internal pressure build-up inside the encloser and pose a
safety issue.

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Spool Valves and Pilots

Illustration #11: Spool Valve Assembly
Fail Closed Spool Valve Replacement Assemblies

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

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

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

Flame arrestor O-ring

(x5)

Fail Last Position Spool Valve Replacement Assemblies M5 x 25mm SHCS (x4)
(4mm hex wrench)

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

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

Spool Valve with No Manual Override
AV-BFLPV620 Std 316SS Spool Valve Assy w/Buna seals

Block-Center Spool Valve Replacement Assemblies

Spool Valve with Single Palm Actuator Override
AV-BBCVA20 Std Alum Spool Valve Assy w/Buna seals

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

AV-BBCV620 Std 316SS Spool Valve Assy w/Buna seals Push-button Style Override

**Consult factory for more options.

Spool Valve with Dual Palm Actuator Override

Illustration #12: Pilot Device Assembly

Manifold

24V, 110V, 220V or

IntrinsicallySafe Pilot Device
(no plug connector on I.S. pilots)
(x1) for Fail Closed Apps
(x2) for Fail Last Position &
Block Center Apps

Bracket

4-40x0.25 (x2)

**Orifice only applicable to Explosion Proof units. All others use standard fitting.

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D-Series with GO Switch Installation, Operation & Maintenance 502.969.8000

Wiring & Safe Use

Chart: L2 Option Wiring
Switch 1
Illustration #14: Terminal Strip Assembly
Green to GND Ground
Bracket
COM (Black) Terminal 2
NO (Blue) Terminal 3
Terminal Strip Label
NC (Red) Terminal 1
Switch 3
12pt Terminal Strip (x2)
Green to GND Ground
COM (Black) Terminal 5
NO (Blue) Terminal 6
NC (Red) Terminal 4

Chart: L4 Option Wiring

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
4-40x0.5 self tap screw (x6)
Torque 40 IN-OZ Switch 3 Switch 4
Green to GND Ground Green to GND Ground
COM (Black) Terminal 8 COM (Black) Terminal 11
4-40x0.25 SEM screw (x2)
Torque 100 IN-OZ NO (Blue) Terminal 9 NO (Blue) Terminal 12
NC (Red) Terminal 7 NC (Red) Terminal 10

**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.

Special Conditions of Safe Use (All installations)

Clean only with a damp cloth to prevent possibility of electrostatic discharge.

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

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

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

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

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

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

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Certifications & Approvals

AREA CERTIFICATION 0518

Ex ia IIC T4 Ga, Ex t IIIC T70°C Db, IP67
–40°C ≤ Tamb ≤ 55°C (mech. and Go switches without spool valve option)
Ex ia IIC T4 Gb, Ex t IIIC T70°C Db, IP67
–20°C ≤ Tamb ≤ 53°C (p+f switches without spool valve option)
Ex ia IIC T4 Gb, Ex t IIIC T70°C Db, IP67
0 –10°C ≤ Tamb ≤ 50°C (with pilot/spool valve option)
SIRA 07ATEX2214X
Ui=28V, Ii=100mA, Pi=0.7W, Ci=14nF, Li=2.06mH
Class I, Div 1&2, Groups A,B,C,D; T4, Type 4, 4X
Intrinsically Safe / Securite Intrinsique
SPDT 4A/120Vac; 3A/24Vdc Hermetically Sealed Cont.
DXP Class I Div 1 Groups C,D; Class 1 Div 2 Groups A,B,C,D Type 4, 4X
Ex d IIB+H2 T6 –40°C ≤ Tamb ≤ 60°C, IP67
1
SIRA 07ATEX1273X IECEx SIR 07.0093X
SPDT 4A/120Vac; 3A/24Vdc Hermetically Sealed Cont.
Class 1 Div 2 Groups A,B,C,D; Type 4, 4X
2 Ex nC IIC T6 –40°C ≤ Tamb ≤ 60°C, IP67
SPDT 4A/120Vac; 3A/24Vdc Hermetically Sealed Cont.
EEx d IIC T6 –40°C ≤ Tamb ≤ 60°C, IP67
C SIRA 07ATEX1273X SIRA IECEx SIR 06.0093X
SPDT 4A/120Vac; 3A/24Vdc Hermetically Sealed Contacts
W NEMA 4, 4X
Ex ia IIC T4 Ga, Ex t IIIC T70°C Db, IP67
–40°C ≤ Tamb ≤ 55°C (mech. and Go switches without spool valve option)
Ex ia IIC T4 Gb, Ex t IIIC T70°C Db, IP67
–20°C ≤ Tamb ≤ 53°C (p+f switches without spool valve option)
Ex ia IIC T4 Gb, Ex t IIIC T70°C Db, IP67
0 –10°C ≤ Tamb ≤ 50°C (with pilot/spool valve option)
SIRA 07ATEX2214X
Ui=28V, Ii=100mA, Pi=0.7W, Ci=14nF, Li=2.06mH
Class I, Div 1&2, Groups A,B,C,D; T4, Type 4, 4X
Intrinsically Safe / Securite Intrinsique
DXS SPDT 4A/120Vac; 3A/24Vdc Hermetically Sealed Cont.
Class I Div 1 Groups C,D; Class 1 Div 2 Groups A,B,C,D Type 4, 4X
Ex d IIB+H2 T6 –40°C ≤ Tamb ≤ 60°C, IP67
1
SIRA 07ATEX1273X IECEx SIR 07.0093X
SPDT 4A/120Vac; 3A/24Vdc Hermetically Sealed Cont.

Class 1 Div 2 Groups A,B,C,D; Type 4, 4X

2 Ex nC IIC T6 –40°C ≤ Tamb ≤ 60°C, IP67
SPDT 4A/120Vac; 3A/24Vdc Hermetically Sealed Cont.

W NEMA 4, 4X
Ex ia IIC T4 Gb, Ex t IIIC T70°C Db, IP6X
–20°C ≤ Tamb ≤ 53°C (without spool valve option)
–10°C ≤ Tamb ≤ 50°C (with pilot/spool valve option)
0
SIRA 07ATEX2214X
4-20mA Loop Entity Parameters:
DXR Ui=28V, Ii=100mA, Pi=0.7W, Ci=14nF, Li=2.06mH
Type 4, 4X
G
SPDT 4A/120Vac; 3A/24Vdc Hermetically Sealed Cont.

Type 4, 4X
W
SPDT 4A/120Vac; 3A/24Vdc Hermetically Sealed Cont.

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Warranty

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NOTES:

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Visit [Link] for comprehensive information

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

[Link]@[Link]

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GLOBAL SUPPORT OFFICES

Americas Europe Asia-Pacific

TopWorx, Inc TopWorx, Ltd TopWorx Pte, Ltd
3300 Fern Valley Road Suite 56, Stafford Business Village TT International Tradepark
Louisville, Kentucky 40213 USA Dyson Way 10 Toh Guan Road
+1 502 969 8000 Staffordshire Technology Park #02-04 Singapore 608838
[Link]@[Link] Stafford ST18 0TW, England +65 6793 0980
+44 1785 887 960 [Link]@[Link]
[Link]@[Link]

Africa Middle East

TopWorx (Pty) Ltd. TopWorx
10 Field Street P.O. Box 17033
Wilbart, Evandale 1609 Jebel Ali Free Zone
South Africa Dubai 17033
+27 011 445 4475 tel United Arab Emirates
[Link]@[Link] 971(4) 811 8100 tel
[Link]@[Link]

© 2009 TopWorx, Inc. All rights reserved. TopWorx, Valvetop, GO Switch, and Leverless Limit Switch are all trademarks
of TopWorx, Inc. All other marks are the property of their respective owners. Information herein – including product
specifications – is subject to change without notice.

ES-01284-1 R4