TopWorx™ D-ESD: Partial Stroke & Emergency Shutdown

Installation, Operation & Maintenance Manual

Credible Solutions
Table of Contents
Page 4 ESD Theory of Operation
Page 5 Installation on Actuator
Page 6 Pneumatic Hookup Procedures
Page 8 ESD Conventional Instruction & Operation-Fail Closed Valves Partial
Page 10 Stroke Tolerance Range Selection/Partial Stroke Test ESD
Page 11 Calibration-Fail Closed Valves
Page 12 ESD Conventional Instruction & Operation-Fail Open Valves Partial
Page 13 Stroke Tolerance Range Selection/Partial Stroke Test ESD
Page 15 Calibration/PST Flow Chart-Fail Open Close
Page 18 Dimensions and Materials: TopWorx™ DXP
Page 19 Dimensions and Materials: TopWorx™ DXP - Flameproof Ex d IIC
Page 20 Dimensions and Materials: TopWorx™ DXS
Page 21 Interior & Indicator Assembly
Page 22 Certifications & Approvals
Page 25 Safe Use
ESD Theory of Operation:
The purpose of the TopWorx™ Emergency Shut-Down (ESD) model is to partially stroke a valve that maintains a full open or full closed
position for an extended period of time while offering an ESD function. A partial stroke test (PST) verifies functionality of critical valves that
must be in their fail position during an emergency. Increasing the frequency of partial stroke testing (i.e. reducing the proof test interval)
improves the SIL (Safety Integrity Level) that the system can achieve through a reduction in the PFD avg (Average Probability of Failure On
Demand). These partial stroke tests can be performed without shutting down or disrupting the process. In an emergency, the ESD function
overrides partial stroke testing and the valve moves to its fail position.
This ESD unit incorporates a sensor communication module (SCM-ESD) to perform the partial stroke test, verify its status, and output
that status back to the user. In combination with the SCM, the ESD unit uses either the optional TopWorx™ pilot and spool valve or a
customersupplied solenoid valve to drive the actuator during both normal operation and partial stroke testing. A TopWorx™ GO™ Switch is
included for partial stroke confirmation and two (2) limit switches built into the SCM confirm open and close position.
Once the unit is installed, the SCM-ESD must be calibrated for that specific valve, actuator, and solenoid exhaust settings. During calibration,
the unit records the time to partially stroke the valve. All future PST times are compared to this original value for determining the test status.
To pass a PST, the time must be within +/-20%, 30%, or 40% of the stored calibration value. This PST time tolerance can be changed prior to
calibration.
The partial stroke test is initiated via an optional partial stroke test button with a lockable cover, the calibration button on the top of the SCM,
or a simulated closed dry contact from the PLC or DCS. Upon issuing a PST command, the SMC-ESD begins a timer while switching a relay to
de-energize the pilot/ solenoid. The valve moves from its normal position toward its fail position until the GO™ Switch is made. Once made,
the SCM energizes the pilot/solenoid and the valve moves to its normal position while outputting the PST status.

Option ES: SCM

CAL/ALARM
Electrical Ratings
PST PST / CAL
SWITCH ACTIVATION Current/Voltage
TopWorxTM ESD
Open/Closed Indication 0.25A@24VDC w/5V drop
PARTIAL STROKE 0.25A@120VAC w/5V drop
POSITION 2 POSITION 1 MODULE POWER
POSITION 1
INDICATION (OPEN)
LED (RED) LED (GREEN) Dry Contact Rating Minimum Current Through Switch
PILOT VALVE Contacts: 5 mA
CONTROL
Module Voltage 18-28VDC
TO
Module Current 50mA (MAX)
ALARM COM PSI
POSITION 2 PILOT VALVE
INDICATION (CLOSED)
CAL SW PILOT VALVE Pilot Current (Standard) 20mA
CONTROL
PST Feedback Relays 800mA@24VDC MAX
250mA@125VAC MAX
Solenoid Pilot/SOV 800mA@24VDC MAX
DIAGNOSTIC Maximum PowerRating 250mA@125VAC MAX
PARTIAL
COM STROKE TEST

Figure 1: Input/Output Diagram

4
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 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.

The image to the right shows a TopWorx™ 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.

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 mounting kit documentation for specific mounting instructions.

Storage
Until conduit, conduit covers, and any applicable spool valve port connections are properly installed, the TopWorx™ 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 -40°F (-40°C) to 160°F (71°C). Once properly installed, the temperature range listed on the
nameplate will supersede this storage temperature range.

Mounting Assembly
Installation Notes

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

1. 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.

2. 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.

3. This product comes shipped with conduit covers 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.

4. 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.

5
Pneumatic Hookup Procedures PORT TO OPEN PORT TO CLOSE PORT TO OPEN/CLOSE PLUG
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. A 40 micron point of use filter at every device is
recommended.

4-Way Spool Valves SUPPLY SUPPLY

The TopWorx™ spool valve is a 5 port, 4-way valve driven by an
ALWAYS INSTALL VENTS ALWAYS INSTALL VENTS
internally mounted pilot. The spool valve supply port and work ports
DOUBLE ACTING ACTUATORS SPRING RETURN ACTUATORS
are marked as follows:
Highly Recommended
TopWorx™ highly recommends Locktite 567 brand thread sealant.
PORT TO PORT TO
ACTUATOR OPEN ACTUATOR CLOSE 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.
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.

VALVE SPECIFICATION
ITEM PERFORMANCE
Media Air
Media temperature Min: -40°C (-40°F); Max: 60°C (140°F)
Operational ambient Min: -40°C (-40°F); Max: 60°C (140°F)
EXHAUST OF PORT 4 EXHAUST OF PORT 2 temperature
(WHEN ACTUATOR CLOSES) (WHEN ACTUATOR OPENS)
Inlet/system pressure Min: 45 PSI (3.1 bar); Max: 150 PSI (10.3 bar)
SUPPLY
Operational pressure Min: 45 PSI (3.1 bar); Max: 150 PSI (10.3 bar)
differential
Safe working pressure 150 PSI (10.3 bar)
Flow / Cv (Kv) Cv = 0.86 (Kv = 0.74)
Body port connections 1/4” NPT
Allowable leakage External: 2 sccm
Internal: 10 cc/min max for -15°C to 60°C.
FAIL CLOSED
3300 cc/min max for -40°C to -15°C
Optimal design life 500,000 cycles
Material in contact with Body: Aluminium (black anodized) and
fluid Stainless Steel 316L
Internal: Stainless Steel, LT, nitrile, PTFE, Acetal
Spool Valve Assembly
* Refer to the wiring diagram on the inside lid of your product to determine actual
pin out location

FLAME ARRESTORS & ORINGS (X5)

O-RINGS (X2)

M5 X 30MM
SCHS (X3)(4MM
HEX WRENCH)

ADAPTER PLATE

M5 X 12MM SCHS (X4)

(4MMHEX WRENCH)

ASCO™ VALVE WITHOUT

MANUAL OVERIDE

6
Spool Valves and Pilots

SINGLE PILOT ASSEMBLY

PILOT
ASCO™ 302
M3 X 18 CHEESE HEAD SCREW MINI PIEZO
TORQUE TO 20 IN-OZ AMISCO 110 VAC
AMISCO 220 VAC

SEAL AND PLATE

(NOT USED WITH MINI PIEZO)

MANIFOLD

10-32 METAL BARB FITTING

TORQUE TO 60 IN-OZ

10-32 METAL PLUG

RED URRETHANE
4-40 X .25” SEM SCREW TUBING (SUPPLY)
TORQUE TO 100 IN-OZ

10-32 METAL BARB FITTING

TORQUE TO 60 IN-OZ

BRACKET

YELLOW URETHANE ORIFICE TO BE USED IN

TUBING (WORK) EXPLOSION PROOF APPLICATIONS

7
ESD CONVENTIONAL INSTRUCTION AND OPERATION—Fail Closed Valves
Operation: Before operation, the ESD must be calibrated (see Calibration below). After calibration, a Partial Stroke Test (PST) 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. Nonvolatile
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, flashes unique visual indicators to signal pass/fail of tests and possible maintenance issues (please see
ESD Conventional Flow Chart and Message Table for ESD Conventional for more details).
*Note that the following instructions assume the valve is FAIL CLOSED and the direction of travel from CLOSED to OPEN is CCW.

Fail Closed CALIBRATION

LED (AMBER)

BLUE
GO™ Switch connection (Prewired) External PST button (Prewired)
Black

Valve Pos 1 (Open) switch NO contact. During bench testing only, add a TopWorx™ ESD
Power for electronics module 24VDC-
2500 Ohm, 1/2 W resistor for path back to DC supply via terminal 6.
POSITION 2 POSITION 1
Valve Pos 1 NC Contact LED (RED) LED (GREEN)
Power for electronics module 24VDC+

Valve Position 1 (Open). COM. Tie it to Valve Position 1 COM 24VDC+ Solenoid Pilot or SOV Output (-)

Valve Pos 2 (Closed) switch NO contact. During bench testing only, add a
2500 Ohm, 1/2 W resistor for path back to DC supply via terminal 6. BLACK (-)
ALARM COM PSI
To Solenoid Pilot or SOV
Valve Pos 2 NC Contact RED (+)

Valve Position 2(Closed) switch COM contact, Solenoid Pilot or SOV Output (+)
CAL SW
wire it back to Terminal 5 24VDC+ 800mA@24VDC MAX
250mA@125VAC MAX

Optional external diagnostic signal. If wired, will pass pulses out

the same as the LED flashes for the calibration diagnostic (pg. #16)

Calibration Switch Optional external signal COMMON.

Tie it to the Valve Pos 1 and 2 COM

Optional external alarm signal.

If wired, will close if PST calibration if passes.
Figure 2: Suggested Test Bench Setup for Fail Closed Applications

Wiring Connections:
1. T erminals 1 and 4: External power source for switching the solenoid valve. Type and voltage level must match type of solenoid selected.
Typical is 24VDC.
2. Terminals 2 and 3: Output to solenoid pilot or SOV.
3. Terminals 5 and 6: Power for electronics module. 5 MUST be +24VDC and 6 MUST be –24VDC.You can jumper the power from terminals 1
and 4 ifthe Solenoid is rated for 24VDC where a separate 24VDC supply is not available.
4. Terminals 7 and 8: Connection to external calibration and partial stroke test button (if installed). Can be used to remotely trigger PST and
Calibration from aDCS.
5. Terminals 9 and 11: Switch common and normally open connections for valve position 2 limit switch. Typically connected to DCS for limit
switch sensing. Forbench calibration or use in applications where alternate means of sensing valve position are used, these 2 terminals
must still be provided withsource and return. The source and return for the electronics module power can be used, but a 2500 Ohm, 1/2W
resistor MUST be installed betweenterminals 6 and 11 to prevent damage to the limit switch contacts from excess current.
6. Terminals 10 & 13: N/C side of Position 1 and 2 limit switch. Make sure current through switch is limited below maximum rating. If the
system this unit is implemented on is monitoring the N/C side of the switches, a 2500 ohm, 1/2W resistor will need to wired between
terminals 10 and 6, as well terminal 13 and 6 for visual indication. If the system is monitoring the N/O side, neither of these terminals are
used.
7. Terminals 12 and 14: Switch common and normally open connections 1 limit switch. Typically connected to DCS for limit switch sensing.
For benchcalibration or use in applications where alternate means of sensing valve position are used, these 2 terminals must still be
provided with source andreturn. The source and return for the electronics module power can be used, but a 2500 Ohm, 1/2W resistor
MUST be installed between terminals 6and 14 to prevent damage to the limit switch contacts from excess current.
8. Terminals 15 and 16: Prewired to the GO™ Switch. Do not change these connections.
9. Terminals 17, 18 and 19: External PST status signals:
A. Terminal 17: PST status signal. In combination with terminal 18, it forms a dry contact that closes if the PST passes.
B. Terminal 18: 24VDC source terminal for diagnostics and status output signal. Wire this to DCS 24VDC output.
C. Terminal 19: PST diagnostic signal. When wired to a DCS DC I/O input, will deliver a pulse train after PST completes to report any
diagnostic information.
8
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%.If the value is
saved to memory successfully, the LED and diagnostic relay will flash message code 5-2.
4. Press and hold the push button for more than twenty seconds to set the partial stroke time tolerance range to 40%.If the value is saved to
memory successfully, the LED and diagnostic relay will flash message code 5-3.
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 willbe turned OFF.
Figure 3
Hardware Configuration:
1. Ensure that the valve is in the OPEN position (the green position 1 LED should be
illuminated.)
2. Refer to Fig. 3 which shows the correct orientation of the GO™ Switch target and sensor
camsfor FAIL CLOSED valves.
3. If the unit conforms to this configuration, you may proceed to calibration. If not,
completeHardware Configuration steps 4-7.
4. Lift the target wheel and rotate it such that the magnet is counterclockwise from the
GO™ Switch.
5. Loosen and slide the magnet in the target wheel so as to position it approximately one
inch from theedge of the GO™ Switch. Tighten to 20 in-oz.
6. Lift up on the upper cam and rotate it such that it is squarely aligned to the front of the
electronicsmodule. The green light on the module should come on.
7. Press down on the lower cam and rotate it such that it is 90º counter clockwise from the
electronics module.

Calibration:
1. Before performing calibration, make certain the valve is fully open (the green position 1 LED should be illuminated,) and the target button
is set to the properpartial 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
thatthe valve is not fully open. The Pass/Fail relay will be turned OFF.
2. Press and hold the calibration 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 predetermined 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 timeranges are from fifty milliseconds to thirty 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 cycles, both the LED and diagnostic relay will be steady, signifying that the calibration is complete.
Reset of the flashingLED and the diagnostic relay may be performed at anytime while the LED is flashing by pressing the calibration button.

9
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 isnot fully open. The Pass/Fail relay will be turned OFF.
2. If using the onboard module calibration button, press the button and hold it for more than half a second and less than five seconds.
If using the optional external PST button, 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 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 7.2 seconds.
6. If the time required for moving the valve to the Partial Stroke position is outside the acceptable range of the “partial stroke
calibration time”, the test will beaborted, 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: Beforerecalibration, make sure any failure codes are addressed (see table pg.#16).
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 rerunning the test, please wait for the LED to become steady or clear it by pressing the button.

10
ESD Calibration/PST Flow Chart—Fail Closed Valves

Apply power

NO LED displays memory error

Is memory ok? continuous fast flashing
Pass/fail relay state 0
YES

NO
Is device calibrated?

YES

Is button pressed and held NO

for at least 0.5 seconds?

YES

Is button Is button NO Is button NO Is button NO NO

NO Is button
releasedbefore released before released before released before
released?
5 seceonds? 10 seceonds? 15 seceonds? 20 seceonds?

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 momory Set partial stroke time

Is device calibrated?
tolerance range to 30%
YES
Writing status value to NO
memory successful?
NO Is stored calibrated value
for partial stroke time YES
within range? Is writing
NO
Valve closes tolerance Set partial stroke time
YES NO range value to tolerance range to 40%
memory
Valve closes successful?
Is maximum Is partial
NO allowed time NO stroke position
(30s) passed? reached? YES
Is partial stroke NO Is calibrartted
position reached? time passed? YES
YES
YES Is minimum
NO
allowed time (50ms)
passed?
Is minimum allewed NO Is writing Is writing
time (50ms) passed? Valve opens YES tolerance tolerance
range value to NO range value to
Valve opens Valve opens memory memory
YES 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 LED displays writing
1-1 pass/fail 5-5 pass/fail 4-4 pass/fail 7-7 pass/fail 5-5 pass/fail writing error code 6-6 error code 6-6 pass/fail
relay state 0 relay state 0 relay state 0 relay state 0 relay state 0 pass/fail relay state 0 relay state 0

LED displays LED displays

partial stroke test calibrarion 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

11
ESD CONVENTIONAL INSTRUCTION AND OPERATION—Fail Open Valves
Operation:
For 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. Nonvolatile 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, flashes unique visual indicators to signal pass/fail of tests and possible maintenancei ssues (please see ESD Conventional
Flow Chart and Message Table for ESD Conventional on pg.#15 for more details).
*Note that the following instructions assume the valve is FAIL OPEN and the direction of travel from CLOSED to OPEN is CCW.

Fail Open CALIBRATION

LED (AMBER)

BLUE
GO™ Switch connection (Prewired)
External PST button (Prewired)
Black
Valve Pos 1 (Closed) switch NO contact, needs path
back to DC
(Add a 2500 Ohm 1/2W resistor to path) TopWorx™ ESD
Power for electronics module 24VDC-

POSITION 2 POSITION 1
Valve Pos 1 NC Contact LED (RED) LED (GREEN)
Power for electronics module 24VDC+

Valve Position 1(Closed) COM. Tie it to Valve Position 1 COM Solenoid Pilot or SOV Output (-)

Valve Pos 2 (Open) switch NO contact, needs path back to DC

(Add a 2500 Ohm 1/2W resistor to path) BLACK (-)
ALARM COM PSI

Valve Pos 2 NC Contact RED (+)

Valve Position 2(Open) switch COM contact, wire it back to Solenoid Pilot or SOV Output (+)
CAL SW
Terminal 5 800mA@24VDC MAx
250mA@125VAC Max

Optional external diagnostic signal. If wired, will pass pulses out the same as
the LED flashes for the calibration diagnostic (pg.#16)

Figure 4: Calibration
Optional external signal COMMON.
Tie it to the Valve Pos 1 and 2 COM
Suggested Test Bench Setup for Switch
Fail Open Applications Optional external alarm signal. If wired, will close if PST calibration passes.

Wiring Connections:
1.  Terminals 1 and 4: External power source for switching the solenoid valve. Type and voltage level must match type of solenoid selected.
Typical is 24VDC.
2.  Terminals 2 and 3: Output to solenoid pilot or SOV.
3.  Terminals 5 and 6: Power for electronics module. 5 MUST be +24VDC and 6 MUST be –24VDC.You can jumper the power from
terminals 1 and 4 if the Solenoid is rated for 24VDC where a separate 24VDC supply is not available.
4.  Terminals 7 and 8: Connection to external calibration and partial stroke test button (if installed). Can be used to remotely trigger PST and
Calibration from a DCS.
5.  Terminals 9 and 11: Switch common and normally open connections for valve position 2 limit switch. Typically connected to DCS for
limit switch sensing. For bench calibration or use in applications where alternate means of sensing valve position are used, these 2
terminals must still be provided with source and return. The source and return for the electronics module power can be used, but
a 2500 Ohm, 1/2W resistor MUST be installed between terminals 6 and 11 to prevent damage to the limit switch contacts from
excess current.
6. Terminals 10 & 13: N/C side of Position 1 and 2 limit switch. Make sure current through switch is limited below maximum rating. If
the system this unit is implemented on is monitoring the N/C side of the switches, a 2500 ohm, 1/2W resistor will need to wired
between terminals 10 and 6, as well terminal 13 and 6 for visual indication. If the system is monitoring the N/O side, neither of
these terminals are used.
7. Terminals 12 and 14: Switch common and normally open connections 1 limit switch. Typically connected to DCS for limit switch sensing.
For bench calibration or use in applications where alternate means of sensing valve position are used, these 2 terminals must still
be provided with source and return. The source and return for the electronics module power can be used, but a 2500 Ohm, 1/2W
resistor MUST be installed between terminals 6 and 14 to prevent damage to the limit switch contacts from excess current.
8.  Terminals 15 and 16: Prewired to the GO™ Switch. Do not change these connections..
9.  Terminals 17, 18 and 19: External PST status signals:
A. Terminal 17: PST status signal. In combination with terminal 18, it forms a dry contact that closes if the PST passes..
B. Terminal 18: 24VDC source terminal for diagnostics and status output signal. Wire this to DCS 24VDC output.
C. Terminal 19: PST diagnostic signal. When wired to a DCS DC I/O input, will deliver a pulse train after PST completes to report any
diagnostic information.
12
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%.If the value is
saved to memory successfully, the LED and diagnostic relay will flash message code 5-2.
4. Press and hold the push button for more than twenty seconds to set the partial stroke time tolerance range to 40%. If the value is saved
tomemory successfully, the LED and diagnostic relay will flash message code 5-3.
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.
Figure 5
Hardware Configuration:
1. Ensure that the valve is in the CLOSED position (the green position 1 LED should be
illuminated).
2. Refer to Fig. 5 which shows the correct orientation of the GO™ Switch target and sensor
cams for FAILOPEN valves.
3. If the unit conforms to this configuration, you may proceed to calibration. If not,
complete HardwareConfiguration steps 4-7.
4. Lift the target wheel and rotate it such that the magnet is counterclockwise from the
GO™ Switch.
5. Loosen and slide the magnet in the target wheel so as to position it approximately one
inch from the edgeof the GO™ Switch. Tighten to 20in-oz.
6. Lift up on the upper cam and rotate it such that it is squarely aligned to the front of the
electronicsmodule. The green light on the module should come on.
7. Press down on the lower cam and rotate it such that it is 90º counter clockwise from the
electronics module.

Calibration:
1. Before performing calibration, make certain the valve is fully closed (the green position 1 LED should be illuminated,) and the target
button is set to the properpartial position.
*NOTE: If the valve is not fully closed, the test will abort and the LED and diagnostic relay will flash message code 7-7 indicating
that the valve is not fully closed. The Pass/Fail relay will be turned OFF.
2. Press and hold the calibration 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 predetermined position is reached.
6. The time required to move the valve from the “fully closed position” to the “partially closed position” is the partial stroke time of the
valve. The acceptable timeranges are from fifty milliseconds to thirty 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 flashingLED and the diagnostic relay may be performed at anytime while the LED is flashing by pressing the calibration button.

13
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 isnot fully open. The Pass/Fail relay will be turned OFF.
2. If using the onboard module calibration button, press the button and hold it for more than half a second and less than five seconds.
If using the optional external PST button, 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 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 7.2 seconds.
6. If the time required for moving the valve to the Partial Stroke position is outside the acceptable range of the “partial stroke
calibration time”, the test will beaborted, 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: Beforerecalibration, make sure any failure codes are addressed (see table pg.#16).
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 rerunning the test, please wait for the LED to become steady or clear it by pressing the button.

14
ESD Calibration/PST Flow Chart—Fail Closed Valves

Apply power

NO LED displays memory error

Is memory ok? continuous fast flashing
Pass/fail relay state 0
YES

NO
Is device calibrated?

YES

Is button pressed and held NO

for at least 0.5 seconds?

YES

Is button Is button NO Is button NO Is button NO NO

NO Is button
releasedbefore released before released before released before
released?
5 seceonds? 10 seceonds? 15 seceonds? 20 seceonds?

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 closed? Valve closes Is valve fully closed?

YES YES

NO Write uncalibrated status to momory Set partial stroke time

Is device calibrated?
tolerance range to 30%
YES
Writing status value to NO
memory successful?
NO Is stored calibrated value
for partial stroke time YES
within range? Is writing
NO
Valve opens tolerance Set partial stroke time
YES NO range value to tolerance range to 40%
memory
Valve opens successful?
Is maximum Is partial
NO allowed time NO stroke position
(30s) passed? reached? YES
Is partial stroke NO Is calibrartted
position reached? time passed? YES
YES
YES Is minimum
NO
allowed time (50ms)
passed?
Is minimum allewed NO Is writing Is writing
time (50ms) passed? Valve closes YES tolerance tolerance
range value to NO range value to
Valve closes Valve closes memory memory
YES successful? successful?
NO
Has valve moved?
YES YES
Is writing NO
Valve closes YES calibrated value
to memory
successful?

YES
LED displays LED displays LED displays LED displays LED displays
valve is not valve opening valve has not valve is not valve opening
calibrated code time failure code moved code fully closed code time failure code LED displays LED displays writing
1-1 pass/fail 5-5 pass/fail 4-4 pass/fail 7-7 pass/fail 5-5 pass/fail writing error code 6-6 error code 6-6 pass/fail
relay state 0 relay state 0 relay state 0 relay state 0 relay state 0 pass/fail relay state 0 relay state 0

LED displays LED displays

partial stroke test calibrarion 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

15
Message Table for ESD Conventional

LED Status Flash

Diagnostic Relay Message Problem Cause / Solution
Code
Solid ON Unit operating correctly No action required
1-1 Device not calibrated Need to perform the calibration procedure before the partial stroke test
Partial stroke test passed within
2-2 No action required
tolerance range
3-3 Calibration completed No action required
Possible causes include:
Valve has not moved during
4-4 1) The valve is stuck
partial stroke test
2) The shaft is broken
Partial stroke time tolerance
5-1 No action required
range is set to 20%
Partial stroke time tolerance
5-2 No action required
range is set to 30%
Partial stroke time tolerance
5-3 No action required
range is set to 40%
The valve did not reach the partial stroke position within the allotted time. Possible causes include:
1) The valve is stuck or sluggish
5-5 Partial stroke test failed
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
Unit cannot calibrate or run a partial stroke test without the valve starting in the required open or
closed position. Check the following:
Valve is not fully at the required
7-7 1) Air supply to actuator
open or closed position
2) Solenoid is powered
3) Cam setting for fail open or fail closed valves as required
Continuous fast
Hardware failure Contact factory
flashing

Electrical Ratings Diagnostic Relay and Pass/Fail Relay Outputs:

Current/Voltage The diagnostic relay outputs the status flash code as shown in the
Message Table Above.
Open/Closed Indication 0.25A@24VDC w/5V drop
0.25A@120VAC w/5V drop
DIAGNOSTIC RELAY
Dry Contact Rating Minimum Current Through Switch TIMING CHART
Contacts: 5 mA EXAMPLE OF A 2-2 RESPONSE
Module Voltage 18-28VDC
Module Current 50mA (MAX)
Pilot Current (Standard) 20mA
PST Feedback Relays 800mA@24VDC MAX
250mA@125VAC MAX
Solenoid Pilot/SOV 800mA@24VDC MAX
Maximum PowerRating 250mA@125VAC MAX
The Pulse Train will repeat 3 times. In order to use this diagnostic
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
one second. The Pulse Train can be reset anytime by activating the
Calibration Switch or the PST/Calibration Activation Input.

16
Pass/Fail Relay: Special Conditions of Safe Use (All installations)
Clean only with a damp cloth to prevent possibility of
The Pass/Fail Relay indicates whether the PST passed or failed. In this
electrostatic discharge.
example the relay is closed (high) from the last successful Partial
Stroke Test. For Explosion Proof installations, the internal ground connection shall
PASS / FAIL RELAY
be used and the external ground connection, if supplied in addition,
TIMING CHART is supplemental bonding allowed where local authorities permit, or is
required.
PARTIAL STROKE TEST When installing with a third party listed nipplemount solenoid, it is
SWITCH / ACTIVATION the responsibility of the installer to provide fittings, and apparatus,
(USER INITIATED)
suitable for the area classification in accordance with the National
PASS / FAIL RELAY Electrical Code.
(HIGH = CLOSED)
All cable entry devices or conduit stopping boxes shall be certified
in type of explosion protection ‘d’, suitable for the conditions of use
When the Partial stroke test button is pressed for less than 5 seconds and correctly installed.
the test begins and the Pass/Fail Relay opens (low). The Pass/Fail
The IIC enclosures are excluded from use in Carbon disulphide
Relay closes again once the unit passes a Partial Stroke Test.
atmospheres.
Hardware Fault Tolerance: HFT = 0
The air pressure to the valve block, when fitted, shall not exceed 7
Device Type: Type A
bar.
Systematic Capability: SC3 - SIL3 Capable
Useful Life: 10 years Preventative Maintenance
The proof test procedure should verify the ESD valve controller allows TopWorx™ are designed to operate for one million cycles without
the ESD valve to function 100% on command, and that any failures servicing. Call the factory when you are approaching this milestone
related to the valve, actuator or partial stroke test function are for a preventative maintenance kit and instructions.
revealed. The partial stroke test should be preformed monthly.
Personal preforming maintenance and testing on the product shall
be competent to do so.

17
Dimensions and Materials: TopWorx™ DXP
Cast aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.

MATERIALS OF CONSTRUCTION
MINIMUM 2.25” (63.5) REQUIRED CLEARANCE Enclosure Cast A360 aluminum with dichromate
IN ORDER TO DISENGAGE THE SHAFT FROM THE LID BUSHING conversion coating inside & out, epoxy
AND REMOVE LID WHERE OPTIMUM CONDITIONS APPLY
coated exterior rated for 250 hrs. salt
spray per ASTM B117
Fasteners 304 Stainless Steel standard
316 Stainless Steel optional
Shaft 304 Stainless Steel standard
316 Stainless Steel optional
Shaft Bushing Oilite Bronze
Indicator Dome Polycarbonate, UV F1 rated
Seals O-ring seals available in:
Buna, & Silicone

Fastener Torque Specifications

Enclosure Housing Bolts 8 ft.-lbs [10.8 N·m] +/-10%
Indicator Dome Screws 320 in-oz. [2.3 N·m] +/-10%
Bottom Mounting Holes 10 ft.-lbs [13.6 N·m] +/-10%

SHAFT TYPE OPTIONAL

SEE SHAFT DETAIL SECTION

18
Dimensions and Materials: TopWorx™ DXP - Flameproof Ex d IIC
Cast aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.

MATERIALS OF CONSTRUCTION
MINIMUM 2.25” (63.5) REQUIRED CLEARANCE Enclosure Cast A360 aluminum with dichromate
IN ORDER TO DISENGAGE THE SHAFT FROM THE LID BUSHING conversion coating inside & out, epoxy
AND REMOVE LID WHERE OPTIMUM CONDITIONS APPLY coated exterior rated for 250 hrs. salt
spray per ASTM B117
Fasteners 304 Stainless Steel standard
316 Stainless Steel optional
Shaft 304 Stainless Steel standard
316 Stainless Steel optional
Shaft Bushing Oilite Bronze
Indicator Dome Polycarbonate, UV F1 rated
Seals O-ring seals available in:
Buna, & Silicone

Fastener Torque Specifications

Enclosure Housing Bolts 8 ft.-lbs [10.8 N·m] +/-10%
Indicator Dome Screws 320 in-oz [2.3 N·m] +/-10%
Bottom Mounting Holes 10 ft-lbs [13.6 N·m] +/-10%

MOUNTING SURFACE

SHAFT TYPE OPTIONAL

SEE SHAFT DETAIL SECTION

VALVE TYPE OPTIONAL

SEE INTEGRATED PNEUMATIC
CONTROL VALVES SECTION

19
Dimensions and Materials: TopWorx™ DXS
Cast aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.

MINIMUM 2.5” (63.5) REQUIRED CLEARANCE MATERIALS OF CONSTRUCTION

IN ORDER TO DISENGAGE THE SHAFT FROM THE LID BUSHING
AND REMOVE LID WHERE OPTIMUM CONDITIONS APPLY Enclosure Cast 316 Stainless Steel
Fasteners 304 Stainless Steel standard
316 Stainless Steel optional
Shaft 304 Stainless Steel standard
316 Stainless Steel optional
Shaft Bushing N/A
Indicator Dome Polycarbonate, UV F1 rated
Seals O-ring seals available in:
Buna, & Silicone

Fastener Torque Specifications

Enclosure Housing Bolts 8 ft.-lbs [10.8 N·m] +/-10%
Indicator Dome Screws 320 in-oz. [2.3 N·m] +/-10%
Bottom Mounting Holes 10 ft.-lbs [13.6 N·m] +/-10%

MOUNTING SURFACE

OPTIONAL CONDUIT ENTRIES USED

ONLY WHEN 4 ENTRIES ARE SPECIFIED
SHAFT TYPE OPTIONAL
SEE SHAFT DETAIL SECTION
OPTIONAL CONDUIT ENTRIES
BOTH SIDES

VALVE TYPE OPTIONAL

SEE INTEGRATED PNEUMATIC
CONTROL VALVES SECTION

20
Interior and Indicator Assemblies
Interior Assembly

24 VDC PILOT

ESD MODULE CONTAINS (2) REED

RELAYS FOR FULL OPEN/CLOSED MODEL 35 GO SWITCH TO SET
INDICATION PLUS TIMER CIRCUIT PARTIAL STROKE POSITION

TARGET MAGNET VALVE

TARGET WHEEL ANODIZED ALUMINUM
316 STAINLESS STEEL
0.86 Cv 1/4” NPT PORTS
3.7 Cv 1/2” NPT PORTS

UPPER CAM
CAM TARGET
LOWER CAM

ENCLOSURE
DXP TROPICALIZED ALUMINUM
DXS 316 STAINLESS STEEL

PAD LOCK PROVIDED

BY END USER

OPTIONAL EXTERNAL PUSH PIEZO SWITCH

WITH LOCKING SHIELD FOR INITIATING
THE PARTIAL STROKE PROCEDURE

21
Certifications & Approvals

PESO

Ex d IIC T* Gb or Ex d IIB+H2 T* Gb; Ex tb IIC T* Db IECEx SIR 07.0093X / Sira 07ATEX1273X USL/CNL Class I,
Div 1, GrCD; Class II, Div 1, GrEFG UL File E125326
EAC RU C-US, M1062.B0027
KOSHA 19-GA4B0-0179X, 19-GA4BO-0180X & 19-GA4BO-0178X
NEPSI GY18.1386X
InMetro UL-BR 18.0096X
PESO P433642

Ex e MB IIC T* Gb; Ex tb IIIC T* Db

IECEx SIR 09.0088X / Sira 09ATEX3209X (DXR)

Ex nA nC IIC T* Gc; Ex tb IIIC T* Dc

USL/CNL Class I, Div 2, GrABCD; Class II, Div 2, GrFG UL
File E125326

USL/CNL General Purpose UL

File E359150

Environmental Ratings: Type 4, 4X; IP 66/67

Conformance to Directives: ATEX 2014/34/EU, EMC 2014/30/EV, LVD 2014/35/EO

*Operating and Ambient temperature ratings vary depending on bus/sensor option(s), reference certificate for specific markings available.

Consult factory for certification questions or to request a custom product.

22
23
24
Safe Use

User instructions (in compliance with ATEX 2014/34/EU Directive, Annex II, 1.0.6)
Instructions for safe selection, installation, use, maintenance and repair
1. The equipment may be used in zones 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 T3, T4, 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
electrostatic 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
approved 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
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 10.0bar.

Special Conditions or Safe Use (Flameproof Installations)

1. The IIC enclosures are excluded from use in carbon disulphide atmospheres.
2. The air pressure to the valve block, when fitted, shall not exceed 10.0 bar.
3. For ambient temperatures above 110ºC, the degrees of ingress protection IP66 and IP67 are not endorsed.
4. The slotted hexagonal head cover screws are not of standard form; they shall only be replaced with identical screws sourced from the
equipment manufacturer.
5. The hexagonal head cover screws are to be replaced only with stainless steel 304, grade A2-70 or A4-80 screws to ISO 35061.
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. Cover fasteners are to be tightened to a torque valve of 10.85Nm (8 ft./lbs) minimum.

25
Notes:

26
27
GLOBAL SUPPORT OFFICES

North America Asia-Pacific Europe

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

Middle East Africa

P.O. Box 17033 24 Angus Crescent
Jebel Ali Free Zone Longmeadow Business Estate
Dubai 17033 East Modderfontein
United Arab Emirates Gauteng South Africa
T. +971 4 811 8283 T. +27 11 451 3700
[email protected]

For comprehensive information on our company, capabilities, and products –

including model numbers, data sheets, specifications, dimensions, and certifications:

Visit us: Emerson.com/TOPWORX

Your local contact: Emerson.com/contactus

The Emerson logo is a trademark and service mark of Emerson Electric Co. TopWorx™ and GO™ Switch
are registered trademarks of the Emerson family of companies. All other marks are the property of their
respective owners. © 2020 Emerson Electric Co. All rights reserved.
Information contained herein - including product specifications is subject to change without notice.

ES-00936-1 R19-ENUS |06-20

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