Westlock Controls Corporation Beacon Specifications

QUANTUM ROTARY MODELS:
764/864/765/865/784/789/711/811
722/777/877/360/366
INSTALLATION AND
OPERATIONS MANUAL
IOM: Tech-382
Prepared By: Herb Tucker Date: 8/23/05
Revision: A
Reviewed By: Lee Bradley
Approved By: Rhonda Frey
Date: 3/25/13
Drafting Work Order:20285 ECN: 12261
Date: 3/25/13
This IOM contains confidential information and is issued in confidence on the condition that it be returned on demand and not be copied,
reproduced, disclosed to others or used in manufacture of the subject matter thereof without the written consent of Westlock Controls
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 1 of 15
Revision History
Revision
Initial release 8/23/05: Rev. A 3-25-13
Westlock Controls Offices
USA
Westlock Controls Corp.
280 North Midland Ave. Ste 258, Saddle Brook, NJ 07663
Phone: (201) 794-7650 •Fax: (201) 794-0913
Email: westlockinfo@westlockcontrols.com
Internet http://westlockcontrols.com
Europe
Westlock Controls UK
Chapman Way, Tunbridge Wells
Kent, England TN23EF
Phone: 011-44-189-251-6277 •Fax: 011-44-189-251-6279
Email: sales@westlockuk.com
Internet: http://westlockcontrols.com
South America
Westlock Equipamentos de Controle Ltda.
Operations:
Sales:
Av. Antonio Bardella, 3000
Al. Araguaia, 2044 – Sl. 1101, Bloco B
Galpões 2A e 2B – Alto da Boa Vista
Edifício CEA – Alphaville
Sorocaba – São Paulo – Brazil
Barueri – São Paulo – Brazil
18085-852
06455-000
Tel: + 55 15 2102-7400
Tel: + 55 11 2588-1400
Fax: + 55 15 2102-7400
Fax: + 55 11 2588-1410
Email: comercial@westlock.com.br
Internet: http://westlockcontrols.com
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 2 of 15
1. Introduction
1.1. Product Certification
764/864/784: Type 4/4X for Non-Hazardous Locations Only
765/865/789: Non-incendive, Class I, Div. 2 Grps A, B, C, D; Class II, Div. 2
Grps F,G; Type 4/4X
711/811/722: Intrinsically Safe, Class I, Div. 1 & 2 Grps A, B, C, D; Class II,
T6, Ta=60 C, Div. 1 & 2 Grps E, F,G when operated through approved
barriers; Type 4X.
Max Entity Parameters for VA-30061 & VA-30217:
Vmax=35V, Imax=300mA, Ci=0, Li=0; Installed in accordance with
MS-10312.
Max Entity Parameters for VA-30657-002 & VA-30658-002:
Vmax=28V, Imax=115mA, Pi=1.6W, Ci=0, Li=0; Installed in
accordance with WD-12031.
777/877: Class 1, Div. 1 & 2 Grps C, D; Class II, Grps E, F, G T6 Ta=60 C
360/366: Class 1, Div. 1 & 2 Grps C, D; Class II, Grps E, F, G T5 Ta=-50 C to
60 C, Type 4, 4X, 6P
1.2.
Warnings
Never remove enclosure cover or make/break electrical connections
with power connected to the unit.
Perform all wiring in accordance with site and local codes and the
National Electric Code ANSI-NFPA-70 (US) or the Canadian Electric
Code Part I (Canada) for the appropriate area classifications.
Confirm that the Quantum model being installed is approved for the
hazardous area (consult unit identification label).
Ensure that approved and properly sized IS barriers are used in
installations with 711, 811, 722 and 822 (confirm entity parameters
from product ID label).
Confirm that power supplied to switches and solenoid is within rated
specifications listed on the unit identification label.
Protect the unit from exposure to aggressive substances or
atmospheres to ensure that hazard rating is not compromised.
Disconnect power to solenoids and the inlet air supply before
conducting any valve service or maintenance. Avoid the introduction
of any contaminants into the valve.
1.3.
Description
Quantum valve control monitors are intended for use as both visual and
electrical position indicators and controllers for discrete rotary devices, most
commonly pneumatically actuated 2-way quarter-turn or 3-way valves. A
Quantum control monitor is not limited for use in only quarter-turn valve
applications, but that application will be assumed for the purpose of this
document. In addition to the control monitoring features, Quantum control
monitors may serve as wiring junctions for accessories where additional
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 3 of 15
terminals, conduit entries and wiring codes permit. The Falcon integral
solenoid valve is an air piloted solenoid valve system incorporating elastomer
static seals through which a shaped spool moves and are manufactured for 3or 4-way operation. 3-way is normally used for pilot control of the other relay
valves or for the operation of single acting cylinders. 4-way is normally used
to control the action of double acting cylinders.
1.4.
Principles of Operation
A Quantum control monitor mounts to an actuator via a mounting kit, usually
sold separately. The unit shaft couples to the actuator shaft directly via
NAMUR adaptation, or via a coupling provided in the mounting kit. The
Quantum’s integral Falcon solenoid-piloted directional control valve provides
an air signal to the actuator to change its state, thus controlling the actuated
valve. An electrical signal from the control system actuates the integral
solenoid valve system in the Quantum. In a typical, normally closed, springreturn Falcon valve, the spool controlling the direction of air flow is moved by
pressurized pilot air acting on a piston when the coil is energized. The spool
is returned to the normally closed position by a spring, and the piston is
vented to atmosphere. The spool may be manually moved to control air flow
direction with override options. The pilot air supply is normally routed
internally from the air supplied to Inlet port 1. Power is supplied separately to
pre-wired coils via the terminal strip in the Quantum. As the actuator rotates
the unit shaft, adjustable cams on the shaft actuate mechanical or proximity
switches inside the unit enclosure, at the limits of rotary travel set by the
customer. The switches are pre-wired to the terminal strip in the enclosure,
permitting easy connection of switch output to external electrical control
monitoring systems or indication devices. The visual Beacon indicator on the
enclosure cover indicates 90 rotary travel between OPEN and CLOSED
valve positions, unless ordered optionally for other angular strokes or 3-way
valve applications.
1.5.
Special Features/Conditions
To avoid build-up and discharge of static electricity in a hazardous area, only
clean Westlock units with a static-free cloth dampened with water. Avoid the
use of alcohol-based cleaners.
2.
Ordering
Ordering guides for all Quantum product series and spare Falcon valve
assemblies and stand-alone valves for use outside an integrated Westlock
Controls monitor covered by this IOM are available through a local Westlock
distributor, the current Westlock Controls catalog literature or the Westlock
Controls website at westlockcontrols.com. Spare parts lists for refurbishments
or repairs are also available for common Quantum models.
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 4 of 15
3.
Definitions
NAMUR- This term, in the context of mounting brackets and shafts, refers to
the NAMUR VDI/VDE 3845 standard for the dimensions of actuator output
shafts and auxiliary equipment mounting hole patterns. In the context of
inductive proximity sensors, NAMUR refers to conformance of the sensor to
DIN 19 234, allowing its use with any NAMUR style amplifier/isolator.
Switch- A manual or mechanically actuated device for making, breaking or
changing the connections in an electric circuit. This term will be used also for
magnetic or inductive proximity sensors for the purpose of this document.
4.
4.1.
Installation
Mounting Instructions
Required Tools: Open-end wrenches or adjustable wrench to fit all sizes of
hex head bolts in the mounting kit.
1. Obtain a mounting kit suited for the actuator/valve, commonly available
through a local Westlock Controls distributor.
2. Attach the mounting bracket and coupler (if required) to the unit
housing with the hardware provided.
3. Attach the unit and mounting system to the actuator.
4. Ensure proper axial alignment between unit shaft, coupler and actuator
shaft. Failure to ensure alignment could result in long-term stressrelated failure of unit shaft in high cycle or high torque applications.
Fig. 1
Mounting the Quantum units with accessory bracket kits
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 5 of 15
4.2. Solenoid Valve Operating Instructions
4.2.1 Standard Valve Specifications
NOTE: ALWAYS consult the Quantum product ID label for coil electrical
specifications and for pressure and temperature specifications for each
unit, as they will vary with area classification, valve options and other
factors.
Std. Operating Pressure: 45-120 PSIG
Std. Operating Temperature: -4° F to 176° F
(Agency approvals may be valid for different operating temperature ranges).
Operating Media: Lubricated or dry air, filtered to 20 microns.
4.2.2 Installation/Connection of Falcon Directional Control Valve
Porting Designation
1/4” NPT air ports for inlet, outlet, and exhaust
(3.5 Cv valve has 1/2” NPT air ports)
Spring Return 4-way (5/2) Valve
Description of Operation: Solenoid De-energized air flows from Inlet Port 1 to Outlet Port 2 and
exhausts from Port 4 to Port 5. Solenoid Energized air flows from Inlet Port 1 to Outlet Port 4 and
exhausts from Port 2 to Port 3.
Spring Return 3-Way (3/2) Valve
Description of Operation: Solenoid De-energized air flows from Outlet Port 2 to Exhaust Port 3.
Solenoid Energized - air flows from Inlet Port 1 to
Outlet Port 2.
Dual Coil 4-way (5/2) Valve
Description of Operation: Coil B Energized air flows from Inlet Port 1 to Outlet Port 2 and
exhausts from Port 4 to Port 5.
Coil A Energized air flows from Inlet Port 1 to Outlet Port 4 and
exhausts from Port 2 to Port 3.
Fig. 2
Air Flow Diagrams
Note: The valve will not change state until the energized
coil is de-energized and the opposite coil is energized in
that order.
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 6 of 15
4.2.3 Usage Instructions for Option Valves
Fig. 3
Fig. 4
Fig. 5
N - No-Voltage Release (Latching)
Push palm button to shift valve completely and latch by depressing small
button underneath the valve with finger. Open position will be sustained and
latch will automatically disengage when air and voltage are applied. When the
coil is de-energized, the valve will return to its original position. Available for
1.2Cv and 3.5Cv valves only (see Fig. 3).
R - No-Voltage Release (Non-Latching)
Energize coil and push palm button to manually shift valve. Valve will not
shift unless the palm button is depressed but will remain shifted until coil is
de-energized or air is lost. Available for 1.2Cv and 3.5Cv valves only (see
Fig. 4).
L - Locking Manual Override
Push palm button and rotate clockwise to maintain shifted position until
manually disengaged (see Fig. 5).
Coils must be de-energized before operating manual override.
M - Momentary Manual Override
Push palm button and hold to maintain shifted position until button is released
(see Fig. 5).
Coils must be de-energized before operating manual override.
E - External Pilot
Provide auxiliary pressurized air supply to the external pilot connection of the
valve. Supply a pressure signal (min. 45 psi) to this auxiliary port in
conjunction with electrical signal to solenoid to shift the valve. This feature
should be used when the pressure supplied to inlet port 1 is below the
minimum 45 psi operating pressure.
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 7 of 15
D/C - Dual Coil Option
Four way valves are available with solenoid actuators on both ends of the
Falcon valve, coil “A” and coil “B”, for fail-last logic. When only coil “A” is
energized, the valve will shift as a standard 4-way does. If coil “A” is then deenergized, the valve will remain in this last position. The valve will not return
to the original state until coil “A” is de-energized and coil “B” is
energized. The process is the same for coil “B”.
NOTES - For Dual Coil Valves
1. The valve may be in either position upon installation. Refer to the Air
Flow Diagrams (Fig. 2) and energize the appropriate coil (with air) to
reset valve to the desired position.
2. Dual coil valves require both an electrical signal and air pressure to
operate. See Air Flow Diagram for air pressure requirements. If either
or both inputs are lost the valve will remain in its current position.
3. Both coils should never be energized simultaneously.
4. If using overrides on a dual coil valve, the coils must be de-energized.
4.2.4. Plumbing and Air Supply Considerations
Air mains and lines should be sized, routed and pitched properly to avoid
excessive pressure loss (more than 10% of applied pressure at maximum
flow), air flow restriction or condensed moisture at the point of usage. Proper
filtration of air supply per specifications in section 4.2.1 is critical to prevent
premature failure of solenoid valves. If lubricators are used in the air line,
use appropriate oil distribution equipment and oil grades, such as ISO and
UNI FD22. The performance and life of pneumatic valves may be affected by
air supply conditioning methods. Regulation of inlet pressure to within
specified limits is also critical to prevent excessive seal wear, failure by
extrusion or leakage. In general, pipe fittings should not be assembled to a
specific torque because the torque required for a reliable joint varies with
thread quality, port and fitting materials, sealant and other factors. Fittings
should not be over-tightened or distortion and, most likely, complete valve
failure can result. The following general procedure should be followed:
1. Inspect port and connectors to ensure that the threads are free of dirt,
burrs and excessive nicks.
2. Apply sealant/lubricant or Teflon tape to the male pipe threads. With any
sealant or tape, the first one or two threads should be left uncovered
and care must be taken to avoid the application of excessive sealant
media to avoid system contamination.
3. Install connectors into ports and wrench tighten per the fitting
manufacturer’s recommendation to achieve an air-tight joint.
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 8 of 15
4.3. Calibration
Consult factory or a Westlock distributor for setting procedures of units with
six switches or four switches and transmitter.
Note 1: Switch actuation can be confirmed using a signal detection device
such as a multimeter or ohmmeter, set for “continuity”.
Note 2: For NAMUR P+F NJ2-V3-N type sensors, use test meter, P+F model
#1-1350 or equivalent to check sensor actuation and calibration. If the proper
meter is not available, contact the factory for additional assistance with the
test procedure.
Note 3: Adjust cams by hand by pushing/pulling the cam against the shaft
spring to disengage from the mating spline, rotating to adjust and re-engaging
firmly onto spline.
Required Tools: Signal detection device (see note 1); slotted screw drivers
or Allen keys for cover screws (M4, M5, #10, 5/16 or M8 by model)
Switch Adjustment (two switches):
1. Remove unit cover as follows: loosen (but do not remove) captive screws,
rotate cover slightly to grip corners, pull firmly.
DO NOT PRY COVER WITH TOOLS.
2. With valve in the closed position, adjust bottom cam until bottom switch
(#2) actuates.
3. Stroke valve to the open position, adjust top cam until top switch (#1)
actuates.
4. Cycle actuator several times to confirm proper switch indication at each
end of stoke. Finely adjust cams if necessary.
5. Skip to Field Wiring section or replace unit cover, applying approximately
20 in-lbs of torque to cover screws.
TOP CAM
PUSH DOWN, TURN
& RELEASE
BOTTOM CAM
LIFT UP, TURN
& RELEASE
MAGNUM & MAGPAC
PROXIMITY
SWITCH
MECHANICAL
SWITCH
iNDUCTIVE
PROXIMITY
SENSOR
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 9 of 15
Switch Adjustment (four switches, no CS transmitter):
Follow steps as above for the calibration of two switches but adjust the first
and third cams from the top for switches #1 and #2 and the second and fourth
cams from the top for switches #3 and #4 (see illustration below).
TOP & 3RD CAM
PUSH DOWN, TURN
& RELEASE
2ND & BOTTOM CAM
LIFT UP, TURN
& RELEASE
MAGNUM
PROXIMITY
SWITCH
MECHANICAL
SWITCH
iNDUCTIVE
PROXIMITY
SENSOR
Transmitter setting (optional CS transmitter):
For the calibration of optional current signal (CS) transmitter, see Westlock
Controls Installation/Operations Manual TECH-301, available through your
local sales representative or at westlockcontrols.com.
Beacon Adjustment:
Note: Skip this step if cover is flat or Beacon already displays the correct
valve status.
Required Tools: slotted screw driver for #12 screws.
1. For two-way OPEN/CLOSED: remove, rotate and re-fasten outer beacon
to synchronize displayed position with valve position.
2. For three-way flow paths: remove, rotate and re-fasten outer beacon
and/or inner beacon coupler to synchronize displayed flow path with
valve/actuator flow path.
OPEN
Valve in
Position
OPEN
OPEN
CLOSED
Valve in
Position
CLOSED
CLOSED
For the 360 and 366 models:
Required Tools: set screw driver for M4 set screws and snap ring tool.
1. Remove shaft snap ring and inner beacon.
2. Disengage set screws from outer beacon, rotate and re-fasten outer and
inner beacon to synchronize displayed position with valve position.
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 10 of 15
5.
Field Wiring
See the warnings section of this document for important warnings
pertaining to the wiring of Quantum units. Remove and replace cover
before and after wiring, per instructions given in the Switch Adjustment
section above.
Required Tools: slotted screw drivers for terminal strip screws (#2), cover
screws (M4, M5, #10 or 5/16 by model), and grounding screw (#8 or M5 by
model); wire strippers as required for field wires; Allen key for M8 cover
screws (777/877).
1. Wire the AccuTrak monitor strictly according to the wiring diagram on the
inside of the enclosure cover.
2. Confirm that the ground wire is secure under the green grounding screw in
the enclosure.
3. Seal all unused conduit entries as required with suitably certified plugs
having an ingress protection rating of IP67 or better.
4. Ensure that only suitably certified cable glands are used, having an
ingress protection rating of IP67 or better.
5. Ensure that the temperature rating of all field wiring meets the service
temperature range of the application.
6.
Maintenance and Repair
Maintenance or repair of Westlock equipment must only be done by Westlock
Controls or by qualified personnel that are knowledgeable about the
installation of electromechanical equipment in hazardous areas. All parts
needed for repairs or maintenance must be purchased through a Westlock
Controls authorized distributor to maintain warrantee and to ensure the safety
and compliance of the equipment.
No routine maintenance of Westlock AccuTrak units is recommended when
units are installed in environments for which they are designed. Severe
environments may warrant regular replacement of field units every two to five
years for maximum performance and safety.
Troubleshooting
Problem: No signal at the control device
Check that power supply to the loop is functioning correctly and
adequate to power all devices on the loop;
Check that power being supplied to switches is within the rated
specifications;
Check wiring integrity immediately at the connection to the control
device;
Check field wiring coming into the AccuTrak terminal strip for proper
connection and good wire preparation practices (approximately ¼” of
insulation removed and all strands intact);
Check that field wiring is no larger than 12AWG for proper fit in
terminal strip and compliance with terminal strip rating;
Check that wiring integrity is good between switches and terminal strip;
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 11 of 15
Check that cams are set to trigger switches properly in each valve
position (see Switch Adjustment section under installation);
Use multimeter set for “continuity: to check for failed switch; observe
continuity between common and normally open when triggered and
between common normally closed when not triggered.
Problem: Beacon does not display the correct flow path
Reset Beacon per the Beacon Adjustment section under Calibration.
Problem: Unit appears to be binding during valve stroke or unit shaft has
broken
Carefully measure and adjust axial alignment of unit shaft, coupler and
actuator shaft to eliminate lifting or twisting of the coupler during travel.
Problem: Unit has signs of moisture ingress
Check torque on cover screws
Check gaskets and sealing surfaces for debris and clean if necessary
Check that conduit connections are properly sealed, including gland
fittings and quick-disconnect receptacles
Check that conduit pipes are properly pitched to direct condensing
moisture away from units
Check that all unused conduit entries are properly sealed with suitably
certified plugs having an ingress protection rating of IP67 or better.
Problem: Solenoid valve will not shift when energized.
Check for sufficient pressure (45 psi min.) at solenoid valve inlet port
#1 or at the external pilot port (if applicable)
Check that only one solenoid coil is energized at a time for dual-coil
solenoid valves
Check that the valve is plumbed correctly: supply at #1, outlets at #2
and #4, exhausts at #3 and #5.
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 12 of 15
7.
Appendix A
Wiring Diagram
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 13 of 15
Appendix B
Installation Drawing
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 14 of 15
WESTLOCK CONTROLS CORPORATION
280 N. MIDLAND AVE., STE. 258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com
4/7/10
TECH-382/D.W.O. 17072
Page 15 of 15