II 2GD. xxxx. Westlock 2200 Series Quantum - ATEX certified Installation & Operating Instructions
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1 Installation and operating instructions for Westlock 00 series Quantum valve control monitor with mechanical switches, inductive proximity sensors or Magnum proximity switches xxxx II GD EPSILON 08 ATEX 70X Ex d IIB +H T* Tamb -* C to +* C Ex td A IP6X T* C Tamb -* C to +* C Flat cover -0 C to +8 C (T); -0 C to +7 C (T); -0 C to +60 C (T6) Beacon cover -0 C to +8 C (T); -0 C to +7 C (T); -0 C to +60 C (T6) Environmental parameters: 80 kpa (0.8 bar) to 0 kpa (. bar). Air with normal oxygen content, typically %. Product description The 00 series valve control monitor provides two methods of end of travel indication by the means of mechanical switches, inductive proximity sensors or proximity switches and an external visual indicator. For applications that require position feed back, ancillary components such as a -0 ma current signal transmitter or a resistive signal feed back can be installed. To allow this product to be used with network communication bus protocols, the 00 series enclosure can house various network modules. The 00 series enclosure comprises of a two parts, a cover and housing. The cover has three variations, flat cover, standard beacon cover or a high cover to suit different applications. The housing can offer up to two integral solenoid coils and upto three of the following conduit entries; M0 x.p, M x.p, / - NPT or / - NPT cable entries for connection to an external power source via appropriate ATEX certified cable glands. EN : 006 Electrical apparatus for explosive gas atmospheres Part 0 - General requirements EN : 007 Electrical apparatus for explosive gas atmospheres Part - Flameproof enclosures d EN 6-0 : 006 Electrical apparatus for use in the presence of combustible dust Part 0 - General requirements EN 6- : 006 Electrical apparatus for use in the presence of combustible dust Part - Protection by enclosures td Note: Before installation of this product, please ensure that the product and its certification is suitable for the intended application. This product uses various O -ring material and an Eastar Copolyester visual indicator. If the equipment is likely to come into contact with aggressive substances, then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection provided by the equipment is not compromised. Installation of any cable entry devices, conduit entry devices or blanking devices shall not compromise the degree of ingress protection level IP6X for use in the presence of combustible dusts. The unit has an ingress protection of IP66/67 and therefore any conduit device fitted must maintain this. Note: These products have been certified with a cable entry temperature rise of C. Ensure that this is taken into consideration when selecting suitable cabling for the ambient temperature in which the product is to be used. Note: These products are not intended to be assembled directly to process pipe work etc that is heated or cooled to temperatures outside of the range as indicated above. Do not open when energised or when an explosive atmosphere is present. Electrostatic hazard, clean only with damp cloth. www. westlockcontrols.com WESIOM-0906-EN-
2 Mounting instructions. Attach the mounting bracket and adaptor (if required) to the Quantum housing and shaft with the fasteners provided with the mounting kit. Twist cover then lift straight up. To ensure that the 00 series Quantum is mounted correctly, it may necessary to stroke the actuator to the fully closed position. Before stroking the actuator to the fully closed position, please ensure that the process is safe to do so.. With the actuator in the correct position, attach the 00 series Quantum / bracket to the actuator using the hardware provided in the mounting kit.. To release the cover, loosen the cover retaining screws. Twist the cover approx and lift up. See Fig. Figure. To set the switches, lift the bottom cam and turn until the switch has activated and then release. The spring will push the cam back onto the splined shaft. Before stroking the actuator, please ensure that the process is safe to do so and that all hands are kept away from the moving shaft. Top cam Push down, turn & release.6 Stroke the actuator to the opposite end of travel. Set the top cam by pushing down and turning the cam until the switch is activated. Before stroking the actuator, please ensure that the process is safe to do so and that all hands are kept away from the moving shaft..7 Stroke the actuator from one end of stroke to the other several times to check the switch operation. If the switches require adjustment, repeat steps. to.7. Figure Bottom cam Lift up, turn & release Field wiring & installation The 00 series should always be handled with care when the cover is removed and wired to electrical power source. Note: Before electrical installation, please read and follow the wiring diagram located inside the cover. The electrical ratings can be found on the product I.D label.. Field wiring must be carried out in accordance with site, local and national electrical codes / requirements. This includes special attention to earth bond to the aluminium enclosure using the internal and external earth points provided.. Installation of this product shall be carried out by competent personnel in accordance with the applicable code of practice such as EN The 00 control monitor housing can offer up to three of the following conduit entries; M0 x.p, M x.p, / - NPT or / - NPT. These entries are detailed on the product I.D label found on the product cover. Please see Fig. for conduit positions. Page
3 Conduit B (double coil - optional) Figure Conduit C Conduit D Conduit A (single coil). The certification applies to equipment without cable glands. When mounting the flameproof enclosure in the hazardous area, only suitably rated IP 66/67 ATEX certified flameproof glands must be used.. All unused cable entries must be plugged with a suitably rated IP 66/67 ATEX certified blanking devices..6 The first two digits of the Westlock nomenclature signifies the series with the third digit defining whether the product has a visual beacon or not. The table below details the applicable ambient ranges: Series code Cover type T class Ambient range * Beacon T6 (80 C) -0 C to +60 C * Beacon T (9 C) -0 C to +7 C * Beacon T (0 C) -0 C to +8 C 6* Flat T6 (80 C) -0 C to +60 C 6* Flat T (9 C) -0 C to +7 C 6* Flat T (0 C) -0 C to +8 C.7 The forth digit designates the switch / sensor type. The following table details the most common switch / sensor types together with their electrical ratings. Series code/switch designation Electrical rating * Mechanical (SPDT) A - or 0 V AC; 0. A - V DC; 0. A - 0 V DC *6 Mechanical (DPDT) 0 A - or 0 V AC; 0 A - 8 V DC; 0. A - V DC *7 Inductive proximity sensors *9 Magnum ratings A - 0 V AC;. A - 0 V AC or A - V DC Note: The series code signifies the maximum electrical rating of the product, suitable overloading protection must be provided to prevent these values being exceeded..8 The 00 series valve position monitor has the option for position feedback by the means of a resistive signal (RS) or current signal (CS). The RS transmitter electrical ratings are K Ohms (standard) or K Ohms (optional). See I.O.M TECH-08. The CS transmitter electrical ratings are current loop -0 ma at 8 to V DC. See I.O.M TECHUK-0.9 The 00 series valve control monitor has the ability to connect to bus networks via Netpak modules. With the Netpak options it may be possible to assemble other switches within the enclosure (depending on enclosure cover variation)..9. Netpak electrical parameters. Page
4 Netpak option Electrical parameters I.O.M. AS-I Actuator Sensor Interface Device Net Modbus Profibus DP Foundation Fieldbus V DC, 0 ma MAX TECH-6 V DC, 0 ma MAX TECH-09 V DC, 8 ma MAX TECH- V DC, 0 ma MAX TECH-6 9- V DC, ma MAX TECH-8.0 Digit 0 of the Westlock nomenclature signifies the coil voltage with the following voltage and type available,, 8, 0 and 0 V AC or V DC.. Before replace the enclosure cover, ensure that both of the housing and cover flange surfaces are clean and undamaged. Tighten the cover screws hand tight using a standard 6 mm A/F Allen key ensuring there are no gaps. Product repair & service. Inspection of this product shall be carried out by suitably trained personnel in accordance with the applicable code of practice such as EN In the event of any repairs that may be required such tasks must be carried out by suitably trained / competent personnel in accordance with the applicable code of practice such as EN The certification of this product has been approved based on the material of construction as per the drawings listed in the schedule within this certificate. Any replacement parts that are not made in accordance to the listed drawing will invalidate the approval / certification.. Replacement parts must be purchased through Westlock Controls UK Ltd or via an approved Westlock Controls distributor. Operating and maintenance instructions for Falcon & Falcon II solenoid valve. General description.. The Falcon II solenoid valve incorporates elastomer static seals through which a shaped spool moves and are manufactured for or way operation. way is normally used for pilot control of the other relay valves or for the operation of single acting cylinders. way is normally used to control the action of double acting cylinders. The seal spacer assembly forms individual annular chambers opposite each valve port and the grooved spool either closes or allows flow between adjacent chambers, hence the position of the spool determines which ports are open or closed. The spool is moved by way of a manually or mechanically operated mechanism normally against a return spring. Operation may be by application or removal of a pilot air supply acting as a pilot piston. This form of control is utilized for electrical actuation where integral solenoid valves control the pilot air supply... Optional features - Falcon II... No-voltage release (latching) With the coil first energized, the palm button is then manually moved and latched. The inward movement of the palm button causes the valve to shift. When the coil is de-energized, the palm button and latching mechanism are automatically tripped, allowing the valve to return to its original position. See Fig. A.... Manual locking override Manually depress palm button and rotate clockwise for maintained condition, must manually disengage to return to original position. See Fig. B. A B... Momentary override Spring return momentary push type, must hold in to actuate. See Fig. C.... Hex drive maintained override Insert Allen key in hex head screw and rotate clockwise (- turns) to shift spool. Valve will stay put until hex head screw is rotated counter clockwise (- turns) back to original position. See Fig. D. Figure C D Page
5 ... D/C - Dual coil option way valves are available with a coil/pilot valve on each end of the Falcon II valve, coil A and coil B. When coil A is energized the valve will shift. If coil A is then de-energized, the valve will remain in this 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. Note - For dual coil valves The valve may be in either position upon installation. Refer to the air flow diagrams and energize the appropriate coil (with air) to reset valve to the desired position. 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 it s current position. Both coils should never be energized simultaneously... Specifications Operating pressure: - 0 psig / bar Operating media: Non lubricated filtered air to 0 microns.. Field wiring Complete the electrical wiring in accordance with national and local electrical requirements. The ground wire should be secure under the green screw. Check all screws for tightness. A B Spring return valve Description of operation: Solenoid de-energized - air flows from Outlet Port to Exhaust Port. Solenoid energized - air flows from Inlet Port to Outlet Port. Spring return valve Description of operation: Solenoid de-energized - air flows from Inlet Port to Outlet Port and exhausts from Port to Port. Solenoid energized - air flows from Inlet Port to Outlet Port and exhausts from Port to Port. Dual coil valve Description of operation: Coil B de-energized - air flows from Inlet Port to Outlet Port and exhausts from Port to Port. Coil A energized - air flows from Inlet Port to Outlet Port and exhausts from Port to Port. Figure - Air line designation, / NPT or BSP air ports for inlet, outlet and exhaust.. (Air line) Installation considerations Air mains and lines should be large enough to avoid excessive pressure loss under conditions of maximum flow. Air lines should be installed with as few restrictions as possible if the cost of compressed air is to be kept to a minimum. Sharp turns in piping should be avoided for more efficient air flow and economical air power. It is advisable to pitch the mains in the direction of air flow so that both gravity and air flow will carry the water to traps or water legs located at frequent intervals. To help in preventing condensed moisture from reaching the point of usage, down pipes should never be taken directly from the bottom of air pipes or mains. Connection should be made at the top of the main and a long radius return bend used...6 Air flow Pipe sizes are normally determined on semi empirical lines, basis for selection being an acceptable pressure drop e.g. not more than 0% of the applied pressure. In sizing pipes, consideration should be given to likely future demands, as a system will be inefficient if the demand outgrows the supply. It is always better to over size mains as this will reduce air velocity and make water separation more effective. Page
6 ..7 Air service equipment The importance of proper filtration (0 micron) and lubrication of the air supply to pneumatic equipment can never be over-emphasized as a means of decreasing friction and preventing corrosion and wear due to moisture and abrasive solids being present in the air supply. At higher pressures than recommended, pneumatic equipment can wear excessively with no significant increase in output and compressed air is consequently wasted. There is much to be gained, therefore, from providing pneumatic equipment with serviced air by including suitable air line filters, pressure regulators and lubricants in the installation...8 Tubes and fittings The use of copper, stainless steel, nylon or polyethylene tube is recommended for piping up air circuits and equipment. As a general rule, pipe threaded 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 used, and other factors. The suggested method of assembling pipe threaded connections is to assemble them finger tight and then wrench tighten further to a specified number of turns from finger tight. The assembly procedure given below is for reference only, the fitting should not be over tightened for this will lead to distortion and most likely, complete valve failure.. Inspect port and connectors to ensure that the threads on both are free of dirt, burrs and excessive nicks.. Apply sealant/lubricant or PTFE tape to the male pipe threads. With any sealant tape, the first one or two threads should be left uncovered to avoid system contamination.. Screw the connector into the port to the finger tight position.. Wrench tighten the connector approximately - turns (to seal) from finger tight. Again this is only reference the fitting should NOT be over tightened. Special notice Delrin valve bodies are fitted with helicoils therefore an extra effort should be made NOT to overtighten pipe fittings or retaining screws (0. - turns from finger tight to seal). Over tightening will result in valve failure or pull helicoils from valve body. Maintenance Routine maintenance is usually confined to the periodic replenishment of Dow Corning III lubricant or equivalent to spool and spring Parts list No. Part name. Pilot end cap VA-006. Pilot piston seal GS Bushing BU-00. Spacer VA-008. O-ring GS Bushing BU Valve body VA Pilot piston VA O-ring GS O-ring GS-000. O-ring GS-000. O-ring GS-008. SCKT HD cap screw HD-0. Spool VA-077. Spring HD Indicator cap VA End cap VA SCKT HD cap screw HD O-ring GS Indicator S/S washer HD-08. Indicator pin VA-0066 Figure 6 - Exploded assembly of way 0. C v Falcon Page 6
7 Parts list No. Part name Figure 7 - Exploded assembly of way. C v Falcon Pilot HD cap screw HD-0. Pilot end cap VA-00. O-ring GS-00. Pilot piston seal GS-008. Pilot piston sleeve VA Guide washer VA Spacer VA O-ring GS Bonded seal GS Valve body VA-00. O-ring GS-007. Pilot piston VA-00. O-ring GS-000. O-ring GS-000. O-ring GS Spring HD Indicator cap VA SCKT HD cap crew HD-0 9. End cap VA Bushing BU-00. Indicator pin VA Spool VA-00 Parts list No. Part name Figure 8 - Exploded assembly of and way. C v Falcon II Pilot piston end cap V. O-ring OZOIN070/00. Pilot piston V9. O-ring OZOIN070/006. Valve body / V6 / V 6. O-ring OZOIN0070/ O-ring / V0 6 off / V0 off 8. Bush V08 9. Spacer / V7 off / V7 off 0. Bush V08. Pilot piston seal V6. Cap screws OSMOKS0. O-ring OZOIN00/00. O-ring OZOIN070/00. Cap screws OSMOKS6 6. Spring end cap V 7. Tell-tale cover V7 8. Spring V7 9. Tell-tale pin V06 0. Spool /V / V Page 7
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