Installation & Operating Instructions Westlock
Contents
1. 4 V3 SPDT Mechanical Switches 7 Unit with 1 4 Inductive Proximity Sensors 9 Unit with 1 4 Magnum XT 90 Proximity Switches SPDT 4 Unit with Beacon Indicator 6 Unit without Beacon Indicator V3 SPDT mechanical switches and Magnum XT 90 proximity switches are considered as THREE WAY VALVE BEACON simple apparatus can be replaced by inductive INDICATION WHEN SPECIFIED proximity sensors STANDARD FLOW ARRANGEMENTS ELECTRICAL ENTITY PARAMETERS ARRANGEMENT NUMBER MAGNUM PROXIMITY SWITCH SIMPLE APPARATUS ep ROTATION Ui 30V li 100mA Pi 3W Ci 10nF Li 10uH V3 MECHANICAL GOLD PLATED SIMPLE APPARATUS Ui 30V li 100mA Pi 3W Ci 10nF Li 10uH NJ2 V3 N P amp F SENSORS Ui 16V li 25mA Pi 34mW Ci 40nF Li 50uH I S COIL Ui 31V li 670mA Pi 2 98W Ci 0nF Li 0uH Valve in CLOSED lt position 13 Replace the enclosure cover ensuring that the position of the valve has been noted either fully open or fully closed 180 ROTATION 14 Make sure that the Beacon visual display indicator coinsides with the position of the valve SPECIAL CONDITIONS FOR SAFE USE 7 BM3 7 The Control Monitor shall be marked with the following warning STATIC DISCHARGE HAZARD CLEAN ONLY WITH DAMP CLOTH 9 When metallic cable glands are used the applicable R earthing requirements of EN 50014 must be complied m with When installing the Control Monitor ensure good enginnering practise correct installtion techn2. A is energized the valve will shift If coil A is then de energized the valve will remain in this Figure 3 Figure 4 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 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 it s current position 3 Both coils should never be energized simultaneously WESTLOCK CONTROLS UK Lid 22 CHAPMAN WAY TUNBRIDGE WELLS KENT TN2 3EF ENGLAND TEL 44 0 1892 516277 FAX 44 0 1892 516279 5 5 04 TECHUK 06 REV 0 Page 3 of 6 Installation amp Operating Instructions Westlock Quantum 3600 ALUMINIUM amp STAINLESS STEEL With Mechanical Switches Inductive Proximity Sensors or MAGNUM Proximity Switches Specifications Operating Pressure 45 120 PSIG Operating Temperature 20 C to 65 C Operating Media Non Lubricated Filtered Air to 20 Microns Field Wiring Complete the electrical wiring in accordance with local and National Electrical Codes The ground wire should be secure under the green screw Check all screws for tightnes
3. Installation amp Operating Instructions Westlock Quantum 3600 ALUMINIUM amp STAINLESS STEEL ith Mechanical Switches Inductive Proximity Sensors or MAGNUM Proximity Switches PRODUCT CERTIFICATION 0539 1 1 GD T85 C EEx ia IIC T6 DEMKO 03 ATEX 133287X This product is designed for use in intrinsically safe systems when connected through the correct barriers 1 Attach the correct mounting bracket and adapter to the Quantum housing with the hardware provided 2 Operate the actuator to full closed position 3 Attach the Quantum and mounting bracket to the actuator 4 Remove screws open latches which fasten the Quantum cover Twist cover approximately 45 and lift up 5 To set 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 Stroke the actuator to the opposite end and push down on the top cam and turn until the open switch has activated 6 Operate actuator from one end of stroke to the other several times to check switch operation TOP CAM PUSH DOWN TURN amp RELEASE BOTTOM CAM LIFT UP TURN amp RELEASE MAGNUM INDUCTIVE PROXIMITY MNH PROXIMITY SWITCH SENSOR FIELD WIRING amp INSTALLATION WARNING The Quantum should always be handled with care when the cover is removed and wired to an electrical power source 7 The correct wiring diagram for the product is shown
4. cation 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 com pressed 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 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 qual ity 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 fail ure 1 Inspect port and connectors to ensure that the threads on both are free of dirt burrs and excessive nicks 2 Apply sealant lubricant or Teflon tape to the male pipe threads With any sealant tap
5. e the first one or two threads should be left uncov ered to avoid system contamination 3 Screw the connector into the port to the finger tight position 4 Wrench tighten the connector aproximately 1 2 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 hellicoils therefore an extra effort should be made NOT to overtighten pipe fittings or retaining screws 5 1 turns from finger tight to seal Overtightening will result in valve failure or pull hellicoils from valve body MAINTENANCE Routine maintenance is usually confined to the periodic replenishment of Dow Corning III lubricant or equivalent to spool and spring BUSHIN BU 10013 EXPLODED ASSEMBLY O RING OF 3 5 Cv 3 WAY FALCON SEER D VA 10048 P N BUSHIN BU 10013 PILOT PISTON SEAI GS 10017 PILOT END CAR VA 10036 VALVE BODY 2 PILOT PISTON V4 10038 SCKT HD CAP SCRI NA VA 10050 HD 10348 O RING F GS 20017 END CAP bed 7 VA 10063 K 2 INDICATOR CAI O RING VA 10078 GS 20018 O RING GS 20002 a SE RIN a aan HD CAP SCRE O RING GS 20020 SPOOL O RING VA 1047 GS 20017 INDICATOR S S WASHER HD 10181 INDICATOR PI VA 10066 WESTLOCK CONTROLS UK Ltd 22 CHAPMAN WAY TUNBRIDGE WELLS KENT TN2 3EF ENGLAND TEL 44 0 1892 516277 FAX 44 0 1892 516279 5 5 04 TECHUK 06 REV 0 Page5 of 6 Installation amp Operating Instructions Westlock Quan
6. iques are used WESTLOCK CONTROLS UK Ltd 22 CHAPMAN WAY TUNBRIDGE WELLS KENT TN2 3EF ENGLAND TEL 44 0 1892 516277 FAX 44 0 1892 516279 5 5 04 TECHUK 06 REV 0 Page 2 of 6 Installation amp Operating Instructions Westlock Quantum 3600 ALUMINIUM amp STAINLESS STEEL ith Mechanical Switches Inductive Proximity Sensors or MAGNUM Proximity Switches Operating and Maintenance Instructions for Falcon Solenoid Valve General Description The Falcon solenoid valve incorporates elastomer static seals through which a shaped spool moves and are manufactured for 3 or 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 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 N No Voltage Release Latching With the coil first energized the palm button is then manually m
7. on the inside of the Quantum cover Please follow carefully 8 Field wiring must be carried out in accordance with site local and National Electrical Codes 9 The ground wire should be secure under the green screw 10 The cerification applies to equipment without cable glands When mounting the enclosure in the hazardous area only suitably certified cable glands and blanking elements must be used to maintain ingress protection of IP67 11 All unused cable entries must be plugged with suitably certified plugs that can maintain an ingress protection level of IP6X 12 The above mention switches sensors and coils shall be electrically connected suitable to the rated data via a certified isolating interface zener barrier placed outside the hazardous area 13 For ambient temperatures below 10 C and above 60 C use field wiring suitable for both minimum and maximum ambient temperatures WESTLOCK CONTROLS UK Lid 22 CHAPMAN WAY TUNBRIDGE WELLS KENT TN2 3EF ENGLAND TEL 44 0 1892 516277 FAX 44 0 1892 516279 5 5 04 TECHUK 06 REV 0 Page of 6 Installation amp Operating Instructions Westlock Quantum 3600 ALUMINIUM amp STAINLESS STEEL ith Mechanical Switches Inductive Proximity Sensors or MAGNUM Proximity Switches Nomenclature for type 36__ Conventional 90 Beacon indication For ON OFF Valves A Aluminium Enclosure S Stainless Steel Enclosure VWa OPEN position m 5 Unit with 1
8. oved 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 1 2 Cv Valves only See Fig 1 R No Voltage Release Non Latching With the coil first energized the palm button is then manually moved The inward movement of the palm button causes the valve to shift When the coil is de energized the palm button automatically returns to its original position 1 2 Cv Valves only See Fig 2 L Manual Locking Override Manually depress palm button and rotate clockwise for maintained con dition must manually disengage to return to original position See Fig 3 M Momentary Override Spring return momentary pushtype must hold in to actuate See Fig 4 H Hex Drive Maintained Override Insert allen key in hex head screw and rotate clockwise 4 5 turns to Figure 1 shift spool Valve will stay put until hex head screw is rotated counter clockwise 4 5 turns back to original position See Fig 5 E External Pilot The 1 8 NPT external pilot connection requires a separate auxiliary pressure line to the valve This feature should be used when the con trolled pressure is below the minimum 45 psi operating pressure D C Dual Coil Option Four way valves are available with a coil pilot valve on each end of the Falcon valve coil A and coil B When coil
9. s If the installation is in a hazardous area all electrical leads must be sealed with an approved com pound in accordance with local and National Electrical Codes unless the switches are hermetically sealed NEC 5051 5 Always check the nameplate to make sure the approval ratings coincide with the application CAUTION To prevent ignition of hazardous atmospheres replace cover before connecting the electrical circuits Keep cover tightly closed when in operation Air Line Designation 1 4 NPT air ports for inlet outlet and exhaust 3 5 Cv valve has 1 2 NPT air ports we 1n a D N a N Spring Return Valve Spring Return Valve Description of Operation Solenoid De energized Description of Operation Solenoid De energized air flows from Outlet Port 2 to Exhaust Port 3 air flows from Inlet Port 1 to Outlet Port 2 and Solenoid Energized air flows from Inlet Port 1 to exhausts from Port 4 to Port 5 Solenoid Energized 2 air flows from Inlet Port 1 to Outlet Port 4 and OUNEDE One exhausts from Port 2 to Port 3 Description of Operation Coil B De 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 Dual Coil Valve 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 in
10. stalled 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 effecient air flow and economical air power It is advisable to pitch the mains in the direction of air flow so that both grav ity 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 WESTLOCK CONTROLS UK Ltd 22 CHAPMAN WAY TUNBRIDGE WELLS KENT TN2 3EF ENGLAND TEL 44 0 1892 516277 FAX 44 0 1892 516279 5 5 04 TECHUK 06 REV 0 Page 4 of 6 Installation amp Operating Instructions Westlock Quantum 3600 ALUMINIUM amp STAINLESS STEEL ith Mechanical Switches Inductive Proximity Sensors or MAGNUM Proximity Switches AIR FLOW Pipe sizes are normally determined on semi empirical lines basis for selection being an acceptable pressure drop e g not more than 10 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 AIR SERVICE EQUIPMENT The importance of proper filtration 20 Micron and lubri
11. tum 3600 ALUMINIUM amp STAINLESS STEEL ith Mechanical Switches Inductive Proximity Sensors or MAGNUM Proximity Switches EXPLODED ASSEMBLY SPACER OF 1 2 Cv 3 WAY FALCON VA 10049 gp xN GUIDE WASHE eo VA 10056 O RING GS 20022 A Za PILOT PISTON SLEEV A 10052 BONDED SEAL er aol SCKT HD CAP SCR HD 10431 Z INDICATOR CAR i A A 10079 SPRIN gy VA 10051 LY pD lt i Q GS 20018 ORIN GS 20002 N ORING GS 20020 SPOOL Solenoid Valve amp Coil Specification PILOT PISTON SI 10018 O RING GS 2002 PILOT END CAR A 10043 SCKT HD CAP SCRI HD 10431 END CAP VA 10065 BUSHING BU 10014 INDICATOR PIN 10068 Type 3 2 WAY 5 2 WAY Cy Jos jo7 Eia 12 35 Material _ Alu Brass St St Delrin Connection w4 NPr 12 NPT _ 1 4 BSP Operating Pressure Range 45 120 PSIG Orifice Size 1 4 0 5 to 1 2 Cv 1 2 3 5 Cv Supply Voltage 24 vpc WESTLOCK CONTROLS UK Ltd 22 CHAPMAN WAY TUNBRIDGE WELLS KENT TN2 3EF ENGLAND TEL 44 0 1892 516277 FAX 44 0 1892 516279 5 5 04 TECHUK 06 REV 0 Page 6 of 6
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