Topworx Valvetop DXP Instruction manual

Installation, Operation & Maintenance Manual
3300 Fern Valley Road, Louisville, Kentucky 40213 USA www.topworx.com
502.969.8000 phone [phone] fax [email protected]
Table of Contents
2Outline Dimensions
2Indicator Assembly
3DXP Enclosure Assembly
5Spool Valve Assembly
5Pilot Device Assembly
6Mechanical Switch Assembly
7Shaft / Cam Assembly
7Approvals & Warranty
DXP - Mechanical Switch Options
0539
The DXP combines limit switches, internally mounted pilot coils and
integral spool valve into a single enclosure.
•Explosion-proof Class I, Div.1, Groups C & D (Zone 1, EEx d IIB)
•SPDT and DPDT contact switches
•Integral Solenoid Valve (24Vdc or 110Vac)

502.969.8000
DXP Installation, Operation & Maintenance
2
.249 [6.32 mm]
.375 [9.53 mm]
.250 [6.35 mm]
.120 [3.05 mm]
4.515 [114.68 mm]
1.665 [42.29 mm]
2.126 [54.00 mm]
5.900 [149.86 mm]
6.650 [168.91 mm]
6.214 [157.84 mm]
OPTIONAL
STANDARD CONDUIT ENTRY
CONDUIT
ENTRIES
5/16-18 UNC .375
6.700 [170.18 mm]
MTG. HOLES
.955 [24.24 mm]
STANDARD SHAFT
2.570 [65.28 mm]
STANDARD CONDUIT ENTRY
SEE SHAFT
DETAILS
.850 [21.59 mm]
1.699 [43.15 mm]
.335 [8.51 mm]
BOLT PATTERN
2.250 [57.15 mm] SQ.
NAMUR SHAFT
1.076 [27.33 mm]
6.214 [157.84 mm] .164 [4.17 mm]
.285 [7.24 mm]
.938 [23.83 mm]
.375 [9.53 mm]
4 mm
Installation Notes
1. Be cautious not to allow undue axial (thrust) load on the DXP 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.
3. Always use sound mechanical practices when torquing down any hardware or making
pneumatic connections.
Color-coded Indicator is
available in several
coordinating rotations and
forms for various valve
types, such as 90 , 180
and Thru-divert applications.
00
O-ring
Available in Buna-N,
Silicone, EPDM, Viton
10-32 Captive screws,
Stainless (x4)
Indicator Dome,
5 adjustable
Polycarbonate
with keyed mask.
Several rotation and
form options.
+
O
Illustration #2 : Indicator Assembly
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200BG-VA09
O
gniroanuB,desolC/deR,nepO/neerG,
200BY-VA09
O
gniroanuB,desolC/klB,nepO/wolleY,
200BT-VA09
O
gniroanuB,treviD/deR,urhT/neerG,
200B4-VA54
O
gniroanuB,desolC/deR,nepO/neerG,
Illustration #1 : Outline Dimensions

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3
Pilot Device Options:
See Illustration
#5
Sensor
Options:
See
Illustration
#6
Indicator Assembly
See Illustration #2
Shaft Assembly
See Illustration #7
Valve Options:
See Illustration #4
External Ground Lug
Internal Ground
Lug
O-ring Seal
Conduit Entry
Screws are
captive
Illustration #3 : DXP Enclosure Assembly
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snoCfoslairetaM/snoitacificepSerusolcnE noitcurtsnoCfoslairetaM/snoitacificepSerusolcnEnoitcurtsnoCfosl
airetaM/snoitacificepSerusolcnE
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imula063Atsac-eiD
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BtfahS sgnihsuBtfahSsgnihsuBtfahSeznorbetiliOni-tsaC
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iavaslaesgnir-O
notiV
seirtnEtiudnoCseirtnEtiudnoC seirtnEtiudnoC seirtnEtiudnoCseirtnEtiudnoC &02M,TPN2/1,T
PN4/3:nielbaliava4-2ytitnauQ
61M
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nrettaP50FlanoitpO,nrettaPerauqS
srenetsaFrofseulaVeuqroTmumixaMsrenetsaFrofseulaVeuqroTmumixaM srenetsaFrofseulaVeuqroTmumixaM srenetsaFrofseulaVeuqroTmumixaMsrenetsaFrofseulaVeuqroTmumixaM
noitpircseDepyTeuqroT.xaM
swercSdiLerusolcnEelbaTcepseeS.sbl.tf8
swercSemoDrotacidnIFNU23-01.zo.ni02
seloHgnitnuoMmottoBFNU81-61/5.sbl.
tf01

502.969.8000
DXP Installation, Operation & Maintenance
4
DID YOU KNOW? TopWorx manufactures
the globally-known GO Switch Leverless
Limit Switch, which comprises a full line
of harsh environment sensors. If your
application is very cold, very hot, under
water or in a caustic atmosphere, then
GO Switch has the answer.
Pneumatic Hookup Procedures
Prior to connecting the supply air to the spool valve, flush the system to remove any debris
or contaminates. Galvanized pipe can easily flake and contaminate the system and
therefore is not recommended.
4-W4-W
4-W4-W
4-Waa
aa
ay Spooly Spool
y Spooly Spool
y Spool VV
VV
Valvesalves
alvesalves
alves
The TopWorx spool valve is a 5 port, 4-way valve driven by an internally mounted pilot
valve. The spool valve supply port and work ports are 1/4” NPT. The exhaust ports are
1/8” NPT, marked as follows for the DXP:
HighlHighl
HighlHighl
Highly Recommendedy Recommended
y Recommendedy Recommended
y Recommended
TopWorx highly recommends Locktite 567 brand thread sealant. Do not use a hard setting
pipe compound. If Teflon thread seal tape is used, start the wrap on the second thread from
the leading thread of the fitting. This will prevent tape shreds from contaminating the spool
valve seals.
Flow controls (AL-M21) or Breathers (AL-M31) should be installed in the exhaust ports to
keep debris from falling into the spool valve and damaging the seals. This must be
addressed prior to installation, or storage.
Don’t fDon’t f
Don’t fDon’t f
Don’t forget!orget!
orget!orget!
orget!
TopWorx has a complete line of breathers,
flow controls, regulators and filters.
Check out wwwwww
wwwwww
www.topworx.com.topworx.com
.topworx.com.topworx.com
.topworx.com or call us at
502.969.8000502.969.8000
502.969.8000502.969.8000
502.969.8000 for more details
***NEVER PLUG, OR BLOCK, PORT 5***
135
2
4
Su
pp
l
y
Exhaust of Port 2 - when actuator closes
Exhaust of Port 4 - when actuator opens
Port to Actuator Open
Port to Actuator Close
Pilot Valve
Internall
y
mounted
TOP VIEW
BOTTOM VIEW
Supply
Port to O
p
en
Port to Close
Always install vents
or speed controls
Plug
Supply
Port to Open
DOUBLE ACTING ACTUATORS SPRING RETURN ACTUATORS
13
5
2
4
FAIL CLOSED
13
5
2
4
Pilot Valve
Internally mounted
13
5
2
4
13
5
2
4
FAIL LAST POSITION
13
5
2
4
BLOCK CENTER
Spool Valve Specifications
Medium Dried, filtered air (40 micron)
Max Operating Pressure 100psi (0.7MPa) (6.89Bar)
Min Operating Pressure 30psi (0.28MPa) (2.76Bar)
Ambient Temperature
Range Refer to Product Nameplate Marking
Flow Coefficient 1.2Cv / 1.0Cv for Cold Temp
Environment Rating Type 4, 4X, IP67
Port Size 1/4" NPT
Manual Override Available in: Latching/non-latching Push Type
& Palm Actuator Type
Valve Body Available in: Hardcoat Anodized Aluminum,
304 & 316 Stainless
Valve Seals
Spool seals: Buna-N
Valve Body Seals available in:
Buna-N, Silicone, EPDM & Viton.
Cold Temp Spools are lap-joint technology
containing no seals.

www.topworx.com
5
Consult factory for more options.
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RevlaVloopSdesolCliaF seilbmessAtnemecalpeRevlaVloopSdesolCliaFseilbmessAtnemecalpeRevlaVloopSdesolClia
F
02AVCFB-VAslaesanuB/wyssAaVloopSmulAdtS
02SVCFB-VAslaesanuB/wyssAaVloopSss403dtS
026VCFB-VAslaesanuB/wyss
AaVloopSss613dtS
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sAtnemecalpeRevlaVloopSnoitisoPtsaLliaF seilbmessAtnemecalpeRevlaVloopSnoitisoPtsaLliaFseilbmessAtnemec
alpeRevlaVloopSnoitisoPtsaLliaF
02AVPLFB-VAslaesanuB/wyssAaVloopSmulAdtS
02SVPLFB-VAslaesanuB/wyssAaVloop
Sss403dtS
026VPLFB-VAslaesanuB/wyssAaVloopSss613dtS
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alpeRevlaVloopSretneC-kcolB seilbmessAtnemecalpeRevlaVloopSretneC-kcolBseilbmessAtnemecalpeRevlaVloopSr
etneC-kcolB
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02SVCBB-VAslaesanuB/wyssAaVloopSss403dtS
026VCBB-VAslae
sanuB/wyssAaVloopSss613dtS
Illustration #4 : Spool Valve Assembly
Flame arrestor O-ring
(x5)
Spool Valve with No Manual Override
Spool Valve with Single Palm Actuator Override
Spool Valve with Dual Palm Actuator Override
Push-button Style Override
10-32 Nylon Plug
Used in Fail Closed
Applications
YELLOW Urethane
Tubing (Work)
RED Urethane
Tubing (Supply)
YELLOW Urethane
Tubing (Work)
RED Urethane
Tubing (Supply)
1 0-32 Barb Fitting
(x4)
4-40x0.25 (x2)
Bracket
24V, 110V 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
Manifold
Red +
Black
-
Illustration #5 : Pilot Device Assembly

502.969.8000
DXP Installation, Operation & Maintenance
6
Illustration #6 : SPDT Switch Assembly
Switch CalibraSwitch Calibra
Switch CalibraSwitch Calibra
Switch Calibration Proceduretion Procedure
tion Proceduretion Procedure
tion Procedure
NeverNever
NeverNever
Never perform calibration while area is known to be hazardous.
Calibration may be performed using a Volt-Ohm meter by using the Ohm setting across
COM and NO. When switch is active, the meter will read <0.5 Ohms, or the Diode setting
may be used 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 15 Amperes when circuit rating is unknown, or permanent
damage may occur.
Step 1:Step 1:
Step 1:Step 1:
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:Step 2:
Step 2:Step 2:
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:Step 3:
Step 3:Step 3:
Step 3: Cycle valve CLOSED and OPEN several times to insure switches will maintain
calibration.
For ReverseFor Reverse
For ReverseFor Reverse
For Reverse Acting actuaActing actua
Acting actuaActing actua
Acting actuators:tors:
tors:tors:
tors:
Step 1:Step 1:
Step 1:Step 1:
Step 1: With valve in the CLOSED 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 2:Step 2:
Step 2:Step 2:
Step 2: Rotate valve to the OPEN position. Disengage the BOTTOM Cam from the splined
Hub and rotate Clockwise until SW1 activates. Release Cam to re-engage the splined Hub.
RepeaRepea
RepeaRepea
Repeat Step 3 at Step 3 a
t Step 3 at Step 3 a
t Step 3 above.bove.
bove.bove.
bove.
When using the (4) and (6) switch options,When using the (4) and (6) switch options,
When using the (4) and (6) switch options,When using the (4) and (6) switch options,
When using the (4) and (6) switch options, use the same calibrause the same calibra
use the same calibrause the same calibra
use the same calibration steps as ation steps as a
tion steps as ation steps as a
tion steps as abovebove
bovebove
bove
ff
ff
for the switches you determine to indicaor the switches you determine to indica
or the switches you determine to indicaor the switches you determine to indica
or the switches you determine to indicate OPEN and which indicate OPEN and which indica
te OPEN and which indicate OPEN and which indica
te OPEN and which indicate CLOSED.te CLOSED.
te CLOSED.te CLOSED.
te CLOSED.
Switches maSwitches ma
Switches maSwitches ma
Switches may also be set ay also be set a
y also be set ay also be set a
y also be set at midpoint,t midpoint,
t midpoint,t midpoint,
t midpoint, or anor an
or anor an
or any point,y point,
y point,y point,
y point, of traof tra
of traof tra
of travel fvel f
vel fvel f
vel for Dribor Drib
or Dribor Drib
or Dribble Control,ble Control,
ble Control,ble Control,
ble Control, oror
oror
or
anan
anan
any other logy other log
y other logy other log
y other logic necessaric necessar
ic necessaric necessar
ic necessary fy f
y fy f
y for the aor the a
or the aor the a
or the applicapplica
pplicapplica
pplication.tion.
tion.tion.
tion.
#hctiwSnoitcennoCedoCroloC#lanimreT
1
CNdeR1
MOCkcalB2
ONeulB3
2
CNthW/deR4
MOCthW/kcalB5
ONthW/eulB6
3
CNegnarO7
MOCnworB8
ONwolleY9
4
CNgrO/etihW01
MOCnrB/etihW11
ONleY/etihW21
5
CNteloiV31
MOCyarG41
ONetihW51
6
CNoiV/etihW61
MOCyrG/etihW71
ONkniP81
Sw1
Sw2
Sw1
Sw2
Sw3
Sw4
Sw1
Sw2
Sw3
Sw4
Sw5
Sw6
V3/V7 Style SPDT
Mechanical Switch
Rated 15.1A, 1/2HP, 125, 250, 277Vac
0.5A/125Vdc, 0.25A/250Vdc
OR
With Gold Alloy Contacts
Rated 1A/125Vac, 50mA/24Vdc
Minimum 1mA
Crimp-on Connector
(3) per switch.
See Lead Color Code Table
for termination points.
COM
NO
NC
4-40x2.25 (x2)
4-40x0.5 (x3)
4-40x0.25 (x2)
Bracket
Spacer
Divider
4-40x3.00 (x2)
Bracket
12pt Terminal Strip
4-40x2.25 (x2)
6-32x2.50 (x2) 4-40x0.5 (x6)
NC2
NO1
NC1
NO2
NC1
NO1
NC2
NO2
COM1
COM2
COM1
COM2
BRACKET
SPACER
SPACER
SW#1
SW#2
DPDT
15A/125Vac
#hctiwSnoitcennoCedoCroloC#lanimreT
1#WS
1CNdeR1
1MOCkcalB2
1ONeulB3
2CNthW/deR4
2MOCthW/klB5
2ONthW/ulB6
2#WS
1CNegnarO7
1MOCnworB8
1ONwolleY9
2CNgrO/thW01
2MOCnworB/thW1
1
2ONleY/thW21
Switch Calibration
NeverNever
NeverNever
Never perform switch calibration
while area is known to be hazardous.
Calibration procedure is the same for
the DPDT switches as with the SPDT
switches. Reference previous page.

www.topworx.com
7
Warranty
TopWorx warrants that each item of new equipment manufactured by it will be free from
defects in material and workmanship under normal use and service; its obligation under
this Warranty, being limited to making good, at its factory, and part of parts thereof, which
shall be returned to it with transportation charges prepaid, within one year after the date of
the purchase of such equipment by the original purchaser, and which its examination shall
disclose to its satisfaction to have been thus defective. TopWorx however, assumes no risk
or liability for results of the use of the products purchased from it.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, WHETHER OF MERCHANTABIL-
ITY FITNESS, OR OTHERWISE EXPRESSED OR IMPLIED, AND ALL OTHER OBLIGATIONS OR
LIABILITIES AND TOPWORX NEITHER ASSUMES , NOR AUTHORIZES ANY PERSON TO
ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS
EQUIPMENT.
No claims for labor in replacing defective parts and equipment and consequential damages
will be allowed by the Company.
This Warranty shall not apply to equipment which has been subjected to misuse,
negligence or accident.
This Warranty shall not apply to any equipment which shall have been repaired or altered,
outside the Company's factory so as to affect such equipment's stability or reliability in the
judgement of the Company.
Special Conditions of Safe Use (All installaSpecial Conditions of Safe Use (All installa
Special Conditions of Safe Use (All installaSpecial Conditions of Safe Use (All installa
Special Conditions of Safe Use (All installations)tions)
tions)tions)
tions)
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.
Telemetering Equipment for use in Hazardous Locations
Zone 1 EEx d IIB T6 -40OC<Tamb<60OC; IP67
DEMKO 04ATEX0320446X
Class I, Div.1, Groups C & D; T6; Type 4, 4X, 7
Electrical rating: SPDT 15A/125Vac, 0.5A/125Vdc
SPDT, gold contacts 1A/125Vac
DPDT 10A/125Vac
Pilot Coil: 24Vdc or 110Vac
0539 II 2 G LISTED
Illustration #8 :
Shaft / Cam Assembly
1
2
3
4mm
0.375 [9.53mm]0.375 [9.53mm]
0.375 [9.53mm]
0.25 in
For more shaft dimension
details, see Page 2.
Std 0.25” DD Shaft,
stainless
NAMUR Shaft,
stainless
htiwesurofstiKtnemecalpeRtfahSRUMAN
sehctiwSlacinahceM)2(
102BSN-VA
&sgnir-oN-anuB/wtfahSRUMAN
noitallatsnihtiwylbmessamac)2(
erawdrah
htiwesurofstiKtnemecalpeRtfahS
sehctiwSlacinahceM)2(
102BSS-VA
sgnir-oN-anuB/wtfahSdradnatS
htiwylbmessamac)2(&
erawdrahnoitallatsni
Consult factory for more options.

502.969.8000
DXP Installation, Operation & Maintenance
88
3300 Fern Valley Road
Louisville, Kentucky 40213 USA
502.969.8000 phone
502.969.5911 fax
[email protected]
www.topworx.com
About Valvetop®
Valvetop valve networking and control devices link on/off valves to process control systems via a variety of fieldbus protocols. Valvetop valve
controllers and monitors support multiple bus protocols, operate in the most demanding plant conditions, and carry a variety of global approvals.
Whether your application is rotary or linear, fieldbus or conventional, hazardous or general purpose, we have a suitable solution for you.
For inquiries, contact TopWorx at: 502.969.8000
www.topworx.com
[email protected]
About TopWorx
TopWorx is the leader in field networking, valve control, and position sensing solutions for the process industries. Our products and services help
plants, mills, and pipelines improve their performance by making it easy to implement modern automation technologies.
TopWorx, Valvetop, Lumitech, GO Switch, and VIP are all trademarks of TopWorx, Inc.
All other marks used in this document are the property of their respective owners.
Information contained herein is subject to change without notice.
©TopWorx, Inc. All rights reserved. S-K129 R1