Table of Contents

Electrical Ratings
Current/Voltage
Open/Closed 0.25A@24VDC w/5V drop
Indication 0.25A@120VAC w/5V drop

Module Voltage 18-28VDC

Module Current 50mA (MAX)

CALIBRATION
SWITCH Pilot Current (Standard) 20mA

ALARM COM
PST Feedback Relays 800mA@24VDC MAX
PSI
250mA@125VAC MAX
Pilot MAX Valve Rating 800mA@24VDC MAX
PASS/FAIL

DIAGNOS-

250mA@125VAC MAX
RELAY

COM
{

PARTIAL
STROKE TEST
FEEDBACK

24VDC(+) COM
LOAD

24VDC(-) WW NO
200(4W) to
2500(1/2W)Ohms

ES-04538-1
ES-04530-1
 Spool Valve Specifications
Medium Dried, filtered air (40 micron)
Max Operating
100psi (0.69 MPa) (6.89Bar)
Pressure

Min. Operating
30psi (0.21 MPa) (2.07Bar)
Pressure

Max Consumption Rate 600 cc/min @ 80psi

Ambient
Refer to Product Nameplate Marking
Temperature Range

Flow Coefficient 1.2Cv or 3.0Cv

Exhaust of Port 4 Supply Exhaust

Exhaust of Port 2 of Port 4 Supply Exhaust of Port 2 Environment Rating Type 4, 4X, IP67
(when actuator opens) (when
(when actuator actuator opens)
closes) (when actuator closes)

TOP VIEW 1/2” NPT for 3.0Cv valve

TOP VIEW Port Size
1/4" NPT for 1.2Cv valve
5 1 3 5 1 3
Pilot Valve Pilot Valve Pilot Valve Pilot Valve
Internally Internally Internally Internally Available in Latching/Non-Latching
mounted mounted Mounted MountedManual Override
4 2 4 2 Push Type & Palm Actuator Type
Port to Port to
Port to Port to
Actuator Close Actuator
Actuator OpenClose Actuator Open Available in Hardcoat Anodized
Valve Body
BOTTOM VIEW BOTTOM VIEW Aluminum, 304, or 316 Stainless Steel

***Never Plug, Block orVER

***NE Restrict Port
PLUG, OR 5***
BLO CK, P O RT 5*** ***NE VER PLUG, OR BLO CK, P O RT 5***
Spool Seals: Buna-N
Always install vents Always install vents
Valve Body Seals available in
or speed controls or speed controls Supply Valve Seals
Supply Supply Buna-N, Silicone, EPDM & Viton.

5 1 3 55 11 33 5 1 3

4 2 44 22 4 2

Port to Close Port to Open Plug

Port to Close Port to
Port Open /Close
to Open Plug Port to Open

DOUBLE ACTING ACTUATORS DOUBLE

SPRING ACTING
RETURNACTUATORS
ACTUATORS SPRING RETURN ACTUATORS

5 1 3 5 1 3

4 2 4 2
FAIL CLOSED FAIL CLOSED

5 1 3 5 1 3

4 2 4 2
FAIL LAST POSITION FAIL LAST POSITION

5 1 3 5 1 3

4 2 4 2
BLOCK CENTER BLOCK CENTER

Push
Button

Flame Arrestor O-Ring (x5)

Push Button Override

M5 x 25mm SHCS (x4)

(4mm hex wrench)

Spool valve with Spool Valve with Spool Valve

dual manual override Single Manual Override Without Manual Override

ES-04540-1
 SINGLE PILOT ASSEMBLY Pilot
Assembly

Manifold
YELLOW Urethane 10-32 Metal Plug
Tubing (Work)
24V, 110V, 220V, or
Intrinsically Safe Pilot Device
(no plug connector on I.S. Pilots)
(x1) for Fail Closed apps
(x2) for Fail Last Position &
4- 40 x .25"
Block Center apps
SEM screw 10-32 Metal
TORQUE Barb Fitting
100 IN-OZ TORQUE 60 IN-OZ

Bracket
ORIFICE TO BE USED
RED
IN EXPLOSION PROOF
Urethane
Bracket APPLICATIONS ONLY
Tubing
4-40x.25 (x2) Orifice
(Supply)
Assem-

F7 F9 USE IN ALL APPLICATIONS

(EXCLUDING M,K,H,L2 SWITCH OPTIONS)
SINGLE I.S. PILOT ASSEMBLY
F18 F21 M, K, & H SWITCH OPTIONS
I.S. Pilot
Assembly 10-32 Metal
Barb Fitting F17 F16 USE IN L2 OPTION ONLY

RED 10-32 Metal Plug

Urethane
Tubing
(Supply) DUAL PILOT ASSEMBLY
YELLOW Urethane
10-32 Metal Coil 1 Pilot Tubing (Work)
Barb Fitting Assembly
TORQUE 60 IN-OZ
RED Urethane
Tubing (Supply) 10-32 Metal Plug
4- 40 x .25"
SEM screw
TORQUE 10-32 Metal
100 IN-OZ Barb Fitting
TORQUE 60 IN-OZ
Coil 2

4- 40 x .25"
YELLOW Urethane SEM screw
Tubing (Work) TORQUE
Bracket 100 IN-OZ
Barbed
Bracket “Y” Fitting

DUAL I.S. PILOT ASSEMBLY 10-32 Metal

RED Urethane
Barb Fitting
Tubing (Supply)

I.S. Pilot RED Barbed YELLOW Urethane

Assembly Urethane “Y” Fitting Tubing (Work)
ORIFICE TO
Tubing BE USED IN
(Supply) EXPLOSION
YELLOW Urethane Tubing Orifice
PROOF Assembly
(Work) APPLICATIONS
ONLY
RED Urethane
Tubing (Supply)

10-32 Metal
Barb Fitting
4- 40 x .25" TORQUE 60 IN-OZ
SEM screw
TORQUE
100 IN-OZ

Bracket
10-32 Metal Plug
 BLUE
GO™ Switch connection (Prewired) External PST button (Prewired)
BLACK

Power for electronics module 24VDC-

Valve Pos 1 (Open) switch NO contact. During bench testing, add a
2500 Ohm, 1/2 W resistor for path back to DC supply via terminal 6.
Power for electronics module 24VDC+

Valve Position 1 (Open). COM. Tie it to Valve Position 1 COM 24VDC+ Pilot valve solenoid power return 24VDC-

BLACK
Valve Pos 2 (Closed) switch NO contact. During bench testing, add a
Pilot valve solenoid output (Prewired)
2500 Ohm, 1/2 W resistor for path back to DC supply via terminal 6.
RED

Valve Position 2(Closed) switch COM contact,

Pilot valve solenoid power 24VDC+
wire it back to Terminal 5 24VDC+

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

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

Optional external signal COMMON.

Calibration Tie it to the Valve Pos 1 and 2 COM
Switch
Optional external alarm signal.
If wired, will close if PST calibration if passes.

ES-04786-1
Fig. X

ES-04787-1
 Apply power

LED displays memory error

No
Is memory ok? continuous fast flashing
Pass/fail relay state 0
Yes

No
Is device calibrated?

Yes

Is button pressed and held for No

at least 0.5 seconds?

Yes

Is button Is button Is button Is button

No No No No Is button No
released before released before released before released before
released?
5 seconds? 10 seconds? 15 seconds? 20 seconds?

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 memory Set partial stroke time
Is device calibrated?
tolerance range to 30%
Yes
Is writing status value to No
No memory successful?
Is stored calibrated
value for partial stroke time Yes
within range? Is writing
No Set partial stroke time
Valve closes tolerance
Yes No
range value to tolerance range to 40%
memory
Valve closes
Is maximum Is partial successful?
No No
allowed time stroke position
(30s)passed? reached? Yes
Is partial stroke No Is calibrated Yes
position reached? time passed? Yes

Yes No
Is minimum
allowed time (50ms)
passed?
Is minimum allowed No Is writing Is writing
Valve opens Yes tolerance tolerance
time (50ms) passed?
range value to No range value to
Yes Valve opens Valve opens memory memory
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 writing LED displays writing
1-1 Pass/fail 5-5 Pass/fail 4-4 Pass/fail 7-7 Pass/fail 5-5 Pass/fail error code 6-6 Pass/ error code 6-6 Pass/
relay state 0 relay state 0 relay state 0 relay state 0 relay state 0 fail relay state 0 fail relay state 0

LED displays LED displays

partial stroke test calibration 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

ES-04788-1
 Fail Open

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

Valve Pos 1(Closed) switch NO contact, needs path Power for electronics module 24VDC-
back to DC
(Add a 2500 Ohm 1/2W resistor to path)
Power for electronics module 24VDC+

Valve Position 1(Closed) COM. Tie it to Valve Position 1 COM Pilot valve solenoid power return 24VDC-

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

(Add a 2500 Ohm 1/2W resistor to path) Pilot valve solenoid output (Prewired)
RED

Valve Position 2(Open) switch COM contact, Pilot valve solenoid power 24VDC+
wire it back to Terminal 5

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

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

Optional external signal COMMON.

Tie it to the Valve Pos 1 and 2 COM
Calibration
Switch Optional external alarm signal.
If wired, will close if PST calibration passes.

ES-04789-1
Fig. X

ES-04790-1
 Apply power

LED displays memory error

No continuous fast flashing
Is memory ok?
Pass/fail relay state 0
Yes

No
Is device calibrated?

Yes

Is button pressed and held for No

at least 0.5 seconds?

Yes

Is button Is button Is button Is button

No No No No Is button No
released before released before released before released before
released?
5 seconds? 10 seconds? 15 seconds? 20 seconds?

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 Valve closes Is valve fully closed?
closed?
Yes Yes
No
Write uncalibrated status to memory Set partial stroke time
Is device calibrated?
tolerance range to 30%
Yes
Is writing status value to No
No memory successful?
Is stored calibrated
value for partial stroke time Yes
within range? Is writing
No Set partial stroke time
No
Valve opens tolerance
Yes
range value to tolerance range to 40%
memory
Valve opens
Is maximum Is partial successful?
No No
allowed time stroke position
(30s)passed? reached? Yes
Is partial stroke No Is calibrated Yes
position reached? time passed? Yes

Yes Yes No Is minimum

allowed time (50ms)
passed?
Is minimum allowed No Is writing Is writing
Valve closes Yes tolerance tolerance
time (50ms) passed?
range value to No range value to
Yes Valve closes Valve closes memory memory
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 time failure code LED displays writing LED displays writing
1-1 Pass/fail 5-5 Pass/fail 4-4 Pass/fail code 7-7 5-5 Pass/fail error code 6-6 Pass/ error code 6-6 Pass/
relay state 0 relay state 0 relay state 0 Pass/fail relay relay state 0 fail relay state 0 fail relay state 0

LED displays LED displays

partial stroke test calibration 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

ES-04791-1
 LED Status Diagnostic Relay
Problem Cause / Solution
Flash Code Message
Solid ON Unit operating correctly No action required

1-1 Device not calibrated Need to perform the calibration procedure before the partial stroke test

2-2 Partial stroke test passed with-in No action required

tolerance range

3-3 Calibration completed No action required

4-4 Valve has not moved during partial Possible causes include:
stroke test 1) The valve is stuck
2) The shaft is broken
5-1 Partial stroke time tolerance range is No action required
set to 20%
5-2 Partial stroke time tolerance range is No action required
set to 30%

5-3 Partial stroke time tolerance range is No action required

set to 40%
5-5 Partial stroke test failed The valve did not reach the partial stroke position within the allotted time. Possible causes include:
1) The valve is stuck or sluggish
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
7-7 Valve is not fully at the required Unit cannot calibrate or run a partial stroke test without the valve starting in the required open or closed position.
open or closed position Check the following:
1) Air supply to actuator
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

Current/Voltage
Open/Closed 0.25A@24VDC w/5V drop
Indication 0.25A@120VAC w/5V drop
Module Voltage 18-28VDC

Module Current 50mA (MAX)

Pilot Current (Standard) 20mA

PST Feedback Relays 800mA@24VDC MAX

250mA@125VAC MAX
Pilot MAX Valve Rating 800mA@24VDC MAX
250mA@125VAC MAX

ES-04792-1
 24VDC(+) COM
LOAD

24VDC(-) WW NO
200(4W) to
2500(1/2W)Ohms

**Same for both open indication and closed indication output .

 MATERIALS OF CONSTRUCTION
Cast A360 aluminum with
dichromate conversion coating
Enclosure inside & 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

Fastener Torque Specifications

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

ES-04542-1
 MATERIALS OF CONSTRUCTION
Cast A360 aluminum with di-
chromate conversion coating
Enclosure inside & 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

Fastener Torque Specifications

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

ES-04543-1
 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:

Seals
Buna, Silicone, EPDM & Viton

Fastener Torque Specifications

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

ES-04544-1
 MATERIALS OF CONSTRUCTION

Enclosure Valox™ 364

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
Seals Silicone

Fastener Torque Specifications

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

ES-04545-1
ES-04793-1
Please visit our website to download a copy of the exida
Functional Safety Assessment Report for the TopWorx™
ESD Valve Controller at http://www.topworx.com

ES-04794-1
ES-04796-1
ES-04551-1
ES-04795-1
GLOBAL SUPPORT OFFICES

North America Asia-Pacific Europe

Africa
Middle East

www.topworx.com

ES-00936-1 R16