Fisher TopWorx D-Series Asi Interface IOM Manuals & Guides

TopWorx™ D-Series with AS-interface

Installation, Operation & Maintenance Manual

Table of Contents

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

D-Series with AS-I 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.

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 your unit unless otherwise specified will
be factory set to operate in this fashion.

Illustration #2

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.
Notice that the indicator dome has been rotated 90°
compared to the unit above.

Illustration #1

2

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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.

Storage

Until conduit, conduit plugs, 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 -40ºF (-40ºC) to
160ºF (71ºC). Once properly installed, the temperature range listed on the nameplate will supersede this storage
temperature range.

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 torqueing 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 entri es
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
he 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.

TM

3

D-Series with AS-I Installation, Operation & Maintenance

Dimensions and Materials: TopWorx™ DXP

502.969.8000

Illustration #4

SHAFT TYPE OPTIONAL

SEE SHAFT DETAIL

SECTION

IN ORDER TO DISINGAGE THE SHAFT FROM THE ID BUSHING

MINIMUM 2.5" REQUIRED CLEARANCE

AND REMOVE LID WHERE OPTIMUM CONDITIONS APPLY

4.52

.85

2.10

MOUNTING SURFACE

OPTIONAL CONDUIT ENTRIES

2.13

6.65

USED ONLY WHEN 4 ENTRIES
ARE SPECIFIED

OPTIONAL CONDUIT ENTRIES

6.21

MATERIALS OF CONSTRUCTION

Cast A360 aluminum with dichro-

Enclosure

Fasteners

Shaft

Shaft
Bushing

Indicator
Dome

Seals

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

304 Stainless Steel standard
316 Stainless Steel optional

304 Stainless Steel standard
316 Stainless Steel optional

Oilite Bronze

Polycarbonate, UV F1 rated
O-ring seals available in: Buna &

Silicone,

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]

4

2.25

2.25

3.85

5/16-18 UNC - 2B
.44 DEEP

6.76

2.19

VALVE TYPE OPTIONAL

SEE INTEGRATED PNEUMATIC

CONTROL VALVES SECTION

www.topworx.com

Dimensions and Materials: TopWorx™ DXP - IIC

TM

Illustration #5

MATERIALS OF CONSTRUCTION

Cast A360 aluminum with dichro-

Enclosure

Fasteners

Shaft

Shaft Bushing Oilite Bronze
Indicator Dome Polycarbonate, UV F1 rated

Seals

Maximum Fastener Torque Specifications

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

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

304 Stainless Steel standard
316 Stainless Steel optional

304 Stainless Steel standard
316 Stainless Steel optional

O-ring seals available in: Buna &
Silicone,

8 ft-lbs [10.8 N·m]

5

D-Series with AS-I Installation, Operation & Maintenance

Dimensions and Materials: TopWorx™ DXS

502.969.8000

Illustration #6

SHAFT TYPE OPTIONAL

SEE SHAFT DETAIL

SECTION

IN ORDER TO DISINGAGE THE SHAFT FROM THE ID BUSHING

MINIMUM 2.5" REQUIRED CLEARANCE

AND REMOVE LID WHERE OPTIMUM CONDITIONS APPLY

4.52

.85

2.10

MOUNTING SURFACE

OPTIONAL CONDUIT ENTRIES

2.13

6.65

USED ONLY WHEN 4 ENTRIES
ARE SPECIFIED

OPTIONAL CONDUIT ENTRIES

6.21

MATERIALS OF CONSTRUCTION

Enclosure Cast 316 Stainless Steel

Fasteners

Shaft

Shaft Bushing N/A
Indicator Dome Polycarbonate, UV F1 rated

Seals

304 Stainless Steel standard
316 Stainless Steel optional

304 Stainless Steel standard
316 Stainless Steel optional

O-ring seals available in: Buna &
Silicone,

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]

6

2.25

2.25

3.85

5/16-18 UNC - 2B
.44 DEEP

6.76

2.19

VALVE TYPE OPTIONAL

SEE INTEGRATED PNEUMATIC

CONTROL VALVES SECTION

www.topworx.com

Dimensions and Materials: TopWorx™ DXR

TM

Illustration #7

SHAFT TYPE OPTIONAL

SEE SHAFT DETAIL

SECTION

IN ORDER TO DISINGAGE THE SHAFT FR OM THE ID BUSHING

MINIMUM 2.5" REQUIRED CLEARANCE

AND REMOVE LID WHERE OPTIMUM CONDITIONS APPLY

6.21

4.51

2.10

1.10

MOUNTING SURFACE

2.00
OPTIONAL CONDUIT ENTRIES

USED ONLY WHEN 4 ENTRIES
ARE SPECIFIED

OPTIONAL CONDUIT ENTRIES

MATERIALS OF CONSTRUCTION

®

Valox

Enclosure

364
Polybutylene
Terephthalate (PBT)

Fasteners

Shaft

Shaft Bushing Delrin

304 Stainless Steel standard
316 Stainless Steel optional

304 Stainless Steel standard
316 Stainless Steel optional

®

500P white

Indicator Dome Polycarbonate, UV F1 rated

Seals O-ring seals available in: Silicone

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]

2.25

5.03

2.25

3.66

2.14

6.10

5/16-18 UNC - 2B
.44DP

VALVE TYPE OPTIONAL

SEE INTEGRATED PNEUMATIC

CONTROL VALVES SECTION

7

D-Series with AS-I Installation, Operation & Maintenance

Dimensions and Materials: Shafts

Illustration #8

: Shaft Detail

502.969.8000

8

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Illustration #9: Enclosure Assembly

TM

Screws are
captive

Pilot Device Options:

See Illustration

#5

#12

O-ring Seal

Sensor

Options:

See

Illustration

pg. 10

#6

Inter nal Ground
Lug

Indicator As semb ly

See Illustration #2

Shaft Assembly

See Illustration #7

#10

Valve Options:

See Illustration #4

#11

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

AV-4B002 90º, Green/Open, Red/Closed, Buna O-Ring

Conduit Entry

External Ground Lug

Illustration #10: Indicator Assembly

Indicator Dome,

O

+

5 adjustable

Polycarbonate

with keyed mask.

Several rotation and

form options.

Available in Buna-N,

Silicone, EPDM, Viton

O-ring

Color-coded Indicator is
available in several
coordinating rotations and
forms for various valve
types, such as 90 , 180
and Thru-divert applications.

10-32 Captive screws,
Stainless (x4)

00

9

D-Series with AS-I Installation, Operation & Maintenance

502.969.8000

Illustration #11: SCM-ASI
Sensor Communication Module

Calibration

Switch

CLOSE ASI OPEN

-

AS-i

Terminals

Solenoid

Terminals

Solenoid Note: Internal mount pilot in the DXP/DXS is 0.6W. For any externally mounted, or customer supplied, solenoid valve 4 watt maximum
power consumption is allowed. A 170 mA max surge current limitation is required to prevent activation of the short circuit protection.

I
S
A
+

LEDs

Open

Outputs

TopWorx

SCM-ASi 2.1

Close

AUX Input

Inputs

Terminals

- D2 + - D3 +

Illustration #12: SCM-ASI
Wiring Diagram

D-Series with ASi Wiring

Step 1

For internally-mounted or external pilot device(s), wire the ‘+’
and ‘-’ leads to the terminals marked D0 (open) and D1
(closed). The internally-mounted pilot has an LED indicator
for power verification. Note: For an externally mounted

solenoid valve, 4 watt maximum power consumption
is allowed. A 160 mA surge current limit is required to
prevent activation of the short circuit protection circuit.

Step 2

Connect the AS-i communication wires to the terminals
marked AS-i ‘+’ and AS-i ‘-’ . (See Illustration 12 for wiring
diagram) Note: For calibration of the switches, a 24 VDC

power supply may be used instead of an ASI Controller.
If an ASI Controller is not available, wire +24 VDC to
ASI+, and GND to ASI-. The calibration switch will still be
able to actuate the valve.

Additional Instruction for wiring an external switch input.

For externally mounted auxiliary input limit switches, wire
switches to the terminals marked -D2+ for the open switch
and -D3+ for the closed limit switch.

Profile S-B.A.0

Device ID
Device I/O

Inputs
D2 Open Limit Switch
D3 Closed Limit Switch

Outputs
D1 Solenoid #1 (Close)
D0 Solenoid #2 (Open)

Current 40mA + open solenoid current and

Voltage 20 to 30VDC

NOTE: When upgrading a TopWorx AS-i module with a

new TopWorx AS-i 2.1 module, make sure the input and
output data bit positions are updated as indicated above.

AS-i Specifications

A Free Profile
B 2 Inputs / 2 Outputs

0 Switch Open
1 Switch Closed

0 De-energize Solenoid
1 Energize Solenoid

closed solenoid current
Max solenoid current = 160mA
per outputMax power = 4 watts per output)

Calibrating Limit Switches inside the SCM-ASi Module

Never perform the switch calibration procedure where area is
known to be hazardous.

Step 1

Once pneumatic hookup and wiring has been completed
close the valve using the SCM-ASI on-board calibration
switch, as seen in Illustration 11. If no AS-i network connec­tion is available, you may connect a 24VDC power supply to
the + ASI - terminals as previously described.

Step 2

With the valve in the CLOSED position, disengage the
BOTTOM Cam from the splined Hub and rotate Clockwise
until the Red LED lights. Release the Cam to re-engage the
splined Hub.

Step 3

Open the valve by sliding the calibration switch to the OPEN
position.

Step 4

Once the valve is in the OPEN position, disengage the TOP
cam from the splined hub and rotate Counter-clockwise until
the Green LED lights. Release the Cam to re-engage the
splined Hub.

Step 5

Cycle the valve CLOSED and OPEN several times using the
calibration switch to verify both limit switches are
maintaining their set points.

Step 6

Finally, slide the calibration switch to the ASI position. The AS-i
network will now have full control of the valve once the SCM­ASI has been addressed.

10

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TM

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. A 40 micron point of use filter at
every device is recommended.

4-Way Spool Valves

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 marked as follows:

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

5

4

DOUBLE ACTI NG ACT UATORS SPRING RETURN A CTUATORS

Supply

1

Always install vents

or speed controls

3

2

Port to OpenPort to Cl o se

Highly 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.

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.

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.

Supply

1

2

Port to Open

3

/Close

5

4

Plug

Spool Valve Specifications

Medium Dried, filtered air (40 micron)
Max Operating

Pressure
Min. Operating

Pressure
Ambient

Temperature Range
Flow Coefficient 1.2Cv or 3.0Cv

Environment Rating Type 4, 4X, IP67

Port Size 1/2” NPT for 3.0Cv valve

Manual Override Available in Latching/Non-Latching

Valve Body Available in Hardcoat Anodized

Valve Seals Spool Seals: Buna-N

100psi (0.7 MPa) (6.89Bar)

30psi (0.28 MPa) (2.76Bar)

Refer to Product Nameplate Marking

1/4" NPT for 1.2Cv valve

Push Type & Palm Actuator Type

Aluminum, 304, or 316 Stainless Steel

Valve Body Seals available in
Buna & Silicone,

Don’t forget!

TopWorx has a complete line of
breathers, flow controls, regulators
and filters.

Check out www.topworx.com or call
us at 502.969.8000 for more details

11

D-Series with AS-I Installation, Operation & Maintenance

502.969.8000

Spool Valves and Pilots

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

Fail Last Position Spool Valve Replacement Assemblies

AV-BFLPVA20 Std Alum Spool Valve Assy w/Buna seals
AV-BFLPVS20 Std 304SS Spool Valve Assy w/Buna seals
AV-BFLPV620 Std 316SS Spool Valve Assy w/Buna seals

Block-Center Spool Valve Replacement Assemblies

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

**Consult factory for more options.

Illustration #13: Spool Valve Assembly

Flame arrestor O-ring

(x5)

M5 x 25mm SHCS (x4)

(4mm hex wrench)

Spool Valve with No Manual Override

Spool Valve with Single Palm Actuator Override

Spool Valve with Dual Palm Actuator Override

Push-button Style Override

Illustration #14: Pilot Device Assembly

Manifold

Manifold

24V, 110V, 220V, or

24V, 110V, 220V or

Intrinsically Safe Pilot Device

(no plug connector on I.S. Pilots)

IntrinsicallySafe Pilot Device

(no plug connector on I.S. pilots)

(x1) for Fail Closed apps

(x2) for Fail Last Position &

Block Center apps

(x1) for Fail Closed Apps

(x2) for Fail Last Position &

Block Center Apps

Bracket

Bracket

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

12

4-40x.25 (x2)

4-40x0.25 (x2)

Coil 2

4- 40 x .25"
SEM screw

TORQUE
100 IN-OZ

Bracket

SINGLE PILOT ASSEMBLY

4- 40 x .25"
SEM screw

TORQUE
100 IN-OZ

Bracket

Coil 1

Pilot
Assembly

RED Urethane
Tubing (Supply)

YELLOW Urethane

Tubing (Work)

YELLOW Urethane

Tubing (Work)

10-32 Metal Plug

Barbed

“Y” Fitting

RED Urethane
Tubing (Supply)

Pilot
Assembly

YELLOW Urethane

Tubing (Work)

10-32 Metal Plug

Orifice
Assembly

10-32 Metal
Barb Fitting

TORQUE 60 IN-OZ

Orifice
Assembly

10-32 Metal
Barb Fitting

TORQUE 60 IN-OZ

ORIFICE TO BE USED
IN EXPLOSION PROOF
APPLICATIONS ONLY

www.topworx.com

TM

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™ Discrete Valve Controllers are designed to operate for one million cycles without servicing. Call
TopWorx when you are approaching this milestone for a preventative maintenance kit and instructions.

13

D-Series with AS-I Installation, Operation & Maintenance

Certifications & Approvals

502.969.8000

14

www.topworx.com

Warranty

TM

15

GLOBAL SUPPORT OFFICES

North America

3300 Fern Valley Road
Louisville, Kentucky 40213 USA
1 502 969 8000
[e-mail]

Middle East

P.O. Box 17033
Jebel Ali Free Zone
Dubai 17033
United Arab Emirates
[phone]
[e-mail]

Asia-Pacific

1 Pandan Crescent
Singapore 128461
65 6891 7550
[e-mail]

Africa

24 Angus Crescent
Longmeadow Business Estate East
Modderfontein
Gauteng
South Africa
27 011 451 3700
[e-mail]

Visit www.topworx.com for comprehensive information on our company,
capabilities, and products — including model numbers, data sheets,
specifications, dimensions, and certifications.

[e-mail]

www.topworx.com

Europe

Horsfield Way
Bredbury Industrial Estate
Stockport
SK6 2SU UK
44 0 161 406 5155
[e-mail]

The Emerson logo is a trademark and a service mark of Emerson Electric Co. ©2015 Emerson
Electric Co. ©2015 TopWorx™, All rights reserved.TopWorx, Valvetop, 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.

™

S-K138 R10