accutrak rotary sec. 04 · 2014. 3. 4. · accutrak rotary valve position monitors " accutrak...

AccuTrak Rotary Valve Position Monitors

" AccuTrak Design Features

" Beacon Visual Position Monitor

" Series 1000 General Purpose

" Series 2000 General Purpose/Explosionproof

" Series 2200 General Purpose/Explosionproof

" Series 360 Explosionproof



" Series 5000 Intrinsically Safe

" Series 7000 All Classes & Groups

" Series 8000 Multiple Conduit Entry Options

" Series 9000 All Classes & Groups

" Position Transmitters

" Digital Position Transmitter

" EPIC Hornet All Classes & Groups

" EPIC N4 Series General Purpose/Nonincendive

" EPIC 360 & 366 All Classes & Groups

POSITIONMONITORINGFOR ROTARYVALVESA

CCUTRAK

"AccuTrak Rotary "AccuTrak Linear "Reference Sheets "Quantum "Network Solutions "Positioners

Valve Monitoring and Control ProductsWESTLOCK Home

www.westlockcontrols.com

POSITIONMONITORINGFOR ROTARYVALVESA

CCUTRAK




For digital signaling to lights,motors, micro processors, orperipheral equipment, two position sensors are standardlyhoused within the enclosure.The requirement for tools to adjust cam settings isunnecessary. The self-lockingTouchSet cam mechanism allows for a quick and simple

hand operation in the setting of both sensors. Additionally, the AccuTrak isspecifically designed for ease of wiring by the incorporation of abundant workingspace and a direct wire-feed terminalblock. All that is necessary to make theunit operational is the bringing in of electrical leads to a single juncture.

BEACONTM High VisibilityPosition MonitorFor isolated redundancy of valve positionmonitoring, the AccuTrak Dual DisplayMonitor is standardly equipped with aBeaconTM high visibility or Three-Way FlowPath Monitor. Either display can be seenclearly up to 150 feet. In a glance, start-up and operating personnel caninstantly determine the position of all monitored valves.

User Design Flexibility

The Dual Display monitor allows the userthe flexibility to design a valve monitoringsystem around processing requirementsas the need for additional information isrequired. The full range AccuTrak offersdesign and operating personnel the following distinct advantages.

! Sensors for positive end positionmonitoring of valve travel.

! Local mechanical display of valve position.

! 0-100% monitoring of full valve travel.

AccuTrakTM

Design Features

EACH COMPONENTINCORPORATED INTO THE DESIGNREFLECTS BASICPRINCIPLES OF SOUND ENGINEERING

! BeaconTM Visual Position Monitors

! TouchSetTM Cams

! Position Sensors

! Prewired Terminal Blocks

! Integrated Solenoid Valves

! Full Range Monitoring

Designed around a unique self-locking,spring-loaded TouchSetTM cam mecha-nism attached to a stainless steelshaft and housed in an NEMA ratedaluminum, stainless steel or engineeredresin enclosure, the AccuTrakTM utilizesbushings at both ends to assure concentric turning of the cams.




PO EN

0PEN

ACCUTRAKTM

Position Monitor

TouchSet CamsInstantaneous hand setting of limit switchesrequires approximately 5 seconds

EnclosuresHigh-impact aluminum, engineered resin, or stainless steel enclosures compatible with any environment.

Visual DisplayValve performance ismechanically confirmedby high visibility localposition monitors.

Position SensorsPosition sensors avail-able in mechanical, proximity and solid state configurations.




SpecificallyEngineered To Meet All Areas and GroupsThe Westlock Series of valve position monitors is available in a wide range of aluminum, engineered resin, and stainlesssteel enclosures meeting the specific standards set by interna-tional approval agencies.

AccuTrakTM

Enclosures

General PurposeAluminum:Area Classification: NEMA 4, 4XCoating: Double PolyurethaneConduit Entries: Up to three 1/2” NPTTerminal Block: Up to 12 contacts

Engineered ResinArea Classification: NEMA 4, 4XMaterial: Engineered ResinConduit Entries: Two 1/2” NPTTerminal Block: Up to 12 contactsCover: Engineered Resin (clear option)

ExplosionproofAluminum:Area Classification: NEMA 4, 4X, 7, 9Class I, Groups C & DClass II, Groups E, F, & GDivision 1 and 2Coating: Polyester PowderConduit Entries: Up to four 3/4” NPTTerminal Block: Up to 16 contacts

ExplosionproofAluminum:Area Classification: NEMA 4, 4X, 7, 9Class I, Groups A, B, C, & DClass II, Groups E, F, & GDivision 1 and 2Coating: Double PolyurethaneConduit Entries: Up to three 3/4” NPTTerminal Block: Up to 12 contacts

Stainless Steel:Area Classification: NEMA 4, 4X, 7, 9Class I, Groups A, B, C, & DClass II, Groups E, F, & GDivision 1 and 2Conduit Entries: Up to three 3/4” NPTTerminal Block: Up to 12 contacts

NonincendiveAluminum:Area Classification: NEMA 4, 4XClass I, Groups A, B, C, & DClass II, Groups F & GDivision 2Coating: Polyester PowderConduit Entries: Up to four 3/4” NPTTerminal Block: Up to 16 contacts

Engineered Resin:Area Classification: NEMA 4, 4XClass I, Groups A, B, C & DClass II, Groups F & GDivision 2Material: Engineered ResinConduit Entries: Up to three 3/4” NPTTerminal Block: Up to 16 contacts

Intrinsically SafeAluminum:Area Classification: NEMA 4, 4xClass I, Groups A, B, C, & DClass II, Groups E, F & GDivision 1 and 2Coating: Polyester PowderConduit Entries: Up to four 3/4” NPTTerminal Block: Up to 16 contacts

Engineered Resin:Area Classification: NEMA 4, 4xClass I, Groups A, B, C, & DClass II, Groups E, F, & GDivision 1 and 2Material: Engineered ResinConduit Entries: Up to three 3/4” NPTTerminal Block: Up to 16 contacts






BeaconTM

Visual Position Monitor

Impact and Corrosion ResistantVisual Position Monitors

For Actuated Valves, GearOperators, Dampers andThree-way Control AssembliesThe high visibility BeaconTM positionmonitor is designed to increasesafety and efficiency in the industrialprocess plant. Start-up engineersand operating personnel may nowdetermine at a glance the exactposition of automated and gearoperated valves. Operating problems, caused by actuatorshaving no means of position identification or conventional low-profile indicators seen only whenoperating engineers are virtually on top of the valve, are easily remedied with the BeaconTM.

Beacon Principle of OperationThe Beacon is a totally enclosedmonitoring instrument devoid of anyexternal moving parts. When thecontrol valve is in a closed position,operating personnel view a highlyvisible yellow cylinder. As the valveopens and becomes fully operational,the yellow cylinder is transformedinto a sharp-edged yellow and blackchecker pattern designed for max-imum visual impact and easily rec-ognizable at distances of 150 feet.

OPEN EN

ENOPEN

CLOSEDCLO

CLO CLOSED

OBSERVATIONNo visible effectNo visible effectNo visible effectNo visible effectNo visible effectNo visible effectNo visible effectNo visible effectNo visible effectNo visible effect

Tensile Strength @ Break psi Izod Impact Strength, notched @ 73oF, ft-lb/inUV Resistance ClarityHeat Deflection Temperature-HDT@ 264 psi,oFUL Flammability Rating

7,600>16YesYes

15194HB

CHEMICAL RESISTANCE @ 23° C

PHYSICAL PROPERTIES

Features! Manufactured from high

impact strength, corrosion resistant, clear Eastman Eastar® copolyester.

! Increases safety for plant personnel.

! Offers instant visual recognition of valve position from all vantage points up to 150 feet.

! 360° color coding for maximum visual impact.

! Totally enclosed instrumentdevoid of any external moving parts.

VALVE INPOSITION A

VALVE INPOSITION B

3-WAY FLOW PATH MONITOR

POSITION MONITORS

VALVE INOPEN

POSITION

VALVE IN50% OPENPOSITION

VALVE INCLOSEDPOSITION

REAGENT10% Sodium HydroxideChlorox Bleach, 5% SolutionSalt Water20% Sulfuric AcidGasoline, RegularHydraulic Fluid50/50 Water/EthanolEthanolMethanolBenzyl Alcohol

BULLETIN NO. AR-10.02


BeaconTM

Flow Path Monitor



Features! Provides a concrete

measure of valve performance.

! Monitors valve position while visually displaying flow path.

! Eliminates guesswork and reduces costs at system start-up.

! Offers positive mechanical monitoring of multiport control valves.

953.75

752.94

592.34 DIA.

DIMENSIONS (mm/ inches)

OperatingTemperatureLimits: -40°C to+82°C

Multiport Flow PathMonitorThe Multiport Flow Path Monitoris a unique and invaluable accessory for any three-way control assembly. Whether gear-operated or automaticallycontrolled, valve flow path andposition are immediately recog-nizable and accurately monitored.Guesswork is eliminated andprocess system information issafely, economically, and reliablysupplied to operating and start-uppersonnel.

Principle of OperationThe Beacon Flow Path Monitormounts directly to the valveoperator. It is dimensionally equal to the Beacon, having thesame operating temperature limits. The outer cylinder is comprised of a graphic flangedtee arrangement, offering a clearview of the inner cylinder. Theinner cylinder designates the flowpath by a highly visible red pattern. This pattern will appearto viewing personnel through theclear outer tee.

BEACONTM 3-WAY BEACONTM

OPEN

OPEN

OPEN

OPEN

OPEN

90° RotationSTANDARD

(Black & Yellow)BY

ANSI YELLOW(Inherently Hazardous)

AY

ANSI GREEN(Liquid-Low Hazard)

AG

ANSI BLUE(Gas-Low Hazard)

AB

ANSI RED(Fire Quenching)

AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3

ORDERING GUIDE

Note: When ordering, please specify actuator make and model number.

Westlock reserves the right to change product designs and specifications without notice, and is not responsible for errors and omissions.




AccuTrakTM 1000

General Purpose

Engineered Resin Enclosurewith Beacon Visual Position Monitor

Designed to Survive inCorrosive EnvironmentsHigh performance polyamideresins, offer a viable alternativeto metal enclosures for applica-tions where caustic washdowns,chloride atmospheres and salt-water environments are a daily occurrence. The "Supertough"AccuTrak Series 1000 combineschemical resistance with high-impact strength and immunity to weathering. Unaffected byelectrolytic corrosion and highconcentrates of alkalies, theSeries 1000 is remarkablyresistant to attack from bacteriaand fungi; a feature especiallyimportant in food and beverageprocessing plants.

Advanced CompositeNEMA 4, 4x EnclosureAvailable in solid EngineeredResin or with clear copolyestercovers, the Series 1000 com-bines strength with corrosionresistance. Each unit carries a UL flammability rating of 94-HB.

Prewired Terminal BlockPrewired terminal blocks are num-bered and color-coded. Generousworking space for wiring.

Micro-Switch V3 (Mechanical)Approvals: UL, CSA

SPDT Form C

15 amps @ 125/250 VAC

10 amps @ 24 VDC

.5 amps @ 125 VDC

.25 amps @ 250 VDC

Electrical Version

Electrical Characteristics

StandardSensorOptions



AccuTrakTM1000



OPEN

59 DIA.2.34

1.1228.5

BOTTOM VIEW

2.9475

.69 / 18

.88 / 22

1.37 / 35

.94 / 24

DIA

SQU SQU

FLAT

OP

EN

OP

EN

BE

AC

ON

TOP VIEW

SIDE VIEW5/16-18 UNC TAP x.38 DP, 4 PLC'S

COLOR CODEDBEACON POSITIONINDICATOR

1/2" NPT2 PLC'S

.5614

.24 6

.3759.52

4.00102

2.2557

.2506.32

.256

5.47139

4.73120

2.2557

+.000-.001 FLAT

.375 DIA

DIA

.156 3.96

9.53

OPTIONAL NAMUR SHAFT

.1573.98

.1914.85

.3508.891.30

33

DIMENSIONS (inches/mm)

ENCLOSURE BEACONTM 3-WAY BEACONTM

10402 SPDT mechanical switchesNEMA 4, 4x

10652 SPDT mechanical switchesNEMA 4, 4x

OPEN

OPEN

OPEN

OPEN

OPEN

OPEN


(Black & Yellow)BY


AY


AG


AB


AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3

MATERIALS OF CONSTRUCTIONHousing

Cover

Shaft

Fasteners

Beacon Monitor

Engineered Resin

Engineered Resin(Optional Clear Copolyester)

Stainless Steel

Stainless Steel

Copolyester

ENCLOSUREConduit Entries

Terminal Strip

2 - 1/2”NPT

8 point standard12 points optional

APPROVALS / CERTIFICATION

ORDERING GUIDE

AREA CLASSIFICATIONS

NEMA 4, 4x

CSA (Canadian Standards Association)

PO EN

0PEN

TouchSetTM CamsCams, secured by set screws, continually lose calibration due to vibration inherent in all pipelines. Self-locking TouchsetTM cams are fastened to a splined shaft and can be set by hand in seconds. Since there are no set screws, the cams will never slip out of adjustment.

BeaconTM

An impact and corrosion resistant valveposition monitor capable of displaying exact valve position from any quadrant at distances of up to 150 feet. Start-up and operating personnel avoid being placedin physically awkward or dangerous situations while attempting to ascertain valve position.


No output shaft(cannot accept beacon)






AccuTrakTM 2000

General Purpose/Explosionproof


0-100%PositionTransmission

Resistive Output Signal1000 ohms

1 watt

Conductive Plastic

100,000 cycles

Standard Output Signal

Power Rating at 70°C

Elements

Rotational Life (no load)

Current Output Signal4-20 mA DC, 2 wire

6.5-33 VDC

950 ohms

-40°C to 85°C


Power Requirements

Max. Load Resistance at 24 VDC

Operating Temperature

High Visibility Position Monitoring

The AccuTrak 2000 is designed to enable the process engineer to add as much feedback from a control valve as the situationrequires. The NEMA 4, 4x, 7, 9rated aluminum enclosure isequipped with two mechanicalswitches and a Beacon high visibility monitor for instant recognition of valve position up todistances of 150 feet. A uniqueself-locking, spring-loadedTouchSet cam mechanism allowsfor instantaneous hand setting oflimit switches requiring only fiveseconds each. A pre-wired numbered and color coded terminal block provides ease andconvenience of wiring. Optionalanalog transmitters provide full

range monitoring of valve position throughout a 0-100%range. Point to point limitswitch signalling combined with continuous on-site visual monitoring and optional analogoutput are all available in onecompact UL/CSA enclosure.

Dual Display Monitor withBeaconTM and TouchSetTM Cams

Micro-Switch V3

VDC

24

125

250

AMPS10

10

10

VAC125

250

VDC

28

VAC125

250

AMPS15

15

6

,5

.25

SPDT (V3) DPDT (Licon)


AccuTrakTM

2000



BOTTOM VIEW

5/16-18 UNC TAP X.44/11.2 DP, 4 PLC'S

5.29134.4

4.05102.9 2.26

57.5

2.25 SQU 57.2

1.1328.6

OPEN

1/2" NPT

.84/21.3

SIDE VIEW

2.3459.4

+.000-.002+.00-.05

FLAT DIA

DIA

2.9474.7

6.54166.1

.3759.5

2.6065.9

2.6567.2

5.29134.4

1.1328.6

.5614.2

.44/11.2 TYP4 PLC'S

.2506.35

.256.3

OPEN3/4" NPT2 PLC’S

SIDE VIEW

2.3459

DIA

+.000-.002

FLAT DIA

2.9475

1.7544

.256.56

14

.9524

.7218

.3759.52

.2506.35

.6216

1.1228

BOTTOM VIEW

SQU

2.2557

4.00102

6.13156

6.42163

5/16 - 18 UNC TAP.44/11.2 DP, 4 PLC’S

DIMENSIONS (inches /mm)

2004 & 2085

2007X

ENCLOSURE BEACONTM 3-WAY BEACONTM TRANSMITTERS

20042 SPDTMechanical SwitchesNEMA 4, 4x

2007X2 SPDTMechanical Switches

NEMA 4, 4x, 7, 9Class I, Grps. C & DClass II, Grps. E, F & GDivisions 1 & 2

20852 SPDTMechanical SwitchesNEMA 4, 4x

OPEN

OPEN

OPEN

OPEN

OPEN

OPEN

OPEN


(Black & Yellow)BY


AY


AG


AB


AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3

1000 ohmsRS

4-20 mACS


UL (Underwriters Laboratories, Inc.)



NEMA 4, 4x, 7, 9

Class I, Groups C, D

Class II, Groups E, F, G,

Divisions 1 & 2


ORDERING GUIDE

Ordering Example: Dual Display Monitor (2 SPDT switches) with standard black and yellow Beacon, 1000 K potentiometer (NEMA-4 enclosure). 2004-BY-RS

Options Available: 4 SPDT switches (2007X only), 2 DPDT switches, epoxy coatings, anodizing, gold alloy contacts, optional terminalstrips, resistive outputs. (Consult Price Sheet)


Terminal Strip

NEMA 4: (1) 1/2” NPTNEMA 4, 4x, 7, 9: (2) 3/4”NPT

8 contacts standard16 contacts available


Cover

Coating

Shaft

Fasteners

Beacon

Die Cast Aluminum

Die Cast Aluminum

Polyester Powder

Stainless Steel

Stainless Steel

Copolyester





BULLETIN NO. A-14.02

AccuTrakTM 2200

General Purpose/Explosionproof

Hermetically Sealed ProximitySensors and Transient/SurgeAbsorption Circuitry

0-100%PositionTransmission

Designed to Survive theIndustrial EnvironmentValve position monitors in processplants are continually plagued byadverse operating conditions whichfrequently result in unit malfunction.Moisture causes unwanted paths to form in electrical circuits. Cams,secured by set screws, continuallylose calibration. Proximity sensors are subject to harm from voltage and current surges.

The Accutrak 2000 is virtually maintenance free! With hermeticallysealed sensors, no set screws forcam adjustment, elevated terminalstrip and transient protection, no unitavailable today is better protectedagainst corrosion and inductive spikes.

Hermetically Sealed Proximity SensorsThe AccuTrak 2200 employs proximitysensors for feedback of valve performance to micro-computers orPLCs. Sealed against explosive gases,

water and corrosive chemicals,these sensors have a low contactresistance of .1 ohms, therebyeliminating “spikes” that may damage sensitive electronic interface equipment.

Transient SuppressionEach monitor is protected againstinductive spikes by a circuit boardemploying plug-in fuses and varisters capable of absorbingtransients of up to 2500 ampsproduced by lightning, switchingsurges and capacitive discharges.

Hermetically Sealed Proximity Sensor

* Resistive: Reduce rating to 1/3 for inductive loads.

SPST SPDT.100

10

200

.5

1.2

.150

3

200

.25

1.2

Contact Resistance (ohms)

Contact Rating* (AC, DC) (Watts)

Volts (max) (AC, DC)

Amps (max) (switching)

Amps (max) (carry)



1 watt

Conductive Plastic

100,000 cycles



Elements



6.5-33 VDC

950 ohms

-40°C to 85°C


Power Requirements



Magnum and Proximity Sensors OnlyFor low power (P ≤ 240 mW) and/or high DI card capacitance (C ≥ 0.01 mfd.) applications refer to the Reference SectionBulletin No. WD-15.02.

!ATTENTION


AccuTrakTM 2200



DIMENSIONS (inches /mm)

ENCLOSURE BEACONTM 3-WAY BEACONTM TRANSMITTERS

2214Proximity SensorsNEMA 4, 4x

2217XProximity SensorsNEMA 4, 4x, 7, 9Class I, Grps. C & DClass II, Grps. E, F & GDivisions 1 & 2

2295Proximity SensorsNEMA 4, 4x

OPEN

OPEN

OPEN

OPEN

OPEN

OPEN

OPEN


(Black & Yellow)BY


AY


AG


AB


AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3

1000 ohmsRS

4-20 mACS


Cover

Coating

Shaft

Fasteners

Beacon

Die Cast Aluminum

Die Cast Aluminum

Polyester Powder

Stainless Steel

Stainless Steel

Copolyester


NEMA 4, 4x, 7, 9



Divisions 1 & 2


Terminal Strip

NEMA 4: (1) 1/2” NPTNEMA 4, 4x, 7, 9: (2) 3/4”NPT

8 contacts standard16 contacts available

ORDERING GUIDE

Ordering Example: Dual Display Monitor (2 SPST sensors) with standard black and yellow Beacon, 1000 K potentiometer. 2214-BY-RS

Options Available: 4 SPST sensors or 4 SPDT sensors (2217X only), epoxy coatings, anodizing, gold alloy contacts, optional terminalstrips, resistive outputs. (Consult Price Sheet)

BOTTOM VIEW

5/16-18 UNC TAP X.44/11.2 DP, 4 PLC'S

5.29134.4

4.05102.9 2.26

57.5

2.25 SQU 57.2

1.1328.6

OPEN

1/2" NPT

.84/21.3

SIDE VIEW

2.3459.4

+.000-.002+.00-.05

FLAT DIA

DIA

2.9474.7

6.54166.1

.3759.5

2.6065.9

2.6567.2

5.29134.4

1.1328.6

.5614.2

.44/11.2 TYP4 PLC'S

.2506.35

.256.3

OPEN3/4" NPT2 PLC’S

SIDE VIEW

2.3459

DIA

+.000-.002

FLAT DIA

2.9475

1.7544

.256.56

14

.9524

.7218

.3759.52

.2506.35

.6216

1.1228

BOTTOM VIEW

SQU

2.2557

4.00102

6.13156

6.42163

5/16 - 18 UNC TAP.44/11.2 DP, 4 PLC’S

2214 & 2295

2217X








AccuTrakTM 360 / 366

Explosionproof

Specifically engineered tomeet all hazardous areaclassifications and groups.

The Westlock 360 Series is specificallyengineered to meet all hazardous areaclassifications and groups. Certified toUL and Canadian Standards, the unithas the flexibility to satisfy a widerange of diverse requirements.

Employing standard Westlock designfeatures, (BeaconTM performancemonitors, Touch-SetTM cams and pre-wired components), the 360 Series is available with a wide range of position sensors and pre-integratedsolenoid valves.

Designed for NEMA 4, 4x, 7, 9 hazardous areas, the 360, in conjunc-tion with high current, hermeticallysealed MagnumTM sensors, eliminatesthe costly requirement of installingseal fittings in Division 1, Class I,

Groups B, C & D and Division 2,Class I, Groups A, B, C & D. InDivision 1, Groups B, C & D theomission of seal fittings is accomplished through the heavyduty construction of the unit'smetal enclosure; enabling it towithstand the various pressure piling tests required by UL andCanadian Standards.


316 Stainless Steel housing forcorrosive environments.

0-100% PositionTransmission

Resistive Output Signal Current Output SignalStandard Output Signal: 1000 ohms

Power Rating at 70°C: 1 watt

Elements: Conductive Plastic

Rotational Life (no load): 100,000 cycles

Standard Output Signal: 4-20 mA DC, 2 wire

Power Requirements: 6.5-33 VDC

Max. Load Resistance at 24 VDC: 950 ohms

Operating Temperature: -40°C to 85°C



Micro-Switch V3

VDC

24

125

250

AMPS10

10

10

VAC125

250

VDC

28

VAC125

250

AMPS15

15

6

,5

.25


Magnum and Proximity Sensors OnlyFor low power (P ≤ 240 mW) and/or high DI card capacitance (C≥0.01 mfd.) applications refer to the Reference SectionBulletin No. WD-13.02.

!ATTENTION

Amps VAC VDC

0.295 120

0.15 240

1 24

Rhodium

SPST/SPDT

Amps VAC VDC

3 120

1.5 240

2 24

Tungsten

MAGNUMTM Proximity SensorsUL, CSA (Hermetically Sealed)


AccuTrakTM 360 / 366


3.8096.5

5.30134.6

BOTTOM VIEW OPTIONAL NAMUR SHAFT

.5714.4

.5614.3

.260

.248

.190 ±001 9.53 DIA .157 ±.003

3.98 ±.08

8.89 ±.10

.157 [4.00]

.155 [3.94]

.0782

1.3133


ENCLOSURE BEACONTM 3-WAY BEACONTM SENSOR SOLENOID

360Aluminum

366316L Stainless Steel

For Eliminator configuration, prefixpart number with the letter (E).Example: E360

OPEN

Mech. (SPDT)M2

Mech. (DPDT)M4

MAGNUM (SPDT)M6

Resistive Output:1000 ohms

RS

Current Output:4-20 mA

CS

To Be Specified By Customer

MutualFactorySystemFactoryMutual

System

OPENOPEN

STANDARD(Black & Yellow) BY


System

OPENOPEN

ANSI YELLOW(Inherently Hazardous) AY

OPEN


System

OPEN

ANSI GREEN(Liquid-Low Hazard) AG


System

OPEN

OPEN

ANSI BLUE(Gas-Low Hazard) AB


System

OPEN

OPEN

ANSI RED(Fire Quenching) AR


System

OPEN


System

OPEN


System

OPEN


System

OPEN


System

OPEN

90° Rotation B1

90° Rotation B3

90° Rotation B5

180° Rotation B7

180° Rotation B9

MATERIALS OF CONSTRUCTIONHousing / Cover

Coating

Shaft

Beacon Monitor

Cast Aluminum316L Stainless Steel

Polyurethane

Stainless Steel

Copolyester

ORDERING GUIDE

Engineered as a pre-integrated unit, the capabilities of the 360 include valve position monitoring and solenoid actuator control.


NEMA 4, 4x, 7, 9

Class I, Groups A, B, C, D


Divisions 1 & 2

c


cUL (UL Canadian Certification)

FM Factory Mutual Research


Terminal Points

2 - 3/4” NPT

10 points standard




TRANSMITTERS



Engineering and plant personnelmay now specify an extremelyreliable, cost efficient system tomonitor and regulate valves inone compact assembly. WestlockControls design engineers havesuccessfully combined three separate products: a junction box,a limit switch, and a solenoid valveinto a single unit — the first of itskind to be listed and recognized asa single assembly by UnderwritersLaboratory for hazardous areaapplications.

A Cost Efficient IntegratedSystem to Monitor and RegulateValves in a Single Assembly

MECHANICAL SWITCHES

CONVENTIONAL METHOD ELIMINATOR® 3000

COMPARATIVE COST ANALYSIS

2 SwitchesSolenoidJunction BoxSeal FittingsWire, ConduitLaborTOTAL COST


*Not Required

$150.100.50.40.20.

170.$530.

IncludedIncludedIncluded

NR*1

NR*NR*

$298.

PROXIMITY SENSORS

CONVENTIONAL METHOD ELIMINATOR® 30002 SwitchesSolenoidJunction BoxSeal FittingsWire, ConduitLaborTOTAL COST

2 SensorsSolenoidJunction BoxSeal FittingsWire, ConduitLaborTOTAL COST

*Not Required1 A seal fitting between the Asco solenoid and Eliminator enclosure is not required

$358.100.50.80.30.

270.$888.


NR*1

NR*NR*

$364.

The Eliminator is a highly reliablevalve position monitor andprewired, integrally mountedASCO® solenoid valve. Compatiblewith all PC’s, the 3000 series isavailable with mechanical orproximity switches and a broadselection of solenoid valves. Thehigh cost of independent junctionboxes, mandatory wiring, sealfittings and field labor is totallyeliminated.

EliminatorTM 3000

Explosionproof






ASCO SOLENOIDAsco is the undisputed choice of theprocess control industry. Specified by engineers and plant personnel worldwide,the ASCO solenoid valve has proven reli-able in millions of industrial applications.

AGENCY LISTINGUnderwriters Laboratoryhas long been recognized for its uncompromising commitment to human safety. Insurance underwriters, government authorities, engineers and plant operators regard thethe UL listing and Classification Mark asevidence that the product has satisfied the strictest safety requirements. TheWestlock Eliminator has been evaluatedand listed by UL and CSA as a singleassembly, rather than an arbitrary combination of unrelated components.

PO EN

0PEN

PROXIMITY OR MECHANICAL SENSORSSwitch requirements will differ withoperating conditions in the industrialenvironment. Mechanical switches areless expensive and possess the highestcurrent rating. Proximity sensors,encapsulated and hermetically sealedagainst explosive gases and liquids, provide maximum moisture and corrosionresistance. The reed type proximity sensor eliminates contact bounce whilebeing totally compatible with all computers and PCs.

ELIMINATORTM 3000UL, CSA Listed for NEMA 4, 4X, 7, 9

Class I, Groups C & DClass II, Group E, F & G,

Divisions 1 & 2

TOUCHSETTM CAMSCams, secured by set screws, continually lose calibration due to vibration inherent in all pipelines. Self-locking TouchsetTM cams are fastened to a splined shaft and can be set by hand in seconds. Since there are no set screws, the cams will never slip out of adjustment.

BEACONTM

An impact and corrosion resistant valveposition monitor capable of displaying exact valve position from any quadrant at distances of up to 150 feet. Start-up and operating personnel avoid being placedin physically awkward or dangerous situations while attempting to ascertain valve position.

TERMINAL BLOCKThe EliminatorTM features an elevated prewired terminal block with two additionalpoints for solenoid valve integration. Theenclosure additionally functions as a junction box.

EliminatorTM 3000


Mechanical SwitchesUL, CSA Listed

Proximity Sensors UL, CSA! All switches are PC compatible! Platinum plated magnetic reed! Hermetically sealed in glass

! Doubly sealed in silicon housing! Repeatability: .002 inches! Switch Life: 100,000,000 cycles

* Resistive: Reduce rating to 1/3 for inductive loads.

SPST SPDT.5

.100

10

200

.5

1.2

200

1.5

.150

3

200

.25

1.2

200

Actuation Time (milli-seconds)

Contact Resistance (ohms)

Contact Rating* (AC, DC) (Watts)

Volts (max) (AC, DC)

Amps (max) (switching)

Amps (max) (carry)

Switch Temp. Rating (°F)

EliminatorTM 3000


Standard SensorOptions

Resistive Output Signal

1000 ohms

1 watt

Conductive Plastic

100,000 cycles



Elements



6.5-33 VDC

950 ohms

-40°C to 85°C


Power Requirements





VDC

24

125

250

AMPS10

10

10

VAC125

250

VDC

28

VAC125

250

AMPS15

15

6

,5

.25


Magnum and Proximity Sensors OnlyFor low power (P ≤ 240 mW) and/or high DI cardcapacitance (C ≥ 0.01 mfd.) applications refer to the Reference Section Bulletin No. WD-15.02.

!ATTENTION


AccuTrakTM 3000


OPEN

COLOR CODED"BEACON POSITIONINDICATOR"

OPTIONALSOLENOID

1/2 NPT

SIDE VIEW

OP

EN

OP

EN

BE

AC

ON

TOP VIEW


2.3459

DIA

+.000-.002

FLAT DIA

6.42163

5.67144

6.13156

2.9475

1.7544

.256.56

14

.7218

2.2557

5.41137

.3759.52

.2506.35

.6216

1.1228

BOTTOM VIEW

SQU2.2557

4.00102

1.1228

2.2858

5/16 - 18 UNC TAP.44 DP, 4 PLC'S

3/4 NPT

+.000-.001 FLAT

.375 DIA

DIA

.156 3.96

9.53

.1573.98

.1914.85

.3508.891.30

33

.8421


ENCLOSURE BEACONTM 3-WAY BEACONTM TRANSMITTERS SOLENOID

3030Mechanical SwitchesSPDT or DPDT

3057Proximity SensorsSPST or SPDT

OPEN

OPEN

OPEN

OPEN

OPEN

OPEN

OPEN


(Black & Yellow)BY


AY


AG


AB


AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3

1000 ohmsRS

4-20 mACS

ASCOTo Be Specified By Customer


Cover

Shaft

Fasteners

Beacon

Die Cast Aluminum

Die Cast Aluminum

Stainless Steel

Stainless Steel

Copolyester



ORDERING GUIDE


NEMA 4, 4x, 7, 9



Divisions 1 & 2


Ordering Example: Eliminator with 2 proximity sensors and standard black and yellow Beacon. 3057-BY with 2 SPDT and Asco 8320A90.

Options Available: The 3000 Series is available with up to six switches and four separate conduit entries. Special coatings, special features ofASCO valves are available upon request.


Terminal Strip

1-3/4” NPT, 1-1/2” NPT

8 contacts standard16 contact available





AccuTrakTM 4000

Explosionproof

Hazardous Area PositionMonitor with GO® ProximitySwitches

Available in both AccuTrakTM andEliminatorTM configurations, Westlockhas combined the engineering andcost-effective features of its standardUL listed and CSA certified productswith the high performance, high current-carrying capacity of the GO®

proximity switch. This unit offers theprocess industry all of the designcharacteristics of the AccuTrakTM

and EliminatorTM (BeaconTM positionmonitor, TouchsetTM cams, pre-wiredterminal strip, pre-wired Asco®

solenoid valve) with the proven reliability of the GO® proximity switch.

Available as an extremely dependable,cost-effective system designed tomonitor and regulate both rotary and linear-stroke valves, the high cost of independent junction boxes,mandatory wiring, and field labor is

totally eliminated. The cost ofinstalling seal fittings between theAsco solenoid and switch enclosureis also eliminated. The series 4000 combines three products: ajunction box, GO proximity sensorsand an Asco solenoid valve into asingle unit for hazardous areaapplications. All units are UL listedand CSA certified to NEMA 4, 4x, 7& 9 Class I, Groups C & D, Class IIGroups E, F & G Divisions 1 & 2.Besides being housed in theWestlock explosionproof enclosure,the sensors themselves are environmentally sealed and completely self-contained.

All GO® switches have a high contact rating of SPDT, Form C,2 amps at 240 VAC /4 amps at120 VAC /50mA at 24 VDC.

VDC

24

VAC

120

240

AMPS

4

2

.05 (50 mA)

SPDT GO

GO®

ProximitySwitch

Electrical Characteristics SPDT, Form C

! All GO® switches are environmentally sealed.! Cables: Potted in with 3-conductor no.18 AWG stranded wire leads,

80°C, 300V, PVC jacket.! Response Time: 8 milliseconds

ComparativeCost Analysis

NOTE:1Asco 8320 A90

*Not Required2A seal fitting between theASCO Solenoid and Switchenclosure is not required.

Conduit runs entering theenclosure must have a seal-ing fitting connected within 18inches of the enclosure

GO® PROXIMITY SWITCHES

CONVENTIONAL METHOD ELIMINATORTM 40002 Switches w/bracketSolenoid1

Junction BoxSeal FittingsWire, ConduitLaborTOTAL COST


$358.100.50.80.30.

270.$888.


NR*2

NR*NR*

$570.




AccuTrakTM 4000


ENCLOSURE BEACONTM 3-WAY BEACONTM SOLENOID

AccuTrak4040Aluminum2-SPDT GO® Switches

Eliminator4080Aluminum2-SPDT GO® Switches

OPEN

OPEN

OPEN

OPEN

OPEN

OPEN

OPEN


(Black & Yellow)BY


AY


AG


AB


AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3

ASCOTo Be Specified By Customer

ORDERING GUIDE



NEMA 4, 4x, 7, 9



Divisions 1 & 2OPEN


OPTIONALSOLENOID

1/2 NPT

SIDE VIEW

OP

EN

OP

EN

BE

AC

ON

TOP VIEW


2.3459

DIA

+.000-.002

FLAT DIA

6.42163

5.67144

6.13156

2.9475

1.7544

.256.56

14

.7218

2.2557

5.41137

.3759.52

.2506.35

.6216

1.1228

BOTTOM VIEW

SQU2.2557

4.00102

1.1228

2.2858

5/16 - 18 UNC TAP.44 DP, 4 PLC'S

3/4 NPT

+.000-.001 FLAT

.375 DIA

DIA

.156 3.96

9.53

.1573.98

.1914.85

.3508.891.30

33

.8421


Cover

Shaft

Fasteners

Beacon

Die Cast Aluminum

Die Cast Aluminum

Stainless Steel

Stainless Steel

Copolyester





Terminal Strip

4040: 2 - 3/4” NPT4080: 1-3/4” NPT,

1-34” NPT Male

12 contacts standard

Note: drawing representative of the 4080





AccuTrakTM 5000

Intrinsically Safe

Valve Position Monitor forIntrinsically Safe Applications.*

A Universal Standard for Intrinsically SafePosition MonitoringWestlock Controls, through a technical alliance with the world’spremier sensor manufacturer,Pepperl+Fuchs, has jointly engineered an Intrinsically Safeposition monitor that incorporatesinto a single unit the primary designfeatures of both companies. Bycombining field proven components,cost-effective design elements,international approval agency certifications and adherence toNAMUR specifications, Westlockand Pepperl + Fuchs have createdan Intrinsically Safe position monitor engineered to become an industry standard.

The new AccuTrak 5000 is a highlycorrosion resistant FM/CSAapproved valve position monitorhaving the capability to house a

wide range of sensors, includingthe P+F Namur sensor. The P+FNamur sensor NJ2-V3-N meets allrequirements of the EN 60947-5-6(NAMUR) standard and carriesapproval certifications from PTB,CENELEC, FM and CSA. In addition, the AccuTrak 5000 is also available with Magnumproximity sensors and mechanicalMicro Switches for Intrinsically Safe“simple apparatus” applications.

P+F, NJ2-V3-NProximity Type (Solid State), Intrinsically Safe, PTB, FM, CSA, CE

Contact Rating100 mA Resistive

100 mA Resistive

VDC12

24


Mechanical V3 w/ Gold Plated Contacts UL, CSA “Simple Apparatus”, SPDT

*Westlock 5000 Series valve position monitors are FM and CSA approved GeneralPurpose enclosures. For use in IntrinsicallySafe applications, the Accutrak 5000 mustbe used in conjunction with an approvedIntrinsically Safe barrier.



2mmD.C. Voltage 2 wire in accordance with EN 60947-5-6 (NAMUR)3-15% (5% typical)1 KHz5-25 VDCCam Trigger Present: ≤ 1 mACam Trigger Absent: ≥ 3 mA (15 mA max)-10°C to +100°C

Sensing RangeElectrical Version

HysteresisSwitching FrequencyInput Voltage RangeOutput/Current Consumption

Operating Temp.

Magnum and Proximity Sensors OnlyFor low power (P ≤ 240 mW) and/or high DI card capacitance (C≥0.01 mfd.) applications refer to the Reference SectionBulletin No. WD-13.02.

!ATTENTION

Voltage 24 VDC NominalNominal Contact Resistance ≤ .10 ohmOperating Current Range 0.5mA to 1APower Range 10mW to 25WTemperature Range -40°F to +185°F

MAGNUMTM Proximity Sensors w/ Low Power ContactsUL, CSA “Simple Apparatus”, Hermetically SealedSPST or SPDT, Rhodium Contacts


AccuTrakTM 5000


BOTTOM VIEW

5/16-18 UNC TAP X.30/7.6 DP, 4 PLC'S

5.40137.2

1.3835.1SQU .69

17.5

2.2557.2 SQU

1.1328.6

3.0978.5

OPEN

1/2" NPT

.91/ 23.1

SIDE VIEW

2.3459.4

+.000-.002+.00-.05

FLATDIA

DIA

2.9474.7

6.59167.4

.3759.5

2.6166.2

2.7168.8

5.40137.2

1.1328.6

.6917.5

.5614.2

.256.3

.44/11.2 TYP4 PLC'S

.2506.35

M6 x 1 TAP x.30/7.6 DP, 4 PLC'S

5044

5004


NEMA 4, 4x



Divisions 1 & 2

MATERIALS OF CONSTRUCTIONHousing/Cover

Shaft

Screws

Beacon

Engineered Resin

Stainless Steel

Stainless Steel

Copolyester

FM (Factory Mutual Research)


MATERIALS OF CONSTRUCTIONHousing/Cover

Shaft

Screws

Beacon

Die Cast Aluminum

Stainless Steel

Stainless Steel

Copolyester



Terminal Strip

2 - 1/2” NPT


ENCLOSURE BEACONTM 3-WAY BEACONTM SENSORS TRANSMITTERS SOLENOID

OPEN

OPEN

OPEN

OPEN

OPEN


(Black & Yellow)BY


AY


AG


AB


AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3

To BeSpecified

By Customer

MAGNUM(SPDT)M12

MAGNUM(SPDT)M10

Mech. (SPST) w/ Gold Plated

ContactsM9

P+FM8

Consult Factory

ORDERING GUIDE

For Eliminator configuration on 5000 series enclosures, prefix part numbers with the letter “E”NOTE: The 5000 series may be ulitized with any I.S certified solenoid valve.

5044Engineered ResinNEMA 4, 4X

5004AluminumNEMA 4, 4X

OPEN

OPEN

5044 & 5046

5004

BOTTOM VIEW

5/16-18 UNC TAP X.44/11.2 DP, 4 PLC'S

5.29134.4

4.05102.9 2.26

57.5

2.25 SQU 57.2

1.1328.6

OPEN

1/2" NPT

.84/21.3

SIDE VIEW

2.3459.4

+.000-.002+.00-.05

FLAT DIA

DIA

2.9474.7

6.54166.1

.3759.5

2.6065.9

2.6567.2

5.29134.4

1.1328.6

.5614.2

.44/11.2 TYP4 PLC'S

.2506.35

.256.3






MATERIALS OF CONSTRUCTION

Housing

Cover

Shaft

Fasteners

Die Cast Aluminum

Die Cast Aluminum

Stainless Steel

Stainless Steel

TerminatorTM 7000

All Classes & Groups

Junction housings (less switches)

Westlock units are available (lessswitches) as central terminationjunctions with NEMA 4 orExplosionproof UL listed housings,having variations of conduitentries, local valve position indication and pre-wired solenoidvalves. All electrical connectionsmay be terminated at one point

eliminating costly field labor andconduit runs. If at a later date,switches for remote monitoringof valve position are to be added,all that will be necessary is toadd a pre-wired switch modulewhich will easily adapt to theexisting enclosure.

ENCLOSURE BEACONTM 3-WAY BEACONTM

OPEN

OPEN

OPEN

OPEN

OPEN


(Black & Yellow)BY


AY


AG


AB


AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3

7000

Aluminum NEMA 4 4x, 7, 9Class I, Groups C & DClass II, Groups E, F, GDivisions 1 & 2

OPEN

OPEN

SIDE VIEW

2.3459

DIA

+.000-.002

FLAT DIA

2.9475

1.7544

.256.56

14

.9524

.7218

.3759.52

.2506.35

.6216

1.1228

BOTTOM VIEW

SQU

2.2557

4.00102

6.13156

6.42163

5/16 - 18 UNC TAP.44 DP, 4 PLC'S

1/2 NPT

3/4 NPT

.8421


ORDERING GUIDE


NEMA 4, 4x, 7, 9, Class I, Groups C, D, Class II, Groups E, F, G, Div. 1 & 2






Multiple Conduit Entry Options


Multiple Conduit EntryEnclosures

8020 NEMA 4, 4x Enclosure: Two 1/2” NPT entries*8030 NEMA 4, 4x Enclosure: Three 1/2” NPT entries*8040 NEMA 4, 4x, 7 & 9 Enclosures: Three 3/4” NPT entries*8060 NEMA 4, 4x, 7 & 9 Enclosures: Four 3/4” NPT entries*

Specify number of terminal points: up to 16 points available

All Explosionproof units meet Class I, Groups C & D, Class II,Groups E, F & G, Division 1 & 2. If proximity switches are utilized, all explosionproof units will additionally meet Groups A & BDivision 2 only.

OPEN

SIDE VIEW

2.3459

DIA

+.000-.002

FLAT DIA

2.9475

1.7544

.256.56

14

.9524

.7218 .375

9.52

.2506.35

.6216

1.1228

BOTTOM VIEWSQU

2.2557

4.00102

1.1228

5/16 - 18 UNC TAP.44 DP, 4 PLC'S

3/4" NPT4 PLC'S

BOTTOM VIEW

5/16-18 UNC TAP X.44/11.2 DP, 4 PLC'S

5.29134.4

1/2" NPT(8020/8030)

1/2" NPT(8020/8030)

1/2" NPT(8030 ONLY)

4.05102.9 2.26

57.5

2.25 SQU 57.2

1.1328.6

OPEN

1/2" NPT

.84/21.3

SIDE VIEW

2.3459.4

+.000-.002+.00-.05

FLAT DIA

DIA

2.9474.7

6.54166.1

.3759.5

2.6065.9

2.6567.2

5.29134.4

1.1328.6

.5614.2

.44/11.2 TYP4 PLC'S

.2506.35

.256.3


ORDERING GUIDE: Order standard units as required (i.e.2004, 2007X, 9479 etc.) and request special designation asabove for multiple conduit entry enclosures.

*Consult factory for Eliminator configurations and/or alternateconduit entry sizes.

8020/8030

8060

OPEN

SIDE VIEW

2.3459

DIA

+.000-.002

FLAT DIA

2.9475

1.7544

.256.56

14

.9524

.7218 .375

9.52

.2506.35

.6216

1.1228

BOTTOM VIEWSQU

2.2557

4.00102

1.1228

5/16 - 18 UNC TAP.44 DP, 4 PLC'S

3/4" NPT4 PLC'S

8040






AccuTrakTM 9000


MagPAC Modular SensorsBifurcated Reed Swicheswith LED Indication

MAGNUMHigh-current Hermetically Sealed Proximity Sensors.

Corrosion ResistanceThe MagPAC and Magnum switchcontacts are hermetically sealed in aninert atmosphere to protect themfrom dust, oxidation or external corro-sion. The entire sealed unit is thenencapsulated in an epoxy resin tocushion the sensor in case of shock orvibration. The encapsulation processrenders the sensor impervious tomoisture, chemicals and solvents.

Low Power and/or HighCapacitance ApplicationsThe MagPAC has been specificallydesigned for use in low power (P ≤ 240 mW) and high DI cardcapacitance (C ≥ 0.01 mfd) dis-crete position feedback applications.The bifurcated switch design creates a self cleaning snap actionmovement that prevents contactoxide buildup and breaks non-resis-tive loads. With all the advantagesof a solid state sensor and withzero leakage current the MagPAC is the sensor of choice.

By applying the economic advantagesoffered by the National ElectricalCode, and by utilization of hermet-ically sealed MagPAC and Magnumsensors, the AccuTrak 9000 mergestechnology with economy. Cost saving benefits are realized by theconsolidation of components and thecomplete elimination of hazardouslocation seal fittings, wiring, conduitand their associated labor costs.

MagPACTM & MagnumTM

These proximity sensors weredesigned in response to our cus-tomers needs. The main requirementfor any product in a process plant isreliability. That is why the MagPACand Magnum sensors are warrantedto perform as specified for a full fiveyears. This warranty reflects ourcomplete confidence in the capabili-ties of our product.



MagPAC ModularSensors


Magnum SensorsThe Magnum sensor was developedspecifically for valve monitoring applications. The Form C, SPDT contacts are manufactured fromsolid hunks of pure tungsten. Sincetungsten has the highest meltingpoint of all metals plus excellentelectrical conductivity characteris-tics, the Magnum proximity sensoris capable of handling 3 amps(switching) at 120 VAC and 2 amps(switching) at 24 VDC. The sensor isUL listed and CSA recognized.

MAGNUM®

SENSORS

$338$100N/R*N/R*N/R*N/R*

$438

$109,500

MECHANICALSWITCHES

$150$100$50$40$20

$170

$530

$132,500

PROXIMITYSWITCHES

$358$100$50$80$30

$270

$888

$222,000

ROTARYVALVE

*Not Required Solenoid: Asco 8320A90Comparative costs were based upon list prices from major manufacturers.

CONVENTIONAL METHOD WESTLOCK

NATIONAL ELECTRICAL CODE (1999):Article 501-5(a) & (b). Conduit Seals, Class I, Div. 1 & 2In each conduit run entering an enclosure for switches which may produce arcs, seals shall beplaced no more than 18 inches from such enclosures.Exception: Conduit runs 1 1/2 inches and smaller entering an explosion-proof enclosure forswitches need not be sealed if the current-interrupting contacts are enclosed within a chamberhermetically sealed against the entrance of gases or vapors.NOTE: Note: For conformance to UL and CSA requirements, all conduit runs in Class I, Division 1hazardous locations must have a sealing fitting connected within 18 inches of the enclosure.

COMPARATIVE COST ANALYSISMerging Technology with EconomyUL/CSA Listed Valve Position Monitors for NEMA 4, 4X, 7, 9; Class 1, Groups C, D, Class II, Groups E, F & G, Div. 1 & 2

MAGNUM®

SENSORS

$480$100N/R*N/R*N/R*N/R*

$580

$145,000

MECHANICALSWITCHES

$550$100$50$40$20$170

$830

$207,500

PROXIMITYSWITCHES

$630$100$50$80$30

$270

$1160

$290,000

2 switches w/ bracketrysolenoidjunction boxseal fittings wire, conduitlabor

TOTAL COST

TOTAL COST (250 Valves)

CONVENTIONAL METHOD WESTLOCK

LINEARCONTROLVALVE

High CurrentSwitching

Capacity

2 switches w/ bracketrysolenoidjunction boxseal fittings wire, conduitlabor

TOTAL COST

TOTAL COST (250 Valves)

AccuTrakTM 9000

Technical Specifications



MagPAC SensorsMagPAC sensors are designed forcapacitive, high and low switchingcapacity on capacitive,inductive andresistive loads while offering excellent performance for low current applications.

The hermetically sealed elementsform a compact modular unit thataffords interchangeability with otherWestlock monitors. Ultra brightLED’s provide positive indication inthe field for coil status and valveposition.

Specifically designed for heavy dutyapplications, where superior per-formance and high reliability are amust. The MagPAC clearly sets thestandard for new sensor technologydesired in industrial applications.




AccuTrakTM 9000

Technical Specifications

9044NEMA 4, 4x

9358NEMA 4, 4x

9468NEMA 4, 4X NonincendiveClass I, Groups A, B, C, DClass II, Groups F, G, Division 2 onlyFM, CSA

9479NEMA 4, 4X, 7, 9Class I, Groups C, DClass II, Groups E, F, G, Division 1 & 2Class I Groups A, B, Division 2 FM, UL, CSA



1 watt

Conductive Plastic

100,000 cycles



Elements


Current Output Signal

4-20 mADC, 2 wire

6.5-33 VDC

950 ohms

-40°C to 85°C


Power Requirements



Technical Data

Contact Arrangement

Contacts

Operating Time

Initial Contact Resistance

Seal

Housing (Flame Retardant)

Approvals

Temperature Range

Operational Life

Repeatability

Warranty

Protection Class

SPST/SPDT, Form C (Normally Open)

Pure Tungsten

3.0 m Sec.

.50 ohms (Max)

Hermetic

High Impact Valox®

UL, CSA

-40°F to +185°F

600,000 Cycles (full rated load)

.125 mm.

5 Years

IP 67

MagnumTM XT-90Hermetically SealedProximity Sensor

Area Classifications

MagPacTM Modular SensorsBifurcated Reed Proximity Sensor, SPST • (Hermetically Sealed)FM, CSA

UPPER LOWER

SOL 2

SOL 1

LOWER LIMIT SWITCH

UPPER LIMIT SWITCH

MAGPAC

TOP VIEW

SIDE VIEW

IN1 1N2 OUT1 OUT2

1 2 3 4

J1 J2 J3

1 2 3 4 1 2 3 4

A

B

C D

Upper Limit SwitchA

Upper Limit SwitchB

Lower Limit SwitchC

Lower Limit SwitchD

Solenoid 2 Output -1

Solenoid 2 Output +2

Solenoid 1 Output -3

Solenoid 1 Output +4

Solenoid 2 Input -5

Solenoid 2 Input +6

Solenoid 2 Input -7

Solenoid 2 Input +8

Technical Data

Contact Arrangement

Contact Material

Operating Time

Releasing Time

Initial Contact Resistance

Seal

Approvals


Operational Life

Repeatability

Warranty

Protection Class

Electrical Rating

Rated Voltage

Rated Current

Allowable Sol. Coil Input Vol.

(2) SPST, Form A (Normally Open)

Movable Contact - Silver Cadmium Oxide

Stationary Contact-Molybdenum

≤ 4ms

≤ 2ms

≤ 250 milliohms

Hermetic

CSA, FM

-40°C - 85°C

100,000,000 Operations

.125 mm

5 Years

That of accociated enclosure,typically NEMA 4, 4X

12 - 120 VAC/VDC

Min. - 2 mA to light LED, Max. - 750 mA

25 - 120 VAC/VDC

Magnum and Proximity Sensors OnlyFor low power (P ≤ 240 mW) and/or high DI card capacitance(C≥0.01 mfd.) applications refer to the Reference Section Bulletin No. WD-13.02 or specify the MagPAC sensor module.

!ATTENTION

Electrical Rating

Rhodium

Tungsten

SPST/SPDT Form C (Normally Open) 0.295 amps/120 VAC, 0.15 amps/240 VAC, 1 amp/24 VDC

SPST/SPDT Form C (Normally Open) 3 amps/120 VAC, 1.5 amps/240 VAC, 2 amps/24 VDC


AccuTrakTM 9000

BOTTOM VIEW

5/16-18 UNC TAP X.30/7.6 DP, 4 PLC'S

5.40137.2

1.3835.1SQU .69

17.5

2.2557.2 SQU

1.1328.6

3.0978.5

OPEN

1/2" NPT

.91/ 23.1

SIDE VIEW

2.3459.4

+.000-.002+.00-.05

FLATDIA

DIA

2.9474.7

6.59167.4

.3759.5

2.6166.2

2.7168.8

5.40137.2

1.1328.6

.6917.5

.5614.2

.256.3

.44/11.2 TYP4 PLC'S

.2506.35

M6 x 1 TAP x.30/7.6 DP, 4 PLC'S

OPEN

SIDE VIEW

2.3459

DIA

+.000-.002

FLAT DIA

2.9475

1.7544

.256

.5614

.9524

.7218

.3759.52

.2506.35

.6216

1.1228

BOTTOM VIEW

SQU

2.2557

4.00102

6.13156

6.42163

5/16 - 18 UNC TAP.44 DP, 4 PLC'S

3/4" NPT2 PLC'S


9358 & 9044 For dimensions of 9358 enclosure see page A-13 1000 SeriesFor dimensions of 9044 enclosure see page A-17 2004 Series

9479

9468

9044 ENCLOSUREEnclosure

Conduit Entries

Terminal Strip

Die Cast Aluminum

2 -1/2”, optional 3-1/2”


Enclosure

Conduit Entries

Terminal Strip

Sensors

Die Cast Aluminum

2 -3/4” optional 4-3/4”


up to 4


Conduit Entries

Terminal Strip

Sensors

Engineered Resin Clear Cover optional

2 -1/2” optional 3-3/4”


up to 4


Conduit Entries

Terminal Strip

Engineered ResinClear Cover optional

2 -1/2”


9479 ENCLOSURE

SERIES II (Magnum Sensors) BEACONTM 3-WAY BEACONTM TRANSMITTERS SOLENOID

9358Engineered ResinNEMA 4, 4XCSA

9044AluminumNEMA 4, 4XCSA

OPEN

OPEN

OPEN

OPEN

OPEN


(Black & Yellow)BY

ResistiveOutput:

1000 ohmsRS

(Approvals for:Nema 4, 4X

General PurposeOnly unless in

9479 enclosure)

CurrentOutput: 4-20 mA

CS

Spectrum: 4-20 mA

DT

(9479 only)

Magnum(SPDT)M6

Magnum(SPST)M7

Magnum(SPDT)M10

Magnum2 (SPDT)M12

MagPAC2 (SPDT) W/

LED INDICATIONM13


AY


AG


AB


AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3

9468Engineered Resin NEMA 4, 4XHaz. Loc. NonincendiveClass I, Groups A, B, C, DClass II, Groups F, GDivision 2 Only, FM, CSA

9479AluminumHaz. Loc. NEMA 4, 4X, 7, 9Class I, Groups C, DClass II, Groups E, F, GDivision 1 & 2Class I, Grps. A, B, Div. 2, UL, CSA

For Eliminator configuration on 9479 and 9468 enclosures, prefix part numbers with the letter (E).For flat cover (no Beacon) suffix part number with the letter (F). Example: 9044F

OPEN




OPEN

OPEN SENSOR


OPEN



AccuTrakTM RS &CS

Position Transmitters

0-100% Valve Position Transmitters

Westlock transmitter optionscombine local visual display withremote electronic signaling for continuous flow device status.Point-to-point limit switch signalingis integrated with on-site visualmonitoring and full range analogposition transmission in one compact NEMA 4 or explosionproofenclosure.

RS: A 1000 ohm or 10,000 ohm analog resistive output pro-portional to valve position.

CS: A 4-20 mA analog currentoutput proportional to valve posi-tion. The CS current transmitterfeatures the latest technology insolid state transmitter design and operates with one of the lowestoperating voltages in the industry(6.5 VDC) with a maximum loadresistance of 1650 ohms at 33volts DC.

User Design Flexibility

The Westlock Dual Display Monitorallows a user the flexibility todesign a valve monitoring systemaround processing requirements as the need for additional informa-tion is required. The Full RangeAccuTrak offers design and operating personnel the followingdistinct advantages.

! 0-100% readout of valve travel is continuously monitored by ananalog output signal. By combiningan analog current output signalwith two limit switches, theAccuTrak now offers completetravel range display, accuracy andspeed of response. Additionally, a1000 ohm resistive analog output,proportional to valve position, canbe provided for continuous remotemonitoring, trend analysis, or computer interface.

! Limit switches for positive endposition monitoring of valve travel.

! Local mechanical display of valveposition throughout the full range of travel.

RS Transmitter

CS Transmitter

The RS and CS options monitorvalves throughout a 0-100%range. At full open or closed,switches will confirm end posi-tion limits.




AccuTrakTM RS &CS

Position Transmitters


Power Supply Range:

Operating Temperature Range:

Recommended Power Supply:

Output Signal Range:

Load Impedance:

Output Current Limit:

Ambient Temperature:

Maximum Rotation:

Minimum Rotation:

Linearity:

Hysteresis:

Repeatability:

Power Supply:

6.5 volts DC to 33 volts DC

-40°C to 85°C

24 volts DC

4 to 20 milliamperes DC

0 to 950 ohms at 24 volts DC

55 milliamperes DC

For a 100°C change in ambient temperature. Themaximum zero shift is plus or minus .3%, and themaximum span shift is plus or minus .4% of span.

95°

45°

Plus or minus 1.0%

.55% of full scale

Plus or minus .3% of full scale

Output signal changes .018% when the supply voltageis varied between 6.5 and 33 volts DC.


Power Rating At 70* C

Elements


1000 ohms

1 watt

Conductive Plastic

100,000 cycles

4-20 mA Transmitter! Precision analog position

transmitter.

! Operates with any voltage from 6.5 to 33 volts DC.

! Polarity Independent.

! Transient protected.

! Easy set up, non-interactiveadjustment.

! CW and CCW rotation easily accommodated.

! Accommodates long cable runs and multiple receivers.

! Available with proximity sensors or mechanical switches.

RS POSITION TRANSMITTER (RESISTIVE)

CS POSITION TRANSMITTER (CURRENT)

1500

1200

900

300

010 20 30 40 50 60

Max

imu

m L

oad

Res

ista

nce

(o

hm

s)

Power Supply Voltage (VDC)

600

1800

0

MaximumLoad

Resistance

OPERATINGRANGE

Power Supply Voltage - 5VDC20 mA=

OPEN

DIGITALSIGNAL

ANALOG RESISTIVESIGNAL

ANALOG CURRENTSIGNAL

PO EN

0PEN

On-Site Graphic Display

Every AccuTrak is equipped with aBeacon High Visibility PositionMonitor. Valve position is recog-nizable from distances up to 150 feet.

ORDERING GUIDE

Order standard units as requiredand request Transmitter Option bypart number.

RS Resistive Output Signal

CS Current Output Signal





Spectrum DTTM

Digital Position Transmitter

Full-Range Position Transmitterwith Digital Sensing

Westlock has merged absoluteencoder sensing technology withloop-powered analog transmissionto create the Spectrum DTTM

full-range position monitor. Thecommunication mode continues tobe the standard 4-20 mA analogsignal while actual sensing isachieved by a true digital sensor.

Key Performance Benefits! Reference accuracy is threetimes that of traditionalpotentiometric analog sensors.

! Shifts due to environmentaleffects such as temperature areimproved by a factor of three ormore compared with traditionalanalog sensors.

! Greater repeatability and accuracy that digital control systems brought to the controlroom have now been extended intoprocess measurement in the field.

! Non-contact means of positionsensing yields higher accuracyover the life of the product.

True Digital Position SensingAn absolute encoder is a positionverification device which providesposition information for each shaftlocation. The digital code is uniqueto each location. In absoluteencoders, there are several concentric tracks, each with anindependent light source. As lightpasses through a slot, a high statecalled "true 1" is created. Whenlight does not pass, a low stateknown as "false O" is created.Shaft position is identified by thepattern of 1’s and 0’s.

Loop-Powered 4-20 mA TransmissionThe 4-20 mA analog signal, whichhas long been a useful method ofinterfacing sensors to remote computers, is the main standardfor data transmission of theSpectrum DT.

The Spectrum DT PositionTransmitter derives its operatingpower from the 4-20mA loop itself,with no need for an external powerconnection. This is a high-level signal not easily affected by outsidenoise. In addition to the advantagesof standardization, reduced fieldwiring costs and immunity frommost electrical noise, the 4-20 mAtransmitter offers these benefits:

! Any number of signal receiverscan be series-connected into thesignal circuit without upsetting calibration.

! Multiple transmitters may sharethe same power supply.

! A 4-20mA signal is a "live zero"signal, which distinguishes aprocess condition (4mA) from anopen circuit condition (OmA).

! No position loss on power down.

! Operates in electrically noisyenvironments.

180C

OUNTS / 90°

1250

1000

750

500

250

010 20 30 40 50 60

Max

imu

m L

oad

Res

ista

nce

R

Power Supply Voltage, Vps (volts)

OPERATINGREGION

R MAX = Vps-10v20mAL

L

Power Supply Requirements





Operating DescriptionThe shaft encoder is an 8 bit device,utilizing gray code parallel outputs.Gray to binary conversion takes placebefore further signal processing. Datacorresponding to shaft position islatched, and fed to a high quality digital to analog converter, with tim-ing synchronized to encoder LED exci-tation. A precision, low drift voltagereference is utilized for the D/A con-vertor DC source, as it is for thescaling and live zero circuitry whichfollows. Voltage to current conversiondevelops the true current sink outputcharacteristic provided by the trans-mitter. Current sampling and feed-back assure that a current which istruly representative of shaft positionis generated.

The internal power supply is derivedin total from the 4 to 20 mA signalloop. Stored energy from that powersupply is delivered to the encoderLEDs for excitation on a pulsed basisfor a period of several millisecondsapproximately once every 20 millisec-onds. In this manner, LED currentexcitation requirements in excess of100 mA can readily be met despitethe con-straints imposed by 2 wirecurrent loop operation. Operation ofthe data latch and D/A convertor, as mentioned above, is synchronized to LED excitation.

Transmitter type:

Output:

Operating principle:Electrical overrange capability:

Mechanical overrange capability:End of range wraparound:Terminal voltage req.Temperature range:Temperature effect:

Humidity range:Terminal voltage effect:Linearity:Output update rate:Startup stabilization time:Resolution

Angular position, intended primarily for control valve applications,damper applications, and similar uses.

4 to 20 milliamperes (2 wire), proportional to position. Position range is90° (reversible) corresponding to nominal output current range.

Absolute shaft encoder, non-contacting.

90° of span under range of 4° and over range of 15°. For travel belowrange bottom, output current will limit at minimum of approximately 3.2 mA.

Infinite (shaft may be continuously rotated).

Provided 180° away from range midpoint.

10 to 32 volts DC. Reverse polarity protected.

-32°C to +85°C. Sunshade available for use when needed.

Less than 0.16%°C referred to full scale.

10% to 90%, non-condensing.

Less than 0.1%, from 10 to 32 volts.

Within 0.5 least significant bit.

Once per second.

6 seconds, nominal.

0.7° 256 counts in 180°

TECHNICAL SPECIFICATIONS

ORDERING GUIDE



NEMA 4, 4x, 7, 9



Divisions 1 & 2

OPEN


3/4" NPT2 PLC'S

SIDE VIEW

2.3459

DIA

+.000-.002

FLAT DIA

6.42163

6.13156

2.9475

1.7544

.256

.5614

.9524

.7218

.3759.52

.2506.35

.6216

3.2582

BOTTOM VIEW

SQU2.2557

1.1228.5

2.2858 5/16 - 18 UNC TAP

.44 DP, 4 PLC'S





Terminal Strip

2 - 3/4” NPT


ENCLOSURE BEACONTM 3-WAY BEACONTM SOLENOID

OPEN

OPEN

OPEN

OPEN

OPEN

90° RotationSTANDARD(Black & Yellow)

BY


AY


AG


AB


AR

B1

B5

B7

B9

90° Rotation

90° Rotation

180° Rotation

180° Rotation

B3


AccuTrakDT Transmitter

OPEN



Spectrum DTTM

Digital Position Transmitter


"AccuTrak Rotary "AccuTrak Linear "Reference Sheets



EPICTM HORNET

Non-Contact HART® Enabled Position Transmitter

Non-Contact HART® EnabledPosition Monitoring forRotary Valves

The EPICTM Position Transmitter is a“smart” device with microprocessor-based intelligence providing both 4-20 mA signal for position and digital communications via the HART®

protocol. The Hornet’s design repre-sents a significant departure fromprevious attempts to reliably meas-ure the position of rotary controlvalves. As opposed to conventionaldevices, couplers are not utilized.A magnetic proximity module,attached to the actuator outputshaft is the only "moving" part inthe transmitter. Sensing is per-formed totally by non-contactingmeans, based upon characterizationof flux strength as a function ofaxial position.

The ESD/PS option provides for adiscrete output via the SIS to con-trol an ESD solenoid with integrated

partial stroke test functionality;PS time, configurable PS strokeduration, time/date stamp of testand PS stroke alarm. PS test can be initiated via HART, externaltrigger zones or an internal pushbutton.

Low current operation of the sensor is enabled through the useof new materials, which allows continuous operation rather thandiscrete sampling. Continuousoperation permits high speedupdating of the output currentmaking it suitable for use in fast closed loop systems.

Accurate measurement of valveposition provides the precisiondata required for the use ofadvanced control strategies andpredictive maintenance algorithms.

Conduit Entries

Output

Terminal Voltage Req.

Linearity

Span Adjustment

Zero Adjustment

Resolution

Hysteresis

Temperature Range

Temperature Effect

Humidity

Voltage Effect

Reverse Polarity

Mounting Attitude

Startup Stabilization

3/4" NPT

4 to 20 mA proportional to valve position

10 to 30 volts

≤0.6% F.S.

60 to 120 degrees

30% of calibration span

≤0.05% F.S.

Negligible

-40°F to 185°F

≤0.01% F.S/°C

10% to 90% non-condensing

≤0.2% F.S. from 10 VDC to 30 VDC

Protected

Any Position

.5 seconds

Power Supply RequirementsTECHNICAL SPECIFICATIONS

1200

1000

800

600

400

200

0

1025

0 10 20 30 40 50

LO

OP

RE

SIS

TA

NC

E C

AP

AB

ILIT

Y (

OH

MS

)

MAXIMUM SUPPLY VOLTAGE

‰

OPERATINGRANGE

I'VE GOT

ABILITY

HART




Cover

Cast Aluminum

Cast Aluminum




1084.25

TOP VIEW

TOP VIEW

SIDE VIEW

4.253/4" NPTCONDUITENTRY

4.31

1.00

1.13SQU

3.75DIA

.50COUPLER

ENGAGEMENT

.50

1.765

108

3.36SQU

1/4 -20 UNC TH'DTHRU, 4 PLC'S

1084.25

4.25

B

SIGHT GLASSFOR SWITCH

LED INDICATION108

3.36SQU

1.350.750

2X .312 x .525(FLAT BOTTOM)

SECTION B-Bview shown without cover

1/4 -20 UNC TH'DTHRU, 4 PLC'S

B


Class I, Groups B, C, D

Class II, Groups E, F, G, Divisions 1 & 2

Class I, Group A, Division 2


EPICTM HORNET




Ordering Example

D420-R0-X-3-0000-0-1-1— Beacon Options “1” = Black/Yellow (for add. options refer to Price Book)

— Special Operation Options “0” = No Special Option, “1” = ESD/PST Relay Controller

— Solenoid Coil Options “0” = None

— Solenoid Override Options “0” = None

— Solenoid Valve Body “00” = No Solenoid

— Conduit Options “1” = 1/2” NPT, “2” = M20, “3” = 3/4” NPT, “6” = M25

— Area Class Option “X” = Explosion Proof (Class I, Div. 1, Grps B-D/Class I, Div. 2, Grps A-G)

— Valve Type Options “R0” = Rotary Valve, “RR” = Rotary Valve with Remote Option

— Enclosure Options “10” = Mod 3 - Standard Epic Enclosure with Site Glass

“20” = Mod 3 - Standard Epic Enclosure

— Product Code for Digital Epic D4



EPICTM N4 Series



The EPICTM N4 Series PositionTransmitters are “smart” deviceswith microprocessor- based intelli-gence providing both 4-20 mA sig-nal for position and digital communi-cations via the HART® protocol. TheN4 Series features low copper content aluminum, engineered resinor 316 SS enclosures with single solenoid valve or optional redundantsolenoid valve. The N4 Seriesdesign represents a significantdeparture from previous attemptsto reliably measure the position ofrotary control valves. As opposed toconventional devices, couplers arenot utilized. A magnetic proximitymodule, attached to the actuatoroutput shaft is the only "moving"part in the transmitter. Sensing isperformed totally by non-contactingmeans, based upon characterizationof flux strength as a function ofaxial position.

The ESD/PS option provides for adiscrete output via the SIS tocontrol an ESD solenoid with inte-grated partial stroke test func-tionality; PS time, configurable PSstroke duration, time/date stampof test and PS stroke alarm. PStest can be initiated via HART orpush button.



Conduit Entries

Output


Linearity

Span Adjustment

Zero Adjustment

Resolution

Hysteresis

Temperature Range

Temperature Effect

Humidity

Voltage Effect

Reverse Polarity

Mounting Attitude


3/4" NPT


10 to 30 volts

≤0.6% F.S.

60 to 120 degrees


≤0.05% F.S.

Negligible

-40°F to 185°F

≤0.01% F.S/°C



Protected

Any Position

.5 seconds


1200

1000

800

600

400

200

0

1025

0 10 20 30 40 50

LO

OP

RE

SIS

TA

NC

E C

AP

AB

ILIT

Y (

OH

MS

)


‰

OPERATINGRANGE



I'VE GOT

ABILITY

HART



MATERIALS OF CONSTRUCTIONHousing/Cover Engineered Resin

MATERIALS OF CONSTRUCTIONHousing/Cover Cast Aluminum

MATERIALS OF CONSTRUCTIONHousing/Cover 316 Stainless Steel

4-20" UNC TH'D4 PLC'S

OUTLET 1/4 NPTPORT #2

INLET1/4 NPTPORT #1

EXHAUST1/4" NPTPORT #5

INLET1/4 NPTPORT #2

EXHAUST1/4" NPTPORT #3

3.7595.3

1.1328.7

1.6842.7



6.41

5.31

.88

.312 PLC's

1.502 PLC's

.752 PLC's

2.25

BOTTOM VIEW

TOP VIEW

SIDE VIEW

1.16

3.68

AE

B

D

DIA

SQU

1.76544.8

.843 PLC'S

1.6842.7

1.12

1.10

1.95

C

SQUARE D4 BUTTON

SWITCH

.50 [12.7] COUPLERENGAGEMENT

3.3685.3

9.17

7.07

5.50

1.54

INLET1/4" NPTPORT #4

3/4" NPT

AREA CLASSIFICATIONSClass I, Groups A, B, C, DClass II, Groups E, F, G, Division 2


EPICTM N4 Series




.3 & .5 Cv

1.2 Cv

3.5 Cv

A

1.50

2.00

2.75

B (3-WAY)

3.31

4.50

5.25

C (4-WAY)

4.06

5.50

6.56

D

1.13

1.38

1.88

E

4.24

4.49

4.87

Solenoid ValveDimensions

D450RO D440RO D430RO

Ordering ExampleD450-R0-N-3-5900-1-2-1

— Beacon Options “1” = Black/Yellow (for add. options refer to Price Book)


“2” = PST- Pushbutton Initiation

— Solenoid Coil Options “1” = FSO 24Vdc, 0.5W (for additional options refer to Price Book)

— Solenoid Override Options “0” = None (for options E, L, M, N, R or S refer to Price Book)

— Solenoid Valve Body “0” = No Solenoid, 2100- 5900 or 2Y00- 4Z00 (see Falcon Sol. Ordering Guide)

For additional solenoid options (3rd character) refer to Price Book.


— Area Class Option “N” = Nonincendive (Class I Division 2, Groups A thru G


— Enclosure Options “30” = N4R2- Resin Single/Dual Coil Falcon, “40” = N4A2- Aluminum Single/Dual Coil Falcon

“50” = N4S2- Stainless Steel Single/Dual Coil Falcon





ORDERING GUIDE (FALCONTM SOLENOID)

CV Body 3-Way

Brass 2100

Alum. 3100

303 S.S. 4100

316 S.S. 5100

Brass 2200

Alum. 3200

303 SS 4200

316 S.S. 5200

Brass 2300

Alum. 3300

303 S.S. 4300

316 S.S. 5300

Alum. 3400

4-Way

2500

3500

4500

5500

2600

3600

4600

5600

2700

3700

4700

5700

3800

OPTIONAL FEATURES (See BULLETIN NO. Q-18.02)

COILS

FSO24 VDC

0.5 watts

FAO120 VAC4.0 watts

FVO125 VDC

0.85 watts

FHO220 VAC4.0 watts

.3 Cv

.5 Cv

1.2 Cv

3.5 Cv



EPICTM 360 & 366 Series



The EPICTM 360 and 366 PositionTransmitters are “smart” deviceswith microprocessor- based intelli-gence providing both 4-20 mA signal for position and digital com-munications via the HART® protocol.The 360 & 366 Series features low copper content aluminum or 316 SSenclosures with single solenoid valveor optional redundant solenoid valvefor explosionproof service in Class I,Div. 1 Group B hazardous areas.The 360 & 366 Series design represents a significant departurefrom previous attempts to reliablymeasure the position of rotary control valves. As opposed to con-ventional devices, couplers are notutilized. A magnetic proximity mod-ule, attached to the actuator outputshaft is the only "moving" part in thetransmitter. Sensing is performedtotally by non-contacting means,based upon characterization of flux strength as a function of axialposition.

The ESD/PS option provides for adiscrete output via the SIS tocontrol an ESD solenoid with inte-grated partial stroke test func-tionality; PS time, configurable PSstroke duration, time/date stampof test and PS stroke alarm. PStest can be initiated via HART.



Conduit Entries

Output


Linearity

Span Adjustment

Zero Adjustment

Resolution

Hysteresis

Temperature Range

Temperature Effect

Humidity

Voltage Effect

Reverse Polarity

Mounting Attitude


3/4" NPT


10 to 30 volts

≤0.6% F.S.

60 to 120 degrees


≤0.05% F.S.

Negligible

-40°F to 185°F

≤0.01% F.S/°C



Protected

Any Position

.5 seconds


1200

1000

800

600

400

200

0

1025

0 10 20 30 40 50

LO

OP

RE

SIS

TA

NC

E C

AP

AB

ILIT

Y (

OH

MS

)


‰

OPERATINGRANGE

I'VE GOT

ABILITY

HART





TOP VIEW

BOTTOM VIEW

SIDE VIEW

3.133 PLC'S

2.06

2.00

6.504.91DIA

4.91DIA

1.13SQU.

.27

3.92

1.765

.250

B

AC

D

4.00

3/4" NPT

2.00

.50 COU[LERENGAGEMENT

7.19 APROX.

ELBOWFILTER2 PLC'S

5.25

9.09APROX.

11.01 APROX.

2.50

3.36SQU

2.80

1.68

1/4-20 UNCTH'D4 PLC'S

AREA CLASSIFICATIONSClass I, Groups B, C, DClass II, Groups E, F, G, Divisions 1 & 2Class I, Group A, Division 2


EPICTM 360 & 366 Series


.3 & .5 Cv

1.2 Cv

3.5 Cv

A

1.50

2.00

2.75

B (3-WAY)

3.31

4.50

5.25

C (4-WAY)

4.06

5.50

6.56

D

4.26

4.69

5.01

Solenoid ValveDimensions

MATERIALS OF CONSTRUCTION

360 Housing/Cover

366 Housing/Cover

Cast Aluminum

Cast 316 Stainless Steel



Ordering ExampleD470-R0-X-3-2100-1-1-1

— Beacon Options “1” = Black/Yellow (for add. options refer to Price Book)


— Solenoid Coil Options “6” = XSO 24Vdc, 0.5W (for additional options refer to Price Book)

— Solenoid Override Options “0” = None (for options E, L, M, N, R or S refer to Price Book)

— Solenoid Valve Body “0” = No Solenoid, 2100- 4800 (see Falcon Solenoid Ordering Guide)

For additional solenoid options (3rd character) refer to Price Book.


— Area Class Option “X” = Explosion Proof (Class I, Div. 1, Grps B-D/Class I, Div. 2, Grps A-G)


— Enclosure Options “60” = 360- Aluminum Single/Dual Coil Falcon “70” = 366- Stainless Steel Single/Dual Coil Falcon






CV Body 3-Way

Brass 2100

Alum. 3100

303 S.S. 4100

316 S.S. 5100

Brass 2200

Alum. 3200

303 SS 4200

316 S.S. 5200

Brass 2300

Alum. 3300

303 S.S. 4300

316 S.S. 5300

Alum. 3400

4-Way

2500

3500

4500

5500

2600

3600

4600

5600

2700

3700

4700

5700

3800

OPTIONAL FEATURES (See BULLETIN NO. Q-18.02)

COILS

XSO24 VDC

0.55 watts

XAO120 VAC4.0 watts

XVO125 VDC1.0 watts

XHO220 VAC4.0 watts

.3 Cv

.5 Cv

1.2 Cv

3.5 Cv


Positioners

P10 Pneumatic Positioner

" P10 Cam-Characterized Pneumatic Positioner

Designed for Single and Double-Acting Actuators

I/P module available for 4-20 mA input

K10 Electro-Pneumatic Positioner

" K10 Electro-Pneumatic Positioner w/ Keypad & Remote Infrared AutoCal Calibration

ICoT Smart Positioners

" Design Features

" ICoT 5200 Intelligent Positioner with Keypad

" ICoT 5300 Intelligent Positioner with Hart Capability

" ICoT 5400 Foundation Fieldbus Enabled Intelligent Positioner

" Ordering Ordering Guide & Dimensional Data

POSITIO

NERS




P10

Pneumatic Positioner

Cam-CharacterizedPneumatic Positioner

2

The Westlock Model P10 is a cam-characterized pneumaticvalve positioner designed to provide optimal performance forsingle and double-acting actuators in rotary or linear applica-tions using standard pneumatic signals. The lapped spool andmatched sleeve design delivers significant energy savings inthe form of extremely low air consumption in the balancedstate with no compromise of out-flow capacity. The rugged and durable design is exceptionally reliable for use in harshenvironments.

FEATURES

! Ease of calibration

! Zero and span adjust-ment are dynamicallyindependent.

! 2 year warranty.

! Beacon visual positionmonitor available.

! Integrated positionsensor capability.

! Corrosion resistantNema 4, 4x enclosure standard.






3

3-15 PSI3

6-30 PSI6

Flat Cover w/Disk Indicator

F

Beacon IndicatorBlack & Yellow

B

Beacon IndicatorGraduated

G

StandardS

NamurN

No Gauges0

Gauges1

No Switches 0

1 Mech. SwitchA

2 Mech. SwitchesB

1 InductiveProximity Sensor

C2 Inductive

Proximity SensorD

4-20 mAPosition Transmitter

E

P10 Input Signal Indicator Mounting Gauges Position Sensor

No Transducer0

General PurposeNonincendive

G

ExplosionproofX

I/P Transducer

P10

OUT 1OUT 2IN IN


P10 SPECIFICATIONS

Input Range 3-15 PSIG (20-100 kPa/0.2-1.0 bar) 6-30 PSIG (40-200 KPa/0.4-2.0 bar)

Supply Pressure 20-150 psi (0.14-1 MPa)Air Consumption 0,10 SCFM (2.8nl/min) @ 60 PSIG (4 bar)Air Delivery Capacity 12,8 SCFM (370 nl/min) @60 PSIG (4 bar)Stroke Range Linear: 0.5” to 4” based on 60° rot.

Rotary: 90°Temperature Limits -40°F / 185°FWeight Excluding options: 4.2 lbs (1.9) Kg

With gauges: 4.6 lbs (2.1) KgConnection Connector threads: 1/4” NPT

Gauge Threads: 1/8” NPTMounting Any mounting orientation

Diaphragm actuators: according IEC 534-6 (Namur)

OPERATING SPECIFICATIONS

OUT 1OUT 2IN IN

1/4 - 18 NPT (4x)

1/8 - 27 NPT (4x)(GAUGES)

1.77(45)

1.77(45)

1.77(45)

1.38 SQ(35.0)

0.71(18)

0.71(18)

0.10(2.5)

2.25 SQ(57.1)

1.14(29)

1.33(33.6)

3.35(85)

4.04(102.5)

2.66(67.5)

6.20(57.5)

6.30(160)

5/16"-18 UNC (4x)

M6 X 1(4x)

1/8 - 27 NPT (3x)

EXHAUST PORT

WESTLOCK P10

DIMENSIONS (Inches)

Materials of Construction

Housing Epoxy paint Die cast alum.Fasteners Stainless SteelDiaphragm and seals Buna-N

Options

• Beacon open/closed or graduated.

• One or two Position Switches are either SPDT Mechanical or Inductive Proximity Switches.

• 4-20 mA Position Transmitter.

• General Purpose/Nonincendive, or Explosionproof I/P unit mounted directly on the positioner.

• Supply, output and input, and signal pressure gauges.

• Input signal 3-15, 6-30 PSIG

Performance

Repeatability <0.5% of spanLinearity <2% of spanHysteresis <0.75% of spanDead Band <0.3% of spanEffect Temperature <0.07% / °CSupply pressure change effect <0.14% of spanfor 1 PSIG

Note: shown without I/P module.


K10

Electro-Pneumatic Positioner

Electro-Pneumatic Positionerwith Keypad & RemoteInfrared AutoCal Calibration

4

The model K10 electro-pneumatic positioner is the first of its kindhaving calibration either by a simple AutoCal push of a button orremotely by implementing an infrared signal from a handheld.The K10 positioner brings a new level of efficiency to operatingpersonnel responsible for the calibration of I/P positioners.

FEATURES

! Fast calibration through a simple pushbuttonAutoCal procedure orremote calibration byutilizing an infraredhandheld.

! Certified General Purpose,Nonincendive orExplosionproof orIntrinsically Safe.

! 2 year warranty.

! Beacon visual positionmonitor.

! Integrated position sensorcapability.

! Corrosion resistantengineered resin Nema 4,4x enclosure standard.(Explosionproof unit:Aluminum)

! Optional high flowtransducer.

Nema 4, 4x

Nonincendive:* Class I, Groups A, B, C & DClass II, Groups F & G, Division 2

Intrinsically Safe:Class I, II, IIIGroups A - G; Division 1(must be used with an approved barrier)

Explosionproof:Class I, Groups C & DClass II, Groups E, F & GDivisions 1 & 2

AGENCY APPROVALS






5

3.67

6.59

7.50

3/4" NPT

.375 DIA(Namur shaft optional)

.250+000-.002

SIDE VIEW

.441.56

TOP VIEW

5.24

7.50

5.0

2.34 DIA

2.94

OPEN

OP

EN

OP

EN

BE

AC

ON

Materials of Construction (N/I & I/S))

Housing Engineered Resin Cover Clear Engineered ResinManifold Anodized AluminumConduit Stainless 3/4” NPTShaft Stainless SteelHardware Stainless Steel

Materials of Construction (Explosionproof)

Housing AluminumCover AluminumManifold Aluminum (anodized)Conduit 3/4” NPTShaft Stainless SteelHardware Stainless Steel

Micro-Switch V3

SPDT (V3)AMPS VAC VDC

15 12515 25010 24

0.50 1250.25 125

Infrared Handheld for K10 Positioner K10HH


*Mechanical switch option suitable for General Purpose applicationsonly. Nonincendive approvals/certifications void when ordered withmechanical switches.

K10

ORDERING GUIDE

MOUNTING

StandardS

NamurN

SUPPLYPRESSURE

High Pressure(40 to 120 PSI)

H

Low Pressure(15 to 45 PSI)

L

High Flow(40 to 120 PSI)

V

POSITION SENSOR

No Switches 0

1 Mech. Switch*A

2 Mech. Switches*B

1 Inductive Proximity Sensor

C2 Inductive

Proximity SensorD

4-20 mAPosition Transmitter

E

AREACLASIFICATION

Nema 4, 4xNonincendive

Class I, Grps. A, B, C & DClass II, Grps. F & G; Div. 2

N

Intrinsically SafeClass I, II, III; Grps. A - G,

Div,1 (must be used with anapproved barrier)

I

K10

OPEN

K10 SPECIFICATIONS

Input current 4 to 20 mA (analog)Voltage drop 9 voltsSupply air pressure (low) 15 to 45 psi, (high) 40 to 120 psiResolution 0.2% of spanLinearity ±1% of spanHysteresis 0.2% of spanRepeatability 0.2% of spanThermal coefficient 2%/100°COutput flow rates (low) 8.0 scfm @ 25 psi, (high) 16.2 scfm @ 90 psiAir consumption (low) 0.003 scfm @ 20 psi, (high) 0.008 scfm @ 90 psiGain Electronically adjustableAir Connection Ports 1/4” NPT

OPERATING SPECIFICATIONSDIMENTIONS (Inches)

P+F NJ2-V3 Sensors Proximity Type (Solid State), I.S., PTB, FM, CSA, CE

Sensing Range 3 mmElectrical Version D.C. voltage 2 wire in accordance

with DIN19234 (NAMUR)Hysteresis Approx. 5%Switching Frequency 1.5KHzNominal Voltage 8 VDCInput Voltage Range 5-25 VDCOutput/Current Cam Trigger Present ≤1mAConsumption Cam Trigger Absent ≥3mA (15mA max)Operating Temp. -25°C + 100°C


ICoTTM

UNLIKE CONVENTIONAL POSITIONERS, THE ICOTPOSITIONER FEEDS BACKVALVE POSITION WITHOUT THE NEED FOR LINKAGES OR LEVERS.

Non-Contact Position FeedbackUnlike conventional positioners, theICoTTM (patent pending) feeds backaccurate valve position without theneed for linkages, levers, and rotaryor linear seals. Position sensing isperformed totally by non-contactingmeans, permitting use of advancedcontrol strategies where knowledge ofvalve position is used in predictive andother algorithms.

Negligible BleedDesigned to consume the least possibleamount of control air at steady state,the ICoT 5000 Series positioner cangreatly reduce the air consumption ofyour process and reduce the demand oninstrument air compressors. To increasereliability, the ICoT employs a patentedlapped spool and floating sleeve design.This balanced construction relies on anair bearing which eliminates any metal-to-metal contact and results in a meantime between failures (MTFB) of1,666,666.7 hours or 333.3 years.

6

Proximity Positioner

Non-contactposition feed-back is accom-plished throughthe use of aproximity typesolid statesensor




7

Remote Mount CapabilitySince valve position feedback to the ICoTTM positioner is accom-plished by non-contacting means, the ICoT has the unique abilityto be mounted remotely (up to a distance of 50 feet) from thedevice it is controlling. In the event the control valve is locatedin either a high vibration or extremely corrosive environment,the non-contact position feedback feature allows for isolatedplacement of the positioner.

Integrated Position TransmitterThe ICoTTM is available with an integrated 4-20 mA. position feedback transmitter. This cost effective feature elimi-nates the requirement for the purchase of externally mounteddevices when knowledge of valve position is required at a remote location

HART® ProtocolThe ICoTTM positioner responds to HART® commands for ease ofcalibration and provides intelligence for the control valve througha microprocessor based diagnostic system utilizing the HART®

protocol. Accurate measurement of valve stem position, inputsignal, and actuator pressure offer operating personnel a real-time perspective on the state of control at the valve.

Intelligent Calibration, Local KeypadICoTTM intelligent positioners are equipped with a HART® inter-face or a 3-button “membrane keypad” for performing on-siteelectronic calibration. The AutoCal feature allows for simple zeroand span adjustments as well as PID and transducer calibration.

The Advantages of the ICoT Non-Contact Positioner

ROTARY CONTROLSince valve position sensing is performed totally by proximitymeans, hysteresis within the positioner is non-existent. This featureallows for extremely accurate tracking of the control signal to within 1/10 of 1 mA. A non-contact position sensor, employing Hall Effectmagnetic principles for position feedback, is embedded within the ICoThousing. An external magnetic module, attached to the output shaft ofthe actuator rotates about the Hall Effect sensor. An analog-to-digitalconverter interfaces between the position sensor and a microprocessorwhile also transmitting the incoming position command (instrumentsignal) to the microprocessor. Servo circuitry is then utilized for implementation of position control.

LINEAR CONTROLThe ICoT proximity positioner represents a significant departure fromprevious attempts to reliably measure valve stem position. A staticslide-by actuation assembly, attached to the valve stem, is the only“moving part” of the positioner. Position sensing is performed totallyby non-contacting means. Output updating takes place twenty timesper second. A microprocessor implements any alteration requiredto provide the equivalent of equal percentage, quick opening, or linear valve characteristics.

Output of the processor is the “setpoint” input for the servo amplifiercircuitry, while the position sensor provides feedback. The positionsensor output signal is also fed to the analog-to-digital converter permitting a wide range of diagnostic information to be generated.

MAGNETMAGNETSENSOR

SENSOR

TOP VIEW

MAGNET

VALVE STEMVALVE YOKE

MAGNET




ICoTTM

System Overview

A microprocessor, housed withinan environmentally sealed canister,performs position sensor lineariza-tion, AutoCal, characterization forvalve type, PID control, autotuning,HART® information processing,and display management.

An electropneumatic transducer,with internal diagnostic elements,converts the servo output signalinto a pneumatic signal for directlydriving valve actuators.

Position feedback is accomplishedby a non-contact Hall effectmagnetic sensor. All rotary posi-tioners are standardly equippedwith a BeaconTM position monitor.

Air lines are connected to amachined aluminum manifoldhaving gauges, filters, and anin-line 20 micron filter.

For positioners not equippedwith a HART® interface, a 3-button “membrane keypad” isprovided for performing on-siteelectronic calibration.

A standard hand-held terminal(the HART® Communicator)may be utilized for field opera-tions in conjunction with a remote PC for maintenance information and documentation.

A B

D

C

FE

8




A 32/64 channel HART® multiplexerprovides diagnostic interfacing formultiple positioners.

F

DIAGNOSTICSPlant operating personnel are givena real-time perspective on the stateof control at the valve, including aview into operating integrity andemerging alarm conditions. Early-warning diagnostic information isconstantly being updated to assistproduction scheduling and mainte-nance personnel.

A preventive maintenance and data logging system, in parallel with the 4-20 mA loops, performs online diagnostics of control valves with automatic record keeping for docu-mentation purposes. The HART®

communications capability of the ICoTTM positioner, coupled with theHPORTTM multiplexer and CornerstoneTM

control valve specific software, provides operating personnel theopportunity of implementing cus-tomized preventive maintenance programs. It additionally simplifiesadherence to occupational health and safety requirements mandated by government regulations.

LOOP CONTROLLER

DCS

HPORT is a trademark of ARCOM Control Systems, Inc.CORNERSTONE is a trademark of Applied System Technologies, Inc.

C

G

Cornerstone

HART CommWindow Status Terminate Help

Instrument communication: Intelligent Modem Unit on Com 1

Vendor: Model:Tag:ID#Date:Cal Scheme:Range:Description:

ICoT5300VP300817621 JuneStandard0 - 100%4020H

Instrument

Positioner-5300

INPUT SIGNAL (mA)

100

90

80

70

60

50

40

30

20

10

04 6 8 10 12 14 16 18 20 22

CLOSING

% O

PE

NIN

G

OPENING

OFFSETDUE TOFRICTION

9




The ICoT 5200 is optionally avail-able with an integrated 4-20 mAposition feedback transmitter. As opposed to conventional devices,position sensing is performed bynon-contacting means, based uponcharacterization of flux strength asa function of axial position.

ICoTTM 5200

Intelligent Positioner with Keypad

Intelligent Proximity Positionerwith Keypad Calibration andOn-Board Sensors

AutoCalThe ICoTTM 5200 is equipped witha 3-button keypad interface and a 4-digit, .5” tall LCD that allowsfor automated calibration of thepositioner.

System calibration is performedeasily requiring only minutes toaccomplish. During the calibrationprocess, the microprocessor measures position sensor voltagealong with input setpoint currentand establishes the amount of control signal required to movethe valve to its end limits.

An on-board microprocessor usesthe calibration data to provideaccurate operation over the fullspan of valve travel during normaloperation. The actual valve positionmeasured and the amount of control signal applied at any time is a result of microprocessor interpolation. The interpolationmethod is operator selectable and can be Linear, Quick Opening, or Equal Percentage.

Split range and reverse actingoperation are easily configured.

Local LCD DisplayThe local LCD display provides amultitude of onsite diagnosticinformation. While the valve isbeing controlled by the positioner,and the error signal is NOT zero,the displayed information will alternate between setpoint andposition as percentage. Each valueis displayed for a period of twoseconds. Once the setpoint andvalve position agree to within lessthan ± 0.5%, the display will onlyshow position.

The range of values displayed arefrom 0.0% (fully closed) to 100%(fully open). Displayed resolution is in 0.1% increments, however,internal calculations are maintainedat higher precision.

4-20 mA0-100%

IntegratedPositionTransmitter

%PS 50.0 SP 50.012.0 mA ACAL

10




A pressure transducer comparesactuator output pressure to theincoming transducer signal for diag-nostic purposes. These two parame-ters are graphically displayed via theHART® interface and provide valuabledata. For example, the relationshipbetween actuator pressure and valvetravel allows for stem friction, springrate, and benchset parameters to becalculated. Excessive stem frictionmay imply the presence of packing orguide bushing problems. Additionally,detection of a non-operational spoolvalve within the ICoTTM positioner is also made possible by the pres-sure sensor whose output is utilizedfor comparison with the servo outputcommand to the transducer.

A pressure switch detects abnor-mal internal pressure within thetransducer indicative of a restrictednozzle or punctured diaphragm.

A pressure switch detects low airpressure entering the positioner. Inconjunction with a supply pressureswitch, a determination can be madethat either a restricted filter isresponsible for low air pressureentering the positioner or a bonafidelow supply pressure conditions exists.

Low air supply pressure isdetected by a pressure switchupstream of the internal filter andprovides warning of insufficient powerfor valve stroking.

A 0-100% position feedbacktransmitter is available integratedwithin the electronics of the ICoTpositioner.

Since valve position feedback to theICoT positioner is accomplished bynon-contacting means, the ICoT has the unique ability to be mount-ed remotely (up to a distance of 50feet) from the device it is control-ling. In the event the control valveis located in either a high vibrationor extremely corrosive environment,the non-contact position feedbackfeature allows for isolated place-ment of the positioner.

1 3 4 52

The ICoTTM positioner has the capability to constantly monitor its own operation. If an error or failure condition occurs, it will be displayed on the local LCD or if the positioner is supplied with a HART®

interface, the error codes will be displayedon a hand-held terminal or PC maintenancestation. The following codes are provided:

The above alarm conditions and addition-al diagnostic capabilities are providedthrough a number of sensor elements inthe transducer which are capable ofindicating problematic operation.

%PS 50.0 SP 50.012.0 mA ERR3

Err1 = Clogged nozzle or change filter

Err3 = Low input pressure or clogged filter

Err6 = Calibration error

2

3

4

5

On-Board Sensors

1

Remote MountCapability

11




ICoTTM 5200

Intelligent Positioner w/ Keypad

100%

CB

A

SETPOINT

0 TIME

PO

SIT

ION

PID Control A positioner is a servo system that con-tinuously controls the position (output) of a valve in accordance with an externalcontrol signal referred to as setpoint. Ina proportional type system, the setpointis constantly being subtracted from theoutput (position). This signal, resultingfrom the constant subtraction, is termedas error (setpoint - output = error) whichmultiplied by a constant is used to modifythe final output. The magnitude of thisproduct is termed proportional gain or“P” (error x constant = P).

It would seem that the greater onemakes “P” the less the error wouldappear in the final output. Unfortunately,in practice, this does not hold true.

Graph #1 displays the response of apositioner to a sudden change of setpointfor different values of “P”. Setting a smallvalue to “P” results in a final output whichdiffers from the desired output by a largeerror (curve A). Setting a large value to“P” results in an uncontrollable continu-ous oscillation of output termed “UltimateP” (curve C). By interpolating differentvalues of “P”, a value may be obtainedwhich produces a medium error having astable response (curve B). However, theresult of a proportional only type systemstill results in a relatively large error andslow speed of response.

The ICoT smart positioner greatlyenhances the performance of the propor-tional only type system. A derivative (“D”)is added to the servo of the ICoT. “D” isthe derivative of the output with respectto time or the speed at which the valveposition moves multiplied by a constant(speed x constant = “D”). The positioner isnow converted into a “PD” servo type sys-tem. The addition of “D” into the systemincreases speed of response whiledecreasing overshoot. It also allows for “P”to increase above the ultimate proportion-al value, thereby reducing the final error(see graph #2).

In order to decrease the error even further, a third function,”I”, is added to the “PD” servo. The integrator (“I”) slowlydecreases the error when the positionreaches stability. This addition of the “I”function converts the ICoT into a “PID”servo type system.

Autotuning The setting of the proportional, inte-gral, and derivative functions (“PID”),also referred to as “tuning” canbecome quite complex and tedious. Byutilizing the microcontroller within theICoT, Westlock has designed an algo-rithm which automatically tunes allthree parameters. This procedure isreferred to as “autotuning”.

Upon receiving a request for autotune, the positioner enters into a digitalmode and overrides any setpoint command. It initiates the routine bysetting “P”, “I”, and “D” at their lowestvalues. It will then begin to increasethe “P” value until it reaches “UltimateP”. At this instance the CPU records“Ultimate P” and the coinciding periodof oscillation. With the recorded datain memory, the CPU then performs amodified Ziegler-Nichols analysis andcorrespondingly assigns correct valuesto the “P”, “I”, and “D” functions.

100%

P

PID

PDSETPOINT

0 TIME

PO

SIT

ION

GRAPH #1

GRAPH #2

12




13



MODEL 5200 LINEAR ROTARY

Input Current 4 to 20 mA (Analog) 4 mA (Digital HART)

Voltage Drop 12.3 Volts

Supply Air Pressure (low) 15 to 45 PSI(high) 40 to 120 PSI

Standard Stroke .25 to 48 inches 0 to 95 Degrees

Resolution 0.2% of span

*Linearity 1% of span (0.4” to 1.25”) 0.5% of span

Hysteresis 0.2% of span

Repeatability 0.2% of span

Thermal Coefficient 2% / 100°C

Output Flow Rates (low) 8.0 scfm @ 25 PSI(high) 16.2 scfm @ 90 PSI

Air Consumption (low) .003 scfm @ 20 PSI(high) .008 scfm @ 90 PSI

Operating Temp. Range -40°C to 85°C (-40°F to 185°F)

Gain Electronically Adjustable w/ Autotuning

Speed Response Electronically Adjustable

Feedback Magnetic (Non-contact)

Diagnostics LCD Display

Air Connection Ports 1/4” NPT

Calibration Method Electronic Keypad


Nonincendive:Class I, Groups A-D Class II & III,Groups F-G, Div. 2

Nonincendive:Class I, Groups A-D Class II & IIIGroups F-G, Div. 2

Intrinsically Safe:Class I, II & IIIGroups A - G, Divisions1 & 2

Intrinsically Safe:Class I, Groups A -D, Class II & III Groups E-G, Div. 1Exia IIC T4; Class I,Zone O

AEx II 2 GEExib IIC T4

AGENCY APPROVALS

ICoTTM 5200

LINEARNonincendive 10NI

Intrinsically Safe 10IS

ROTARYNonincendive 30NI






CONSTRUCTION

Engineered Resin

E

ORDERING GUIDE

PRESSURE/CALIBRATION

High Pressure (40 to 120 PSI)

HK


LK

High Flow(40-120 PSI)

VK

Nema 4, 4X

NonincendiveGroups A - G, Division 2

Intrinsically SafeGroups A - G, Divisions 1 & 2

CONDUITENTRY

1/2” NPTA

M20B

POSITIONSENSOR

(Rotary Only)

No Sensors0

MagnumOne SPST

1

MagnumTwo SPST

2

Position switches notavailable on

remote mount

POSITIONTRANSMITTER

WithoutTransmitter

A

4-20 mAB

MOUNTING CONFIGURATION

52

8060

40

20

0

100120

140

0

246

8

1011

8060

40

20

0

100120

140

0

246

8

1011

STANDARD

REMOTE MOUNT


*NOTE: For linear graphs displaying deviation from straight line (0.4” to 20”)see technical manual #374.


ICoTTM 5300

Intelligent Positioner w/ Hart® Capability

Intelligent Proximity Positionerwith HART® CommunicatorCapability and Online Diagnostics

%PS 50.0 SP 50.012.0mA ACAL

A preventive maintenance and data logging system, in parallel with the 4-20 mA loops, performs online diagnostics of control valves with automatic record keeping for docu-mentation purposes. The HART®

communications capability of the ICoTTM positioner, coupled with theHPORTTM multiplexer and CornerstoneTM

control valve specific software, provides operating personnel theopportunity of implementing cus-tomized preventive maintenance programs. It additionally simplifiesadherence to occupational health and safety requirements mandated by government regulations.

Cornerstone

HART CommWindow Status Terminate Help

Instrument communication: Intelligent Modem Unit on Com 1

Vendor: Model:Tag:ID#Date:Cal Scheme:Range:Description:

ICoT5300VP300817621 JuneStandard0 - 100%4020H

Instrument

Positioner-5300

INPUT SIGNAL (mA)

100

90

80

70

60

50

40

30

20

10

04 6 8 10 12 14 16 18 20 22

CLOSING

% O

PE

NIN

G

OPENING

OFFSETDUE TOFRICTION

DiagnosticCapability

Intelligent CalibrationHART® ProtocolThe ICoTTM 5300 provides intelli-gence for the control valve througha microprocessor-based systemutilizing the HART® protocol.Accurate measurement of valvestem position, input signal, andactuator pressure can be recordedduring normal operation, therebyproviding information for controlvalve signature generation.

A standard hand-held terminal (the HART® Communicator) may be utilized for field operations inconjunction with a remote PC formaintenance information and documentation.

Intelligent ControlICoT, with HART® protocol, opensup an endless array of new possi-bilities for improving efficiency and preventive maintenance procedures in all areas pertainingto control valve usage.

ICoTTM 5300

HPORT is a trademark of ARCOM Control Systems, Inc.CORNERSTONE is a trademark of Applied System Technologies, Inc.

Local LCD DisplayLocal Position Display

Local Diagnostics

Keypad CalibrationHand-Held Communicator

Online DiagnosticsFugitive Emissions Monitoring

End Limit Position Sensing

Auto Cal, PID ControlAutotuning

Remote Position Control

4-20 mA Position TransmitterEarly-Warning Diagnostic

SoftwareMultiplex Capability

14




15



CommunicationThe Model 375 communicates with ICoTTM

Smart Positioners via HART® protocol.Communication is accomplished by super-imposing a high frequency signal on top of the 4-20 mA output signal. Thisallows simultaneous communication andoutput without comprising loop integrity.

FUNCTIONAL SPECIFICATIONSMemory A nonvolatile memory retains stored information when the

Model 375 is powered down; provided a charged battery pack is installed.

Power Supply Five AA 1.5V batteries. (Rechargeable nickel-cadmium battery pack optional.)

PERFORMANCE SPECIFICATIONS - Temperature Limits

Operating Limits 32 to 122°F (0 to 50°C)

Storage Limits -4 to 158°F (-20 to 70°C)

Humidity Limits Operates in 0-95% relative humidity under non-condensing conditions below 104°F (40°C) without error.

PHYSICAL SPECIFICATIONS

Display 4-line liquid crystal display with 20 character line width.

Keyboard Complete alphanumeric keyboard, six dedicated function keys, and four software defined keys.

Weight Approximately 2 lbs. (0.9 kg) including batteries.

HART® Hand-Held TerminalA single 4-20 mA ICoT® positioner with up to two master devices may beconnected to each HART® loop. Theprimary master is generally a manage-ment system or a PC while the second-ary unit can be a hand-held terminal orlaptop computer.

A standard hand-held HART®

Communicator is available for makingfield operations as uniform as possible.Manufactured by Rosemount, the Model 375 functions as a common

tool for HART® microprocessor-basedfield instruments. From any wiring termination point in the loop, the battery-powered Model 375 can perform diagnostic, configuration, andinterrogation functions. Additionally,while the 375 is offline, configurationdata can be stored for later download-ing to one or more positioners.Simultaneous communication capabili-ties allow the hand-held terminal toreceive data from and send data to thepositioner without disrupting the posi-tioner’s signal from the control room.

250

ICoTPOSITIONER

I.S.BARRIER

POWERSUPPLY

SPECIFICATIONS for HART Model 375HAZARDOUS LOCATIONS CERTIFICATIONS

CENELECIntrinsic Safety CertificationEEx ib IIC T6Certificate No. Ex89C2279

Factory Mutual (FM)Intrinsic Safety and Nonincendive ApprovalIntrinsically Safe for Class I, Division 1,Groups A, B, C and D; Nonincendive for Class I, Division 2, Groups A, B, C and D.

Canadian Standards Association (CSA)Intrinsic Safety Approval.Intrinsically Safe for Class I, Division 1,Groups A, B, C and D.


ICoTTM 5300

Intelligent Positioner w/ Hart® Capability

Diagnostic andConfiguration Software

ICoTTM has developed a SmartPositioner possessing the capabili-ty to predict rather than react tovalve maintenance needs. Withthe ICoTTM positioner, operatingpersonnel gain a real-time per-spective on the state of control at the valve, including a view ofoperating integrity and emergingalert conditions. Timely informa-tion about each control valvescondition is quickly made availableto the plant’s production andmaintenance engineers.

THE PRINCIPLE ADVANTAGEOF ONLINE DIAGNOSTICS ISTHE ABILITY TO DETECT DEVI-ATIONS FROM ESTABLISHEDPATTERNS OF BEHAVIOR ASTHEY OCCUR UNDER ACTUALOPERATING CONDITIONS.Control valves are the most mainte-nance intensive components commonlyused in instrumentation and controlsystems. By inclusion of internal parameter sensing within the valvepositioner, forewarning of the need formaintenance is made available with acomfortable degree of lead time.

The ICoTTM positioner’s diagnostic com-patibility is based upon observations ofthe following operating parameters:

" Valve position vs. input signal." Actuator pressure vs. valve position." Airset filter outlet pressure." Confirmation of principal operating

pressures within positioner." Pressure generation within packing

gland area.

Online Diagnostics via HART® Link" “Stick-slip” detection." Excessive static position error." Fugitive emissions monitoring." Low air supply pressure." Clogged air supply filter." Restricted transducer nozzle." Transducer diaphragm air leak." Non-functioning spool valve." Calibration error.

For additional information utilizing Hartcompatible software such asCornerstone or Fisher Rosemounts’AMS, please consult factory.

Window Status Terminate Help

Conventional History Database Reports Diagrams Main

Cornerstone

Positioner - 4020H

%PS 50.0 SP 50.012.0 mA ACAL

Cornerstone software

16






ICoTTM 5300









CONSTRUCTION

Engineered Resin

E

ORDERING GUIDE



HART & KeypadHB


HART & KeypadLB

High Flow(40-120 psi)

Hart & KeypadVB

Nema 4, 4X



CONDUITENTRY

1/2” NPTA

M20B

POSITIONSENSOR

(Rotary Only)

No Sensors0

MagnumOne SPST

1

MagnumTwo SPST

2

Position switches notavailable on

remote mount

POSITIONTRANSMITTER

WithoutTransmitter

A

4-20 mAB


53

STANDARD

REMOTE MOUNT

MODEL 5300 LINEAR ROTARY

Input Current 4 to 20 mA (Analog) 4 mA (Digital HART)

Voltage Drop 12.3 Volts

Supply Air Pressure (low) 15 to 45 PSI(high) 40 to 120 PSI

Standard Stroke .25 to 48 inches 0 to 95 Degrees

Resolution 0.2% of span

*Linearity 1% of span (0.4” to 1.25”) 0.5% of span

Hysteresis 0.2% of span

Repeatability 0.2% of span

Thermal Coefficient 2% / 100°C

Output Flow Rates (low) 8.0 scfm @ 25 PSI(high) 16.2 scfm @ 90 PSI

Air Consumption (low) .003 scfm @ 20 PSI(high) .008 scfm @ 90 PSI

Operating Temp. Range -40°C to 85°C (-40°F to 185°F)

Gain Electronically Adjustable w/ Autotuning

Speed Response Electronically Adjustable

Feedback Magnetic (Non-contact)

Diagnostics HART Protocol

Air Connection Ports 1/4” NPT

Calibration Method HART® or HART® & Keypad


8060

40

20

0

100120

140

0

246

8

1011

8060

40

20

0

100120

140

0

246

8

1011


*NOTE: For linear graphs displaying deviation from straight line (0.4” to 20”)see technical manual #374.

17


Nonincendive:Class I, Groups A-D Class II & IIIGroups F-G, Div. 2




AGENCY APPROVALS


ICoTTM 5400

Foundation Fieldbus® Enabled Intelligent Positioner

Foundation Fieldbus® EnabledIntelligent Positioner with Online Diagnostics

AINOUT

PID

BKCAL_INOUT

IN

AOUT

BKCAL_OUT

CAS_INLevelTransmitter

Valve

Foundation Fieldbus communica-tions protocol is an industry proveninternational standard (IEC 61158)designed for use in the processindustry. Features include multi-drop capabilities (as many as 32devices per segment), extendedtrunk length, single loop integrity,“control in the field”, power andcommunications on a shieldedtwisted pair network, and compati-bility with intrinsically safe net-works. A key feature of the FF pro-tocol is the ability to select wherecontrol of the process is situated -in the host, in the field, or in vari-ous combinations of both locations.

LC

TC

TT

FRESH BFEED

STEEM

FoundationFieldbus

Intelligent CalibrationFoundation Fieldbus® ProtocolThe ICoTTM 5400 provides intelli-gence for the control valve througha microprocessor-based systemutilizing the Foundation Fieldbusprotocol. Accurate measurementof valve stem position, input sig-nal, actuator pressure, cycle timeand cycle count data can be record-ed during normal operation, therebyproviding information for controlvalve signature generation.

The positioner has a local LCD dis-play which indicates valve position,set-point in percentage open, cali-bration status, alarms status andwhether the SmartCal is in local orfieldbus control. The SmartCal hasthe capability to self monitor opera-tion. If a failure condition occurs, anerror message is displayed on thelocal LCD display and communicatedto the Host system via fieldbus.

ATEX Approval for Intrinsically Safe

applications

Calibration via the FF bus,local keypad or using the

Rosemount 375 FieldCommunicator

Online DiagnosticsEnd Limit Position Sensing

Auto Cal, PID ControlAutotuing, Data Trending

Remote Position Control

Local LCD DisplayLocal Position Display

Local Diagnostics

18



Intelligent ControlThe FF ICoT provides accuratemeasurements of valve stem position, input signal, actuatorpressure and travel time. With theICoT’s internal trending capability,information for control valve signa-ture generation is developed foruse in predictive maintenance.

ICoT 5400


Fieldbus Foundation Conformance DocumentationManufacturer Westlock Controls

Model ICoT Valve Controller 5400-IS

Category Final Control Element

Type IS Pneumatic Positioner

Tested Function Blocks 1xAI(S), 1xAO(s), 1xPID(s)

Other Blocks 2xTB(c)

H1 Profile Class 31PS

H1 Device Class Basic

Test Camp. Number IT019200

MANUFAC_ID 0x574343

DEV_TYPE 0x1100

DEV_REV 0x01

ITK Version 4.51

Fieldbus FoundationConformanceDocumentationThe Westlock 5400 IS FF ICoT is aFieldbus Foundation registereddevice having successfully complet-ed the required conformance teststo ITK revision 4.51.

Handheld ProgrammersThe Rosemount Model 375 communicates with the FF ICoTSmart Positioners via the FF protocol.

FF ICoT DD and CFFAvailabilityThe CFF and DD are downloadablefrom the Foundation’s website atwww.fieldbus.org or at www.west-lockcontrols.com. They are alsoavailable on CD, please contact thefactory for a copy.

ICoTPOSITIONER

LINKING DEVICE

EngineeringStation

POWERSUPPLY

ICoTPOSITIONER

ICoTPOSITIONER

I.S.BARRIER

19




ICoTTM 5400

Foundation Fieldbus® Enabled Intelligent Positioner

Diagnostic andConfiguration Software

The ICoTTM possesses the capabilityto predict rather than react tovalve maintenance needs. Withthe ICoTTM positioner, operatingpersonnel gain a real-time per-spective on the state of control at the valve, including a view ofoperating integrity and emergingalert conditions. Timely informa-tion about each control valvescondition is quickly made availableto the plant’s production andmaintenance engineers.

THE PRINCIPLE ADVANTAGEOF ONLINE DIAGNOSTICS ISTHE ABILITY TO DETECT DEVI-ATIONS FROM ESTABLISHEDPATTERNS OF BEHAVIOR ASTHEY OCCUR UNDER ACTUALOPERATING CONDITIONS.Control valves are the most mainte-nance intensive components commonlyused in instrumentation and controlsystems. By inclusion of internal parameter sensing within the valvepositioner, forewarning of the need formaintenance is made available with acomfortable degree of lead time.

The ICoTTM positioner’s diagnostic com-patibility is based upon observations ofthe following operating parameters:

" Valve position vs. input signal." Actuator pressure vs. valve position." Airset filter outlet pressure." Confirmation of principal operating

pressures within positioner." Pressure generation within packing

gland area.

Online Diagnostics " “Stick-slip” detection." Excessive static position error." Fugitive emissions monitoring." Low air supply pressure." Clogged air supply filter." Restricted transducer nozzle." Transducer diaphragm air leak." Non-functioning spool valve." Calibration error.

SP-50% PV-49.9%F-CTRL ERROR 6D

20




21



MODEL 5400 SPECIFICATIONSSignal Two wire FOUNDATION Fieldbus, polarity insensitiveVoltage 9 – 35 VdcPressure: Low: 15 - 45 psi

High: 40 - 120 psiPosition Feedback Magnetic (Non-Contact)Flow Rate Low: 8.0 scfm @ 25 psi

High: 16.2 scfm @ 90 psi Actuator Single Acting or Double ActingStroke Linear: 0.25 to 24 inches

Rotary: 0 to 95 Degrees Resolution 2% Full TravelLinearity Rotary 0.5% Full Scale

Linear 1% Full Scale Hysteresis 0.2% Full ScaleRepeatability 0.2% Over One HourOperating Temp -40°C to 85°C (-40°F to 185°F)Thermal Coefficient 2% / 100°CAir Consumption Low: 0.003 scfm @ 25 psi

High: 0.008 scfm @ 90 psi Material Engineered ResinWeight 7.2 PoundsAir Connections 1/4" NPTConduit Connections Standard:1/2" NPT

Optional:M20



Class I, Groups A-D Class II & IIIGroups F-G, Div. 2




AGENCY APPROVALS


ICoTTM 5400









CONSTRUCTION

Engineered Resin

E

ORDERING GUIDE



FF & KeypadHF


FF & KeypadLF

High Flow(40-120 psi)

FF & KeypadVF

Nema 4, 4X



CONDUITENTRY

1/2” NPTA

M20B

POSITIONSENSOR

No Sensors0

POSITIONTRANSMITTER

WithoutTransmitter

A

4-20 mAB


54

STANDARD

REMOTE MOUNT

8060

40

20

0

100120

140

0

246

8

1011

8060

40

20

0

100120

140

0

246

8

1011




3.15(80.1)

3.42(86.8)

2.19(55.6)

OPEN

7.87(199.8)

1/2" NPT(M20 optional)

TOP VIEW

BOTTOM VIEW

SIDE VIEW

3/4" NPT(2 PLACES)

4.49(114)

2.30(58.4)

3.0(76.2)

1.375(34.9)

2.15(54.6)

4.30(109.2)

5/16-18 x 1/2"M8 x 1.25

(4 PLACES)

8060

4020

0

100

120

140

1600

24 6

8

1011

8060

4020

0

100

120

140

1600

24 6

8

1011

5.01(127.2)

SERIES 5000 - Engineered Resin Enclosure (Dim. inches/mm)

Enclosure: Nema 4, 4XTerminal Block: 8 Point Standard

Conduit Entrance: One 1/2” NPT Standard1-1/2” & 2-3/4” NPT,

OptionalM20 or PG13.5 Optional

53 3 0 NI E H B A 0 B N

52 Non-HART53 HART54 Foundation Fieldbus55 Profibus

1 Linear3 Rotary

Ordering Guide

Dimensional Data

Westlock reserves the right to change productdesigns and specifications without notice, andis not responsible for errors and omissions.

SERIES ACTUATORTYPE

MOUNTING HAZ.RATING

ENCLOSURE PRESSURE CALIB. / COMM.

CONDUITENTRY

OUTPUTOPTION

GAINSWITCHES

SERIES

IS Intrinsically SafeNI Non-Incendive

HAZARDOUS RATING

A NoneB 4-20 mA Analog

OUTPUT OPTTION

B Both Keypad & HARTF Both Keypad & FFK 3 Button On-Board KeypadP Both Keypad & Profibus

CALIBRATION/COMMUNICATION

ACTUATOR TYPE

E Engineered Resin

ENCLOSURE

A One1/2” NPT, Two 3/4” NPTB One M20, Two 3/4” NPT

CONDUIT ENTRY

B 1/4” BSP (3/8” for High Flow)

N 1/4” NPT (3/8” for High Flow)

GAIN

H Above 40 PSIL 40 PSI or lessV High Flow

PRESSURE

O None1 One SPST Magnum2 Two SPST Magnum

SWITCHES

0 Standard5 Remote

MOUNTING


WESTLOCK Westlock Controls Corp.280 Midland AvenueSaddle Brook, NJ 07663201-794-7650 Fax: 201-794-0913

EUROPEWestlock Controls LTD.22 Chapman Way Royal Tunbridge Wells, Kent TN23EF England011-44-189-251-9046 Fax: 011-44-189-251-6279

SOUTH AMERICAWestlock Equipmentos DeControles Ltda.Rua, Sao Paulo 291 - AlphavilleBanueri, Sao PauloSP 06464-130011-55-11-4191-0930 Fax: 011-55-11-4191-0931


Intellis Network Solutions

" Overview Network Systems

" Economic Advantages AS-interface, DeviceNet, Modbus,

" Intellis 7200 Profibus Network Systems

" Intellis 7300 Foundation Fieldbus Network Systems

" Intellis 7500 Modbus Network Systems

" Intellis 7600 DeviceNet Network Systems

" Intellis 7700 AS-interface Ver. 2.1 Network Systems

" Diaphragm Valves DeviceNet, As-interface, Foundation Fieldbus

NETWORKSYSTEMS FOR VALVE AUTOMATIONIN

TELLIS






WESTLOCKC O N T R O L S C O R P O R A T I O N

Network SolutionsN E T W O R K

S Y S T E M S

F O R V A L V E

A U T O M A T I O N

AS-interface

DeviceNet

Foundation Fieldbus

ModBus

ModBus Direct

Profibus

IntellisTM

NETWORK SYSTEMS




NETWORK SYSTEMS FOR VALVE AUTOMATION•

AS-interface®, DeviceNet®, Foundation Fieldbus®

ModBus®, ModBus Direct, Profibus®

WESTLOCKNetwork Systems Group

IntellisTM


Field Network

2

Network SolutionsFor Every Application

Network Systems for Valve AutomationIntellisTM is a family of industrial control field

Network Monitors which use embedded control

systems to automate valves and link field I/O to

the host PLC or DCS. Network Monitors are stan-

dard Westlock Control Monitors with the addition

of a network I/O module. Each Network Monitor

houses two discrete Hall Effect sensors for valve

position monitoring, a low power solenoid valve

for actuation control, and a network interface

module for communication via the AS-interface®

2.0/2.1, DeviceNet®, Foundation Fieldbus,

ModBus® or Profibus protocol. Monitors are

available for Linear, Rotary and Sanitary

Diaphragm applications in all area classifications.

By switching from a conventional hardwired I/O system to

an IntellisTM network, immediate cost savings are realized

through the elimination of hundreds of dedicated wires and

their associated costs.

IntellisTM

NETWORK SYSTEMS




PROGRAM PARTNERThe Network ModuleDepending upon the network protocol selected

(AS-interface®, DeviceNet®, Foundation Fieldbus®,

ModBus®, Profibus®), a dedicated network

module is integrated within the enclosure of

each Network Monitor.

TYPICAL NETWORK MODULE INPUT 1: Valve Position Sensor (open)

INPUT 2: Valve Position Sensor (closed)

INPUT 3: External Device


OUTPUT 1: Solenoid Valve (actuation control)

OUTPUT 2: Dual Coil or External

3

Field ConfirmationThe integrity of every

network is confirmed in

the field through the

utilization of a diagnostic

and programming tools.

Conformance TestingPrior to integration within the Westlock Network

Monitor, each network card is subjected to a rigid

functionality test and then undergoes a specified

period of component “burn-in”. After assurance of

network card integrity, a communications network,

identical to the network specified for a project, is

replicated in-house and conformance tested before

shipment to the field.

A fully operational communications network with

protocol specific network cards and PLC or Host

network interface gateways is assembled and then

required to satisfactorily operate around-the-clock.

A custom software program monitors commands

and response, recording any deviations or failure

within the system.

Network Protocols Supported"AS-interface

"DeviceNet

"Foundation Fieldbus

"ModBus

"ModBus Direct

"Profibus

Peripheral Interface Devices"Cables • Power Supplies

"Gateways • Repeaters

"Extenders

"Configuration Tools

"Software/Diagnostics

Application Support"Engineering Design

"Integration

"Start-up Support

"Training

"Turnkey Installations

SYSTEM SUPPORT




4

Twisted pair for communicationsand two wires for power

1600 ft. trunk + 512 ft. drop

63/network2 networks/system

378/network plus optional 4/20mAanalog I/O. 756/system

45 mA + 20-25 mA/coil

All PLC’s & DCS withDeviceNet Interface

Master/slave multimaster, peer-to-peer

CRC check

Zero drop, trunk drop, tree, star

125 kbps, 250 kbps, 500 kbps

No

Yes

Two wire cable(communications & power)

300 ft.900 ft. with repeater

62/network with 2.1 Master1 network/system

434/network434/system

20 mA + 20-25 mA/coil

All PLC’s & DCS w/ModBus,DeviceNet, ProfiBus Port

Master/slave with cyclic polling

Control sum, parity

Trunk & drop, zero drop

167 kbps

No

No

NetworkProtocolOverview

Physical Media

Maximum Distance

Maximum NetworkMonitors per System

Maximum I/O Points per System

Current ConsumptionPer Network Monitor

Interface Capability

Communications Method

Error Checking

Network Topology

Transmission Speed

Redundancy

Valves Specific Diagnostics

The acceptability of standard network protocols such as ModBus®, DeviceNet® and AS-interface® has made it possible to

effectively integrate process control components into a network. ModBus, DeviceNet, AS-interface, Profibus and

Foundation Fieldbus have emerged as de facto standards for interfacing discrete devices. They have proven themselves to

be extremely reliable, simple to understand and consistently cost effective. The integration of these five major network

standards with various manufacturers of PLC’s and DCS systems is readily accomplished through the implementation of

off-the shelf gateway interfaces.

AS-interface®

Ver. 2.1The AS-Interface® protocolwas developed by a consor-tium of major European companies. Designed specif-ically for use in low levelautomated systems, AS-i can communicate via a gate-way to most higher level bussystems such as DeviceNet,Modbus and Profibus.

DeviceNet®

Allen-Bradley is the origina-tor of the DeviceNet® proto-col. DeviceNet is an opendevice network standardbased upon proven ControllerArea Network (CAN) technology.

Standard Network Protocols

AS-interface® • DeviceNet® • Foundation Fieldbus® • ModBus® • Profibus®




Two wire cable (communications and power)

1900m, including spurs

6/segment if bus powered & IS 12/segment if bus powered & non-IS32/seg. if neither bus powered nor IS

192 / system

18-24 mA IS & 32 mA w/ ULP coil

All PLC’s & DCS supporting the FF protocol

Peer to peer

Manchester encoding

Daisy Chain, trunk/drop (spurs), branching drop (spurs), point to point

31.25 kbps

Yes

Yes

FoundationFieldbus®

The initial specification forFoundation Fieldbus, drafted in 1987, was a joint effortof the IEC and the ISA tocreate an international fieldbus standard.


Physical Media

Maximum Distance






Error Checking

Network Topology

Transmission Speed

Redundancy


Twisted pair for communica-tions, two wires for power

3000 ft.



27 mA + 20-25 mA/coil

All PLC’s & DCS w/ModBus Port

Master/slave withcyclic polling

CRC check

Closed loop bus

9.6 kbps

Yes

Yes

ModBus®

The ModBus® protocol hasbeen placed in the publicdomain, operates over a serial interface and is supported by almost everyPLC, DCS, and operatorinterface (OI) company.

5

Twisted pair for communications, two wires for power.

1200m, trunk

32/segment.126/system using repeaters

1125 / system

120 mA

All PLC’s & DCS supporting theProfibus protocol

Peer to peer and cyclic Master/slave

CRC check

Linear, prefered, drops allowed @ Baud rates below 500 kbd

9.6, 19.2, 93.75, 187.5, 500, 1500, 12000 kbps

No

Yes

Profibus®

Started as a joint Fieldbusproject in 1987 between several companies (Siemens,Klockner-Moeller, Bosch and10 other manufacturers).The Profibus UserOrganization (PNO) wasfounded in 1989 and has amembership of over 1000companies.





Twisted pair for communicationstwo wires for power

3000 ft.

32/network. 1/system

256/network plus optional 4/20mAanalog I/O. 256/system

27 mA + 20-25 mA/coil

All PLC’s & DCS w/ModBus, Port

Master/slave with cyclic polling

CRC check

Zero drop

9.6kps, 19.2kps

No

Yes

ModBus DirectModBus Direct devices can be connected to any PLCor DCS with a ModBus port.




Field NetworkA field communications network iscomprised of a specific number ofNetwork Monitors interconnected by a common communications protocol. Network Monitors may be placed on the field network inany physical order. Each Monitor is assigned a unique address andaccepts input/output signals fromvalve position sensors, solenoids,and external devices.Communications with a PLC, DCSor host computer is accomplishedby a gateway interface or scannercard having specific compatibilitywith the primary control network.

IntellisTM System Overview

AS-interface® • DeviceNet® • Foundation Fieldbus® • ModBus® • Profibus®

External DeviceNetwork MonitorNetwork Monitors are available forcontrol or monitoring of non-valverelated devices (sensors, alarms, actuators, indicating lights, etc.) Integrated network modules, have as standard, protective diodes andoptical isolation and are housed in a General Purpose, Division 2Nonincendive or Explosionproofenclosures with a 16 point terminalblock for simplification of wiring.Depending on the protocol eachstand-alone Network Monitor iscapable of accepting up to six external devices.

Automated Valve Network MonitorThe Network Monitor for automated valves couples directly onto the pneumaticor electric actuator and communicates overa field network via an integrated networkmodule. Each unit has the capability toaccept input/output signals from positionsensors and solenoid valves while simulta-neously performing on-line diagnostics. Inaddition, each Network Monitor is provid-ed with the ability to accept a compre-hensive range of external field devices forcontrol or alarm purposes.

LOW LEVELALARM

TEMPERATURESENSOR

EXTERNAL DEVICENETWORK MONITOR

AUTOMATED VALVENETWORK MONITOR

FIELD NETWORK

PLC

GATEWAYINTERFACE

HIGHLEVELALARM

A major reduction in equip-ment and wiring costs.

Reduction in design/engineering manhours.

The ability to provide on-linepredictive and maintenancediagnostics.

1

2

3

6


Valve ManagementSoftwareAn on-line software program creates the foundation for a PlantWide Valve Management Systemthat takes full responsibility for monitoring and diagnosing valve performance from start-up to predictive/preventive maintenancescheduling. Individual displays provide a detailed level of informa-tion that includes alarm occurrences and graphical trending of valve travel times.

PRESSURE SENSOR



FIELD NETWORK

PROGRAM

ALARM OCCURRENCES

7






Web Site: www.westlockcontrols.com

ORDERING GUIDE (FALCONTM SOLENOID)ORDERING GUIDE (BEACON)

CV Body 3-Way

Brass 21

Alum. 31

303 S.S. 41

316 S.S. 51

Brass 22

Alum. 32

303 SS 42

316 S.S. 52

Brass 23

Alum. 33

303 S.S. 43

316 S.S. 53

Alum. 34

4-Way

25

35

45

55

26

36

46

56

27

37

47

57

38

COILS

FSO24 VDC

0.5 watts

NEMA 4, 4x,Nonincendive


Class II, Grps. F, G, Div. 2

XSO24 VDC

0.5 watts

NEMA 4, 4x, 7, 9Class I,

Groups C, DClass II,

Groups E, F, GDiv. 1 & 2

.3 Cv

.5 Cv

1.2 Cv

3.5 CvNOTE: For dual coil applications, please consult factory.


Beacon 3-Way Beacon

B1

STANDARD(Black & Yellow) BY

ANSI GREEN(Liquid-Low Hazard) AG

ANSI BLUE(Gas-Low Hazard) AB

ANSI RED(Fire Quenching) AR

B3

B5

B7

B9

90°Rotation

90°Rotation

90°Rotation

180°Rotation

180°Rotation

No-Voltage Release (Latching) NNo-Voltage Release (Non-Latching) RFalcon Manual Maintained Override LFalcon Momentary Override MExternal Pilot ELockout K

SOLENOID (MANUAL OVERRIDE OPTIONS)

7344N-BY-N -1-21-00Ordering Example

O R D E R I N G G U I D E

21thru 68Use below listing

for ordering solenoid

These options arebased from the

Valve Body optionsfrom the price booktotaling 55 options.

All Dual Coil optionscan be used withenclosure option45 and 75

BY

AG

AB

AR

B1

B3

B5

B7

B9

Use chartbelow

No Option0

N

R

L

M

E

K

Use chartbelow

StandardShaftS

Namur ShaftN

1/2” NPT1

M202

PINConnector

6

Gland Fitting7

No Option0

AluminumJunction

1

Resin Junction

2

Class 1, Division 2Groups A thru G (Nonincendive)

N

Class 1, Division 1, Groups C & D

(Explosionproof)X

Class 1, Division 2, Groups A, B, C, D

Class II, Groups E, F, GDivisions 1 & 2(When operated

through approved I.S.barriers)

I

Area ClassOption

BeaconOption

NetworkProtocol

EnclosureOption

Shaft OutputOption

On/OffJunctionOptions

Solenoid ConduitOption

SolenoidOverrideOptions

ORDERING GUIDE Intellis Networks

Prefix D (Discrete Junction Box) indicates no shaft and Beacon.For Sanitary Diaphragm valves, see bulletin number 720For Stainless Steel and Bronze Enclosure options, please consult factory.

N4 AluminumSingle Coil

04

LZ1 Engineered ResinSingle Coil

44

LZ2 Engineered ResinDual Coil

45

Quantum Aluminum Single Coil

79

Quantum Aluminum Dual Coil

75

Lonworks71

ProfiBus72

Foundation Fieldbus73*

ModBus Direct74

ModBus75

DeviceNet76

AS-interface77


*COILS - 7300 PRODUCTS ONLY

BKO7.2 VDC

0.014 watts

NEMA 4, 4x, NonincendiveClass I, Groups A, B, C, DClass II, Grps. F, G, Div. 2


The Economic Advantages of Field Networks*

Labor Costs

The utilization of an industrial communications field networkwill greatly contribute to theoverall reduction of labor costsas compared to a conventional hardwired schemewhere individual wires must be pulled through a protective conduit that is hundreds of feet long.

Hardwired 180 valve system $223,905Networked 180 valve system $102,129

Engineering/Design CostsAutomated valves and process sensors are simply connected tothe network at the points along the path where they are located. A total engineering/design savings of over 5 hours per valve can be realized.


*A detailed cost analysis using an example DeviveNet network system can be found on

the following pages.

Cost Overview 2-3A•B DeviceNet 4-7

Maintenance CostsField networks create the foundation for a plant wide valvemanagement system that takesfull responsibility for monitoringand diagnosing valve performance from start-up to predictive/preventive maintenance scheduling.

PROGRAM

OPERATE

SLEW GRAPH

5 Sec Timeout

Cycle Time 5.4 Sec

Break 2.2 Travel 3.2

I/O Failure

Bus / Power Break

Temperature

Supply Pressure

Fugitive Emissions

User Definable

Tag# 022Point# 009LocationService

C O

TOTAL CYCLES 320

NETWORK 1, GROUP 1

CYCLE TIME (SEC)

20 60 100 140 180 220 260 300 340 380

NUMBER OF OPERATIONS

02468

101214

8642

16141210

16

OP

EN

CLO

SE

CURRENT CYCLES

TIMEOUTPACKINGTIMEOUTTIMEOUTPACKING

10-08-9501-06-9403-27-9311-06-9207-30-92

TYPE DATE TIME

10:16 am12:19 pm06:05 pm04:37 am11:55 pm

ALARM OCCURRENCES$$Material CostsThe amount of conduit, fittings, wire, and junction housings is greatly reduced. When compared with conventional systems, field networks eliminate a substantial amount of field wiring and the labor necessory to install it.






Remote I/O Cabinet PLC

System Comparisons

Labor & Material Cost $452,309 $838 Per I/O Point

Engineering/Design Cost $116,460 $216 Per I/O Point

TOTAL COST $568,769 $1,054 Per I/O Pt

HARDWIRED SYSTEM COST(180 Valve System)

A detailed cost analysis for each field network can be found on the following pages: AS-interface 4-7 • DeviceNet 8-11 • ModBus 12-15

Conventional wiring systems generally require that individual control wires run from the I/O cabinet to the position sensors and solenoid of each automated valve. For systemsconsisting of a multitude of pneumatically actuated on-off valves, hundreds of wires mustbe run and properly connected — not only to each position sensor and solenoid valve, but also back to the proper point of connection at the I/O cabinet.

Typical Hardwired System

Valve Position Monitor w/ 2 Position Sensorsand Solenoid Valve

TemperatureSensor

PressureSensor

DedicatedHardwiring

DedicatedHardwiring

LevelSensors

2




PLC

FieldNetwork

Labor & Material Cost $284,484 $526 Per I/O Point

Engineering/Design Cost $51,120 $94 Per I/O Point

TOTAL COST $335,604 $620 Per I/O Pt

IntellisSYSTEM COST(180 Valve System)

A detailed cost analysis for each field network can be found on the following pages: AS-interface 4-7 • DeviceNet 8-11 • ModBus 12-15

By integrating a network module within the Westlock Network Monitor, pneumatically actuated on-off valves and external devices are simply connected to the field network at the points along the path where they are located. The need for remote I/O cabinets and thousands of feet of dedicated control wiring from each automated valve and external sensor is eliminated.

IntellisTM Network System

Network Monitor w/ 2 position sensors,solenoid valve and network module

TemperatureSensor

PressureSensor

LevelSensors

Network Monitor w/network module for external devices

FieldNetwork

3




CONTROL ROOM

MARSHALLINGCABINET

DCS I/OCABINET

(1) -37/C #1450' LENGTH(TYPICAL FOR 5)

1" CONDUIT, 36 #14200' LENGTH TOFIRST CONDUIT TEE(TYPICAL FOR 5)

3/4" CONDUIT, 6 #14(TYPICAL) FOR CONNECTIONS TO ALL VALVES SHOWN)

1" CONDUIT, 30 #14

1" CONDUIT, 24 #14

1" CONDUIT, 18 #14

1" CONDUIT, 12 #14

1" CONDUIT, 6 #14

20' LENGTHBETWEEN CONDUIT TEES(TYPICAL)

20' LENGTHFROM CONDUITTEE TO VALVE(TYPICAL)

AS-interface® Ver. 2.1

Cost Analysis

This sketch is typical for 4 field networks.(30 valves per network,120 valves per system)

NOTES:

1. All valves shown arepneumatic actuatedon/off type, with 3-waysolenoid and open/closeposition sensors.

2. All conduit is aboveground, ridgid galvanizedsteel.

3. All #14 wiring is type THHN insulation

CONVENTIONAL SYSTEM (DCS with Central I/O)

3/4” Conduit 3600 feet 0.1 360.0 50 18,000 0.95 3,420 $21,420

1” Conduit 4800 feet 0.1 480.0 50 24,000 1.39 6,672 $30,672

Conduit Fittings & Supports allowance lot – 672.0 50 33,600 – 14,600 $48,200

#14 Wire 194400 feet 0.006 1,166.4 50 58,320 0.06 11,664 $69,984

37/C #14 Multiconductor Cable 1000 feet 0.04 40.0 50 2,000 1.25 1,250 $3,250

RS-232 Cabling 0 feet 0.008 – 50 – 0.75 – –

Terminations 2920 each 0.08 233.6 50 11,680 0.05 146 $11,826

Valve Solenoid & Position Sensors 120 each 0 – 50 – 450 54,000 $54,000

Profibus Gateway & Power Supply 0 each 0 – 50 – 0 – –

Marshalling Cabinet 360 each 0.075 27.0 50 1,350 80 28,800 $30,150

Input/Output Hardware 360 per I/O point 0 – 50 – 100 36,000 $36,000

TOTALS 2,979.0 $148,950 $156,552 $305,502

MATERIAL DESCRIPTION TAKEOFF QUANTITY INSTALLATION LABOR MATERIAL

PER TOTAL MH LABOR COST/ MATERIAL TOTALAMOUNT UNIT UNIT HOURS RATE COST UNIT COST L&M COST

CONVENTIONAL SYSTEM DCS with Central I/O

4Westlock reserves the right to change product designs and specifications

without notice, and is not responsible for errors and omissions.




PLCPROFIBUS-READY

DCSSYSTEMCABINET

P.S.

ASI

1

2

3

REPEATER(TYP)

28

29

30

P.S.

P.S.

ASI

1

2

3

28

29

30

P.S.

ASI

1

2

3

28

29

30

P.S.

ASI

GATEWAYPROFIBUS/ASI

(TYP)

PROFIBUS

1

2

3

28

29

30

24 VDCSUPPLY(TYP)



3/4" CONDUIT1/2/C, TW SHL50' LENGTH

3/4" CONDUIT2-2/C, TW SHL100' LENGTH


NOTES:


2. All conduit is aboveground, ridgid galva-nized steel.

Intellis System (DCS with AS-interface Network Monitors)

3/4” Conduit 5400 feet 0.1 540.0 50 27,000 0.95 5,130 $32,1301” Conduit 0 feet 0.1 – 50 – 1.39 – –Conduit Fittings & Supports allowance lot 432.8 50 21,600 4,104 $25,704#14 Wire 0 feet 0.006 – 50 – 0.06 – –37/C #14 Multiconductor Cable 0 feet 0.04 – 50 – 1.25 – –#16 Twisted Pair, Shielded 5400 feet 0.007 37.8 50 1,890 0.15 810 $2,700Profibus Drop Cable 400 feet 0.007 2.8 50 140 0.7 280 $420Profibus Trunk Cable 400 feet 0.007 2.8 50 140 1.2 480 $620RS-232 Cabling 0 feet 0.008 – 50 – 0.75 – –Terminations 720 each 0.08 57.6 50 2,880 0.05 36 $2,916Network Monitors 120 each 0 – 50 – 726 87.120 $87,120Profibus Gateway & Power Supply 4 each 0 – – 1,800 7,200 $7,200Repeater 4 each 1,600 6,400 $6,400Marshalling Cabinet 0 each 0.075 – 50 – 80 – –Input/Output Hardware 0 per I/O point 0 – 50 – 100 – –TOTALS 1,073.0 $53,650 $111,560 $165,210



IntellisAS-interface Ver. 2.1SYSTEMDCS with Network Monitors

5


Cost Analysis





ENGINEERING/DESIGN ACTIVITY CONVENTIONAL INTELLISTM

ON/OFF VALVE Network Monitors

P & ID Development/Production 0.1 hrs 0.1 hrs

Instrument Index Development/Production 0.5 hrs 0.5 hrs

I/O Address Assignments 0.3 hrs 0.1 hrs

I/O List Development/Production 1.5 hrs 0.5 hrs

Instrument Loop Diagram Design/Documentation 4 hrs 2 hrs

Marshalling Panel Design/Documentation 0.3 hrs 0 hrs

Field Terminal Box Design/Documentation 0.3 hrs 0.1 hrs

Electrical Cabling and Termination Lists. 2.25 hrs 0.75 hrs

Total Hours 9.25 4.05Cost per Valve $70/hr engineering billing rate $647.00 $284.00

Savings per Valve = $363.00

Savings per I/O Point (3 I/O per valve) = $121.00

Total Engineering & Design Savings for 120 on/off valves = $43,560

Total Schedule Savings = 624 Manhours


Cost Analysis

ENGINEERING/DESIGN COSTSConventional System vs Intellis with AS-interface

The following tabulations are on a pervalve basis for engineering and designactivities normally associated withON/OFF valves on a process industrycapital project.

A total engineering/design savings ofover 5 hours per valve can be realized.On a project with 120 ON/OFF valvesand an engineering billing rate of$70/hr, savings would exceed $43,560. A schedule savings of 624 man-hourswould also be achieved.

6




Conventional System

Labor & Material Cost $305,502

Cost per I/O Point $848

Engineering/Design Cost $77,640


TOTAL COST $383,142 $1,064/I/O pt

Intellis System





TOTAL COST $199,290 $553/I/O pt

Intellis System Total Savings = $183,852Savings per Valve = $1,532

$$COMPARATIVE COST ANALYSISSUMMARYConventional I/O System vs IntellisTM with AS-interface

The following is an abreviated costsummary of the Distributed ControlSystem wiring scheme outlined in theprevious pages. The example utilizesa total of 120 pneumatically actuatedon/off valves with 3-way solenoid andopen/close position sensors. Theentire system calls for a total of 360I/O points (3 per valve).


Cost Analysis





CONTROL ROOM

MARSHALLINGCABINET

DCS I/OCABINET




1" CONDUIT, 30 #14

1" CONDUIT, 24 #14

1" CONDUIT, 18 #14

1" CONDUIT, 12 #14

1" CONDUIT, 6 #14




3/4” Conduit 3600 feet 0.1 360.0 50 18,000 0.95 3,420 $21,420

1” Conduit 4800 feet 0.1 480.0 50 24,000 1.39 6,672 $30,672

Conduit Fittings & Supports allowance lot 672.0 50 33,600 14,600 $48,200

#14 Wire 194400 feet 0.006 1,166.4 50 58,320 0.06 11,664 $69,984

37/C #14 Multiconductor Cable 1000 feet 0.04 40.0 50 2,000 1.25 1,250 $3,250

RS-232 Cabling 0 feet 0.008 – 50 – 0.75

Terminations 2920 each 0.08 233.6 50 11,680 0.05 146 $11,826

Valve Solenoid & Position Sensors 120 each 0 – 50 – 450 54,000 $54,000

PLC with DeviceNet Scanner 0 each 0 – 50 – 0 –

Marshalling Cabinet 360 each 0.075 27.0 50 1,350 80 28,800 $30,150

Input/Output Hardware 360 per I/O point 0 – 50 – 100 36,000 $36,000

TOTALS 2,979.0 $148,950 $156,552 $305,502



DeviceNet®

Cost Analysis


NOTES:





8





CONTROL ROOM

DCSSYSTEMCABINET

60

1

2

1

2

60

(1) RS-232 CABLE50' LENGTH

3/4" CONDUIT, (2) - 2/C SHLDTRUNK CABLE, BELDEN 3082A200' LENGTH

3/4" CONDUIT, (1) - 2/C #16 SHLDAND 2 #14(TYPICAL FOR RUNS BETWEENCONDUIT TEESSHOWN)

3/4" CONDUIT, (2) - 2/C SHLDDROP CABLEBELDEN #3084A(TYPICAL) FOR CONNECTIONS TO ALL VALVES SHOWN)



3/4" CONDUIT(1) - 2/C #16 SHLDAND 2 #14200' LENGTH

PLC WITH DEVICENET SCANNER

24 VDCPOWERSUPPLY


NOTES:


2. All conduit is aboveground, ridgid galva-nized steel.


Intellis System (DCS with DeviceNet Network Monitors)

3/4” Conduit 5160 feet 0.1 516.00 50 25,800 0.95 4,902 $30,7021” Conduit 0 feet 0.1 – 50 – 1.39 – –Conduit Fittings & Supports allowance lot – 412.8 50 20,640 – 8,770 $29,410#14 Wire 0 feet 0.006 – 50 – 0.06 – –37/C #14 Multiconductor Cable 0 feet 0.04 – 50 – 1.25 – –DeviceNet Trunk Cable 2760 feet 0.007 19.3 50 966 1.2 3,312 $4,278DeviceNet Drop Cable 2400 feet 0.007 16.8 50 840 0.7 1,680 $2,520RS-232 Cabling 60 feet 0.008 0.5 50 24 0.75 45 $69Terminations 1440 each 0.08 115.2 50 5,760 0.05 72 $5,832Field Terminal Box 0 per t. block 0.08 – 50 – 0 – –Network Monitors 120 each 0 – 50 – 846 101,520 $101,520PLC with DeviceNet Scanner 1 each – – – – 10,000 $10,000Marshalling Cabinet 0 each 0.075 – 50 – 80 – –Input/Output Hardware 0 per I/O point 0 – 50 – 100 – –TOTALS 1,080.6 $54,030 $130,301 $184,331



IntellisDEVICENET SYSTEMDCS with Network Monitors

9



DeviceNet®

Cost Analysis



ENGINEERING/DESIGN ACTIVITY CONVENTIONAL INTELLISON/OFF VALVE Network Monitors














DeviceNet®

Cost Analysis

ENGINEERING/DESIGN COSTSConventional System vs IntellisTM with DeviceNet


A total engineering/design savings ofover 5 hours per valve can be realized.On a project with 120 ON/OFF valvesand an engineering billing rate of$70/hr, savings would exceed $43,560. A schedule savings of 624 man-hourswould also be achieved.

10




Conventional System





TOTAL COST $383,142 $1,064/I/O pt

Intellis system







COMPARATIVE COST ANALYSISSUMMARYConventional I/O System vs IntellisTM with DeviceNet

The following is an abreviated costsummary of the Distributed ControlSystem wiring scheme example out-lined on the previous pages. Theexample utilizes a total of 120 pneumatically actuated on/off valveswith 3-way solenoid and open/closeposition sensors. The entire systemcalls for a total of 360 I/O points (3 per valve).

$$



DeviceNet®

Cost Analysis



CONTROL ROOM

MARSHALLINGCABINET

DCS I/OCABINET




1" CONDUIT, 30 #14

1" CONDUIT, 24 #14

1" CONDUIT, 18 #14

1" CONDUIT, 12 #14

1" CONDUIT, 6 #14



ModBus®

Cost Analysis


NOTES:






3/4” Conduit 5400 feet 0.1 540.0 50 27,000 0.95 5,130 $32,1301” Conduit 7200 feet 0.1 720.0 50 36,000 1.39 10,008 $46,008Conduit Fittings & Supports allowance lot – 960.0 50 48,000 14,600 $62,600#14 Wire 300000 feet 0.006 1,800.0 50 90.000 0.06 18,000 $108,00037/C #14 Multiconductor Cable 1800 feet 0.04 72.0 50 3,600 1.25 2,250 $5,850#16 Twisted Pair, Shielded 0 feet 0.007 – 50 – 0.15 – –RS-232 Cabling 0 feet 0.008 – 50 – 0.75 – –Terminations 4320 each 0.08 345.6 50 17,280 0.05 216 $17,496Valve Solenoid & Position Sensors 180 each 0 – 50 – 450 81,000 $81.000Intellis Network Interf. Mgr. & PC 0 each 0 – 50 – 7500 – –Marshalling Cabinet 540 each 0.075 40.5 50 2,025 80 43,200 $45,225Input/Output Hardware 540 per I/O point 0 – 50 – 100 54,000 $54.000TOTALS 4,478.1 $223,905 $228,404 $452,309



12Westlock reserves the right to change product designs and specifications

without notice, and is not responsible for errors and omissions.




CONTROL ROOM

INTELLIS NETWORK INTERFACE MANAGER

DCSSYSTEMCABINET

DESKTOPPC

24 VDCPOWERSUPPLY

(1) RS-232 CABLE50' LENGTH

3/4" CONDUIT, (1) - 2/C #16 SHLDAND 2 #14200' LENGTH

3/4" CONDUIT, (1) - 2/C #16 SHLDAND 2 #14(TYPICAL FOR RUNS BETWEENCONDUIT TEESSHOWN)

3/4" CONDUIT, (2) - 2/C #16 SHLDAND 4 #14(TYPICAL) FOR CONNECTIONS TO ALL VALVES SHOWN)



3/4" CONDUIT(1) - 2/C #16 SHLDAND 2 #14200' LENGTH

IntellisTM

MODBUS SYSTEMDCS with Network Monitors


NOTES:




Intellis System (DCS with Network Monitors)

3/4” Conduit 9200 feet 0.1 920.0 50 46,000 0.95 8,740 $54,7401” Conduit 0 feet 0.1 – 50 – 1.39 – –Conduit Fittings & Supports allowance lot – 736.0 50 36,800 8,770 $45,570#14 Wire 25400 feet 0.006 152.4 50 7,620 0.06 1,524 $9,14437/C #14 Multiconductor Cable 0 feet 0.04 – 50 – 1.25 – –#16 Twisted Pair, Shielded 12700 feet 0.007 88.9 50 4,445 0.15 1,905 $6,350RS-232 Cabling 60 feet 0.008 0.5 50 24 0.75 45 $69Terminations 1810 each 0.08 144.8 50 7,240 0.05 91 $7,331Network Monitors 180 each 0 – 50 – 846 152,280 $152,280Intellis Network Interf. Mgr. & PC 1 each 0 – 50 – 9000 9000 $9,000Marshalling Cabinet 0 each 0.075 – 50 – 80 – –Input/Output Hardware 0 per I/O point 0 – 50 – 100 – –TOTALS 2,042.6 $102,129 $182,355 $284,484



13

ModBus®

Cost Analysis





ENGINEERING/DESIGN ACTIVITY CONVENTIONAL INTELLISON/OFF VALVE Network Monitors














ModBus®

Cost Analysis

ENGINEERING/DESIGN COSTSConventional System vs IntellisTM with Modbus


A total engineering/design savingsof over 5 hours per valve can berealized. On a project with 180ON/OFF valves and an engineeringbilling rate of $70/hr, savings wouldexceed $65,340. A schedule savingsof 936 man-hours would also beachieved.




Conventional System





TOTAL COST $568,769 $1,054/I/O pt

Intellis System







COMPARATIVE COST ANALYSISSUMMARYConventional I/O System vs IntellisTM with ModBus

The following is an abreviated costsummary of the Distributed ControlSystem wiring scheme example outlined on the previous pages. Eachexample utilized a total of 180 pneu-matically actuated on/off valves with3-way solenoid and open/close posi-tion sensors. The entire systemcalled for a total of 540 I/O points (3 per valve).

$$

ModBus®

Cost Analysis





IntellisTM 7200

Profibus® Network SystemsProfibus®

Started as a joint fieldbus project in 1987 between several companies (Siemens,Klockner-Moeller, Bosch and 10 other manufacturers).TodayProfibus has an installed baseof over 4 million devices in over500,000 applications.

Network Monitors with Profibus® Interface Capability

IntellisTM

Profibus®

Overview

Twisted pair for communications,two wires for power

1200m

32 stations/segment126 stations/system using repeaters

1000 Discrete125 Analog

120 mA

All PLC’s & DCS supportingthe Profibus protocol

Peer to peer and cyclic master/slave

CRC

Linear prefered, drops allowed @ Baud rates below 500 kbd

9.6, 19.2, 93.75, 187.5, 500, 1500, 12000 kbps

No

Yes

Physical Media

Maximum Distance


Maximum I/O Pointsper System



CommunicationsMethod

Error Checking

Network Topology

Transmission Speed

Redundancy

Valve SpecificDiagnosticsWESTLOCK

Network Systems Group

HOST

Profibus

1

2

125

Power Supply





HOST

Profibus

1

2

125

Power Supply

Field NetworkA Profibus field network consists of agroup of Network Monitors interconnectedby a common communications protocol(Profibus). The Profibus is a master-slave system.

Network MonitorEach Network Monitor has an integrat-ed I/O module onboard that is assignedan address from 1 to 126. The addressnumber identifies one Network Monitorfrom all the other monitors in the system

Network InterfaceThe Network Monitors interface withthe host via a bus master. Data gath-ered by the master from the Profibusfield network is communicated to thehost processors via discrete and/orblock transfers.

Number of I/O points on a single system.Because each network may connect up to 125 Network Monitors, the total number of programmable I/O pointscomes to 1125 (750 discrete inputs/125 analog inputs/250 discrete outputs).

Profibus®

How The System Operates

2




Field Network

Field Network

3

An External Device Network Monitor is available for control or monitoring of non-valve related devices (sensors, alarms, actuators, indicating lights, etc.).

Depending upon the process layout, a wide range ofoptions exist. Standard units are supplied with protectivediodes and optical isolation features. External DeviceNetwork Monitors are available in 6 discrete input/1 analog input/2 discrete output configurations.Power requirements for each external device are consid-ered within the design parameters of the overall system.

NETWORK MONITORSA Profibus Network System is established by integrating an OnBoard I/O module directly within the Westlock NetworkMonitor. Each I/O module has the capability to accept input/output signals from automated valves, position sensors, solenoidvalves, emissions monitors and external devices (level alarms, temperature and pressure sensors, flow switches, etc.)

The Automated Valve Network Monitor couples directly tothe pneumatic actuator. It houses three functional compo-nents; position sensors, low-power solenoid valve, and anOnBoard I/O module. The OnBoard I/O module is capable of accepting six discrete inputs, 1 analog input and two output devices.

ONBOARD I/O CARD

INPUT 1: Valve Position Sensor (open)






INPUT 7: Analog position sensor


OUTPUT 2: Dual Coil application or External Device

Automated Valve Network Monitor

External DeviceNetwork Monitor




Profibus®

Profibus specifies two types of masters,DP Master Class 1 (DPM1) and DPMaster Class 2 (DPM2). DP permitsmono or multi master systems.Multimaster systems may consist of multiple DPM1 masters and/or multipleDPM2 masters.

A DPM1 master is the central controller,which interfaces with a PLC, PC or DCSand cyclically exchanges information withthe distributed slaves.

DPM2 masters are devices used forcommissioning, maintenance and diag-nostics, such as engineering and configu-ration tools.

The following lists Profibus-DP compatible PLC’s and controllers:

• A-B PLC-5 with 1785-PFB interface module

• Bosch PLC with DESI-DP interface module

• GE-Fanuc series 90-70 with Profibus-DP interface module

• Mitsubishi MELSEC-A Family

• Modicon Quantum

• Siemens S7/300 and S7/400

• Siemens S5 with IM318 interface module

• SST for A-B’s PLC-5 with SST-PFB-PLC5

• SST for A-B’s SLC-500 with SST-PFB-SLC

• SST for GE’s 90-70 with SST-PFB-GE

• SST for Reliance AutoMax with SST-PFB-REL

• SST provides the following interface cards - ISA, PC/104, PCI, PCMCIA, STD 32 and VME









IntellisTM 7300

Foundation Fieldbus® Network Systems


Foundation Fieldbus communi-cations protocol is an industryproven international standard(IEC 61158) designed for usein the process industry.Features include multi-dropcapabilities (as many as 32devices per segment), extend-ed trunk length, single loopintegrity, “control in the field”,power and communications ona shielded twisted pair net-work, and compatibility withintrinsically safe networks.

Network Monitors with Foundation Fieldbus®


IntellisTM


Overview

Twisted pair for communications, and power


6/segment if bus powered & IS32/segment bus powered & non-IS

192 discrete

18-24mA max. with Piezo operator32mA max. with ULP coil


Peer to peer

Manchester encoding

Daisy Chain, trunk/drop (spurs), branching drop (spurs), point to point

31.25 kbps

Yes

Yes

Physical Media

Maximum Distance






Error Checking

Network Topology

Transmission Speed

Redundancy

Valve SpecificDiagnostics


Host

Input/Output Boards

Point to Point

FOUNDATION





Foundation Fieldbus®

How The System Operates

2

Host Input/OutputBoards

Branching Trunkor Tree

Daisy Chain

Point to Point Bus with Spurs(or drops)

Junction Box

Field NetworkA field network consists of a group ofNetwork Monitors interconnected with a common communications protocol.With the Foundation Fieldbus IntellisTM

System, I/O service and diagnostics arecommunicated over a local area fieldnetwork.

Network MonitorEach Network Monitor is assigned aunique address by the configurator. This number identifies one NetworkMonitor from all the other NetworkMonitors in the system.

Number of I/O points on a single network.Because each segment may connect up to 32 Network Monitors, the totalnumber of programmable discrete I/Opoints would be 192 per segment.

Number of I/O points on a single system.Since each host can accommodatemultiple segments I/O counts adequate for any process can beobtained.




3


Depending upon the process layout, a wide range ofoptions exist. Standard units are supplied with protectivediodes and optical isolation features. External DeviceNetwork Monitors are available in 4 input/2 output configuration. Power requirements for each externaldevice are considered within the design parameters of the overall system.

NETWORK MONITORSA Foundation Fieldbus® Network System is established by integrating an OnBoard I/O module directly within the Westlock NetworkMonitor. Each I/O card has the capability to accept input/output signals from automated valves, position sensors, solenoid valves,emissions monitors and external devices (level alarms, temperature and pressure sensors, flow switches, etc.)

The Automated Valve Network Monitor couples directly tothe pneumatic actuator. It houses three functional compo-nents; position sensors, low-power solenoid valve, and anOnBoard I/O module. The OnBoard I/O module is capable ofaccepting four input and two output devices.

ONBOARD I/O CARD






OUTPUT 2: Dual Coil Application or External Device



Field Network

Field Network





The Fieldbus Foundation defined applica-tion layer is based on Function Blocks.Function Blocks are structures withdefined behavior used to represent differ-ent types of functions that the deviceperforms. The parameter of these blocksfollow a standard framework, but manu-facturers are free to enhance the stan-dard features and add additional func-tions as necessary. Every FieldbusFoundation device has a Resource Block,Function Blocks, and possibly aTransducer Block.

Once the hardware of a FF device is con-figured, fieldbus communication is usedto configure the transducer block param-eters. The desired transducer functionali-ty is associated with a specific functionblock via a Channel. The host system isused to link the function blocks togetherto create a control application that canbe downloaded to the devices on the segment.

Foundation Fieldbus provides the userwith standardization, calibration, diag-nostic and status data that enablesusers of FF registered products to benefit from the advantage of “smart”instruments.

The following companies manufacturehosts for Foundation Fieldbus (FF) thathave undergone the FieldbusFoundation’s Host InteroperabilitySupport Test (HIST).

• ABB• Fisher-Rosemount• Foxboro• Honeywell• Smar• Yokogawa

Description of the HIST

Foundation Fieldbus does not intend todefine the features and components of aFF host. Each host is defined by themanufacturer to provide specific func-tions within a fieldbus network. A hostcould be a configuration tool, a recordingdevice, alarm display panel, humanmachine interface or a combination offunctionality. The HIST provides generictest procedures.

A generic set of FF host features thatmay be implemented within a host aredefined to implement a set of applicabletest procedures. A host will conform tosome, or perhaps all features as definedby the host checklist. As hosts can havevarious definitions, not all features maybe applicable to a host implementation.It is not expected that every host shouldsupport each feature.

Many of the test procedures require thatfeatures be supported by both the deviceas well as the host.

Communications Overview









IntellisTM 7500

ModBus® Network SystemsMODBUS®

The ModBus® protocol has beenplaced in the public domain, oper-ates over a serial interface and issupported by almost every PLC,DCS, and operator interface (OI)company. A single ModBus Intellissystem will accommodate up to 10independent automated valve net-works having a maximum of 100valves per network. The ModBusprotocol provides for 800 program-mable discrete I/O points on eachnetwork or 8000 points per sys-tem. More complex systems maybe developed, including redundancyof network communications andcontrol.Network Monitors with

ModBus® Interface Capability

IntellisTM

ModBus®

Overview

Twisted pair for communica-tions, two wires for power

3000 ft.



47 mA

All PLC’s & DCS w/Modbus Port.


CRC check

Closed loop bus

9.6 kbps

Yes

Yes

Physical Media

Maximum Distance






Error Checking

Network Topology

Transmission Speed

Redundancy


Valve ManagementProgram

PLC or HOST






3 2 1 0 99 98 97

4 5 6 7 8 96

Maintenance GroupPCs running Valve Management software

Network Interface Manager (NIM)

ModBus

Field Network

NetworkMonitor

PLCDCS

ModBus®

How The System OperatesField NetworkA field network consists of a group ofNetwork Monitors interconnected with a common communications protocol.With the ModBus IntellisTM System, I/O service and diagnostics are commu-nicated over a local area field network.

Network MonitorEach Network Monitor is assigned anumber from 0 to 99 which is called itsaddress number. This number identifiesone Network Monitor from all the otherNetwork Monitors in the system.

Network Interface ManagerData is transferred serially in “select-check” form from the Network Monitorto the Network Interface Manager(NIM). One hundred valves are polledby the NIM in approximately two sec-onds. Interfacing to a host computeris implemented via a ModBus port inthe NIM while on-line diagnostics aretransmitted to maintenance stationsfrom the RS232C port

Number of I/O points on a single network.Because each network may connect up to 100 Network Monitors, the totalnumber of programmable discrete I/Opoints would be 800 per network. If the two points utilized for tempera-ture and supply pressure monitoring ofeach Network Monitor were not counted,this would leave a total of 600 I/Opoints per network.

Number of I/O points on a single system.Since each Network Interface Managercan accommodate up to 10 independ-ent field networks, a single ModBussystem may serially connect up to1000 Network Monitors or 8000 I/O points.

2





Depending upon the process layout, a wide range ofoptions exist. Standard units are supplied with protectivediodes and optical isolation features. External DeviceNetwork Monitors are available in a 4 input/2 outputconfiguration. Power requirements for each externaldevice are considered within the design parameters of the overall system.

NETWORK MONITORSA ModBus® Network System is established by integrating an OnBoard I/O module directly within the Westlock NetworkMonitor. Each I/O module has the capability to accept input/output signals from automated valves, position sensors, solenoidvalves, emissions monitors and external devices (level alarms, temperature and pressure sensors, flow switches, etc.)

The Automated Valve Network Monitor couples directly tothe pneumatic actuator. It houses three functional compo-nents; position sensors, low-power solenoid valve, and anOnBoard I/O module. The OnBoard I/O module is capable ofaccepting five input and two output devices.

ONBOARD I/O CARD

INPUT 1: Valve Position Sensor (open)INPUT 2: Valve Position Sensor (closed)INPUT 3: Temperature Monitor (internal electronics)INPUT 4: External Device or

Optional Pressure Monitor (supply air)INPUT 5: External Device

OUTPUT 1: Solenoid Valve (actuation control)OUTPUT 2: Dual Coil Application or External Device



Field Network

3

Field Network

IntellisTM 7500

ModBus® Network Systems




PC runningValve Management Software

Network Interface Manager

Field Network

Network Monitors

PLC or HOST

ModBus®

The Network Interface Manager (NIM),intended for control room installation,supervises the exchange of signal dataon the Field Network and functions as theinterface between the Network Monitorsand the host. A microprocessor in theNIM regulates data exchange with eachNetwork Monitor.

Interfacing to a PLC or DCS is imple-mented via a Modbus port in the NIMwith diagnostic data being sent to aMaintenance Station via a separateRS232C port.

Each NIM can communicate with 10independent field communication net-works having up to 100 valves perNetwork or a total of 1000 automatedvalves. The NIM polls each NetworkMonitor in rotation confirming positiondata, solenoid data, Network Monitoraddress, and a CRC check. Additionally,alarms will respond to excessive valvestroke time, data link failures, localpower failures, supply pressure drops,watchdog timer timeout, fugitive emissions, and excessive electronic component temperature rise.

Network Interface ManagerCommunications

The NIM is an industrial computer usedto provide communication between thefield communications network and a hostcontroller such as a PLC, PC, or DCS.Communication between the host andthe NIM is achieved through a communi-cations link using the Modbus RTU pro-tocol. The communications link is anRS-232C serial link that operates in theRTU mode at 9600 kbps.

The host controller (designated asMaster) communicates to the NIM designated as Slave) by a Master-Slavetechnique, in which only one device (the Master) can initiate transactionsreferred to as ‘queries’; these transac-tion typically consist of commands forreading or modifying registers, coils or discrete inputs. The NIM (Slave)responds by supplying the requesteddata to the Master, or by taking theaction requested in the query.

Data transfer between the host and the communications network isthrough shared data tables. The hostreads input values from an input datatable in the NIM and writes all outputvalues to an output data table in theNIM. The NIM polls the NetworkMonitor in the network and updates theinput data table with the informationreturned; also, it reads the output datatable and sends the open or close com-mands to the Network Monitors.

Communications Gateway









IntellisTM 7600

DeviceNet® Network Systems

Network Monitors with DeviceNet® Capability

IntellisTM

DeviceNet®

Overview

Twisted pair for communica-tions and power

1600 ft.trunk + 512 ft. drop



65 mA w/ solenoid energized

Allen-Bradley, Omron,GE, Siemens, DeltaV

Master/slave multimaster, peer-to-peer

CRC check

Trunkline/droplinewith branching


No

Yes

Physical Media

Maximum Distance






Error Checking

Network Topology

Transmission Speed

Redundancy


PLC DeviceNet®

Allen-Bradley is the originator of theDeviceNet® protocol. DeviceNet is a completely open device networkbased upon proven Controller AreaNetwork (CAN) technology. NetworkMonitors with DeviceNet capabilityconnect automated valves andexternal devices directly to the control system, reducing the I/Ointerfaces and wiring associatedwith a typical hardwired solution. A single DeviceNet Intellis Systemwill accommodate up to two inde-pendent automated valve networkshaving a maximum of 63 valves pernetwork. The DPAC provides for378 programmable discrete I/Opoints on each network or 756points per system.


CONFORMANCE TESTED





2

PLCw/ Scanner Card

1

2

63

1

2

63

DeviceNet®

How The System OperatesField NetworkA DeviceNet® field network consists of a group of Network Monitors intercon-nected with a common communicationsprotocol (DeviceNet). The communicationlink is a master/slave data exchange between the DeviceNet Network Monitorand the scanner.

Network MonitorEach Network Monitor has an integrat-ed I/O module onboard that is assignedand addressed from 0 to 63. Theaddress number identifies one NetworkMonitor from all the other Monitors in the system

Scanner CardThe Network Monitors interface with the PLC via a scanner card thatresides in the PLC or DCS. Data gathered by the scanner from theDeviceNet field networks is communi-cated to PLC processors via discreteand/or block transfers over the chassis backplane.

Number of I/O points on a single network.Because each network may connect up to 63 Network Monitors, the total number of programmable discrete I/O points comes to 378 (63 x 6).

Number of I/O points on a single system.Since each scanner card for the Allen-Bradley PLC-5 series can accommodatetwo independent field networks, a singleDeviceNet system will serially connect126 Network Monitors or up to 756 I/O points.




3


Depending upon the process layout, a wide range ofoptions exist. Standard units are supplied with protectivediodes and optical isolation features. External DeviceNetwork Monitors are available in a 4 input/2 outputconfiguration with the DPAC. For I/O counts up to 16input/8 output consult factory.. Power requirements foreach external device are considered within the design parameters of the overall system.

NETWORK MONITORSA DeviceNet Network System is established by integrating an OnBoard I/O module directly within the Westlock NetworkMonitor. Each I/O module has the capability to accept input/output signals from automated valves, position sensors, solenoidvalves, emissions monitors and external devices (level alarms, temperature and pressure sensors, flow switches, etc.)

The Automated Valve Network Monitor couples directly tothe pneumatic actuator. It houses three functional compo-nents; position sensors, low-power solenoid valve, and anOnBoard I/O module. The OnBoard I/O module is capable ofaccepting six input and two output devices.

ONBOARD I/O CARD

INPUT 1: Valve Position Sensor (closed)INPUT 2: Valve Position Sensor (open)INPUT 3: External Device or

Optional Pressure Monitor (supply air)INPUT 4: External Device or

Optional Fugitive Emissions Monitor

OUTPUT 1: Solenoid Valve (actuation control)OUTPUT 2: Dual Coil Application or External Device



Field Network

Field Network

IntellisTM 7600

DeviceNet® Network Systems




DeviceNet® 76DA

Interface Scanner

DeviceNet Scanner for1771 Chassis (1771-SDN)

The 1771-SDN DeviceNet scanner is a single-slot module that resides in the 1771I/O chassis and provides connection to twoDeviceNet networks.

Multiple scanners can reside in the same I/O chassis, limited only by the I/O chassissize and power supply capacity.

DeviceNet Scanner forSLC Chassis (1747-SDN)

The 1747-SDN DeviceNet scanner is asingle-slot module that resides in the SLC modular chassis and provides connection to the DeviceNet network.

Multiple scanners can reside in the sameSLC chassis, limited only by the chassissize and power supply capacity.

DeviceNet to Analog I/O ModuleThe Westlock Controls Corp. DeviceNet Slave Module operates as aGroup 2 Only slave on a DeviceNet network. The unit supports ExplicitMessages and Polled I/O Message of the predefined Master/Slave connection Set. The device does not support the Explicit UnconnectedMessage Manager (UCMM).

Analog output is a non-isolated 4-20 mA current source powered fromthe DeviceNet power. Analog input is a non-isolated 4-20 mA currentmeasured on the “Input-” side, power is sourced from the DeviceNetpower. Minimum input supply voltage is 16.5 VDC to assure 12 VDC on analog output. Input current is 50 mA with the analog inputs andoutputs disconnected and 90mA with analog input and output at 20 mA.





Device Type GenericExplicit Peer to Peer Messaging NI/O Peer Peer Messaging NConfiguration Consistency Value NFaulted Node Recovery NBaud Rates 125K, 250K, 500KMaster/Slave YI/O Slave Messaging

• Bit Strobe N• Polling Y• Cyclic N• Change of States N

DeviceNet Features

ANALOG TYPE VALUE OF DATAINPUT (Class 10, Instance 1, Attribute 3)

Input 1 4-20 mA 0 to 32767This value is the input current (in mA) multiplied by 1638.35. (Example: 10 mA input yields a value of 10 x 1638.35 = 16383.5 = 0 x 3 FFF)

ANALOG TYPE VALUE OF DATAOUTPUT (Class 10, Instance 1, Attribute 3)

Input 1 4-20 mA 0 to 32767This value is the output current (in mA) multiplied by 1638.35. (Example: 14 mA input yields a value of 14 x 1638.35 = 22936.9 = 0 x 5998)





IntellisTM 7700

AS-interface® Ver 2.1 Network Systems

Network Monitors with AS-interface® Ver. 2.1 Capability

IntellisTM

AS-interface® Ver.2.1

Overview

Two wire cable(communications and power)


62/network1 network/system



All PLC’s & DCS w/Modbus,DeviceNet, ProfiBus Port.


Control sum, parity

Bus, tree, star

167 kbps

No

No

Physical Media

Maximum Distance






Error Checking

Network Topology

Transmission Speed

Redundancy

Valves SpecificDiagnostics

PLC

Gateway GatewayGateway

DCSSystem

AS-interface® Ver 2.1The AS-Interface® protocol wasdeveloped by a consortium of majorEuropean companies. Designedspecifically for use in low level automated systems, any Profibus,ModBus, ModBus+, DeviceNet orInterbus-S PLC may be cost-effec-tively accessed by the integrationof AS-Interface I/O module withinthe Westlock Network Monitor. Asingle AS-Interface Intellis systemwill support a network having a maximum of 62 automated valveswith both power and communica-tions transmitted over the samepair of wires. The AS-InterfaceVer. 2.1 protocol provides for 434programmable discrete I/O pointson each network (248 inputs/186outputs).


CONFORMANCE TESTED





2

PLC

Gateway

Power Supply

AS-interface AS-interface AS-interface

1

2

31

1

2

31

1

2

31

GatewayGateway

DCS System

24 VDCPower Supply

PS PS PS

AS-interface®

How The System OperatesField NetworkAn AS-interface Ver. 2.1field networkconsists of a group of Network Monitorsinterconnected by a common communica-tions protocol (AS-interface). The AS-interface is a master-slave (Gateway-Network Monitor) system and is capableof operating with a 30VDC supply on a

two-wire unshielded and untwistedcable. Communication and power (8A)share the same two wires. The AS-interface system has a cycle time ofless than 5mS with 32 slaves, 10mSwith 62 slaves. Maximum cable length/network (without repeaters) is 300 feetfrom the PLC or master controller.

Network MonitorEach Network Monitor has an integrat-ed I/O module onboard that is assignedand addressed from 1 to 31 subscriptA or 1 - 31, subscript B. The addressnumber identifies one Network Monitorfrom all the other monitors in the system

Gateway InterfaceThe Network Monitors interface to higher level bus system such as aProfibus, DeviceNet, ModBus,Modbus+ and Interbus-S through theuse of gateways. In some instances,direct connection is available to PLC’sor PC’s (Siemens Simatic 55 series, AG90, 95 and 100, ET200V and RS232C,RS422 and RS485 serial interfaces).

Number of I/O points on a single system.Because each network may connect up to 62 Network Monitors, the total number of programmable discrete I/O points comes to 372 (248 inputs/124 outputs).




Field Network

Field Network

IntellisTM 7700

AS-interface® Ver 2.1 Network Systems

3


Depending upon the process layout, a wide range ofoptions exist. Standard units are supplied with protectivediodes and optical isolation features. External DeviceNetwork Monitors are available in a 4 input/2 output configuration with the APAC. For I/O counts up to 4input/4output consult factory. Power requirements foreach external device are considered within the designparameters of the overall system.

NETWORK MONITORSAn AS-interface Network System is established by integrating an OnBoard I/O module directly within the Westlock NetworkMonitor. Each I/O module has the capability to accept input/output signals from automated valves, position sensors, solenoidvalves, emissions monitors and external devices (level alarms, temperature and pressure sensors, flow switches, etc.)

The Automated Valve Network Monitor couples directly tothe pneumatic actuator. It houses three functional compo-nents; position sensors, low-power solenoid valve, and anOnBoard I/O card. The OnBoard I/O module is capable ofaccepting four input and four output devices.

ONBOARD I/O CARD

INPUT 1: Valve Position Sensor (closed)INPUT 2: Valve Position Sensor (open)INPUT 3: External Device or

Optional Pressure Monitor (supply air)INPUT 4: External Device or

Optional Fugitive Emissions MonitorOUTPUT 1: Solenoid Valve (actuation control)OUTPUT 2: Dual Coil application or External Device






Gateway InterfaceThe AS-interface Gateway is responsible for management of the communicationsdata on the field network and functions as the interface between the NetworkMonitors and the primary control system (PLC, DCS, PC). Along with specificPLC and PC interfaces, Gateways are standardly available for use with higherlevel networks such as Profibus, ModBus, DeviceNet and Interbus-S.

PROFIBUS®

The AS-interface/PROFIBUS gate-ways serve to connect the AS-inter-face network to the higher levelPROFIBUS network. The gatewaysact as a complete master for theAS-interface and as a slave forPROFIBUS. All AS-interface functionscan be called up via PROFIBUS.

The combined device has the essen-tial advantage of making it possibleto work in a PROFIBUS-FMS (9.6KBaud to 500 KBaud) as well as in aPROFIBUS-DP network. (9.6 KBaudto 1500 KBaud).

ModBus®

The AS-interface/Modbus gatewayserves to connect the AS-interface to a higher level Modbus network. Thegateway acts as a complete master for the AS-interface and as a slave for the Modbus.

Commissioning, debugging and setting up of the AS-interface param-eters can be accomplished with two push-buttons, the LED display and the LED’s located on the gateway.

DeviceNet®

The AS-interface/DeviceNet gatewayserves to connect the AS-interface to aDeviceNet network. The gateway actsas a complete master for the AS-inter-face and as a slave for the DeviceNet.

All AS-interface functions can be calledup via DeviceNet. Commissioning, configuration and debugging on the AS-interface circuit can be accom-plished with the two push-buttons, theLCD display and the LED’s located onthe gateway. It is also possible to con-figure the network with the DeviceNetManager Software.

AS-interface®

Gateway











NETWORK SYSTEMS FOR DIAPHRAGM VALVES•

AS-interface® Ver. 2.1DeviceNet®



IntellisTM


NETWORK INTERFACE CARD INPUT 1: Valve Position Sensor (closed)



IntellisTM is a family of industrial control field Network Monitors

which use embedded control systems to automate valves and link

field I/O to the host PLC or DCS. Network Monitors are standard

Westlock Control Monitors with the addition of a network I/O

module. Each Network Monitor houses two hermetically sealed

position sensors for valve position monitoring, a low power

solenoid valve for actuation control, and a network interface

module for communication via the DeviceNet®, AS-interface®

or Foundation Fieldbus® protocol.

By switching from a conventional hardwired I/O system to an

IntellisTM network, immediate cost savings are realized through

the elimination of hundreds of dedicated wires and their

associated costs.

Network Systems for Diaphragm Valves

Field Network

The Network CardDepending upon the network standard selected DeviceNet®, AS-interface® or Foundation Fieldbus®

a dedicated network card is integrated within the enclosure of each Network Monitor. The on-board

network card is capable of communicating and controlling 2 inputs and one output.

The Network MonitorThe Network Monitor for diaphragm valves couples directly onto the pneumatic actuator and communicatesover a field network via an integrated network module.Each unit has the capability to accept input/output sig-nals from position sensors and a solenoid valve.

2

PROGRAM PARTNER

CONFORMANCE TESTED

CONFORMANCE TESTED

FOUNDATION



IntellisTM


3

Twisted pair for communica-tions and 2 wires for power

1600 ft. trunk + 512 ft. drop




All PLC’s & DCS supportingthe DeviceNet protocol

Master/Slave

CRC check

Zero drop, trunk drop, tree, star


No

Yes

Two wire cable(communications & power)


62/network1 network/system



All PLC’s & DCS w/ModBus,DeviceNet, ProfiBus Port

Master/slave

Manchester encoding

Zero drop, trunk & drop, tree, star

167 kbps

No

No


Physical Media

Maximum Distance






Error Checking

Network Topology

Transmission Speed

Redundancy


The acceptability of standard network protocols such as DeviceNet®, AS-interface® or Foundation Fieldbus® has made

it possible to effectively integrate process control components into a network. DeviceNet, AS-interface or Foundation

Fieldbus® have emerged as de facto standards for interfacing discrete devices. They have proven themselves to be

extremely reliable, simple to understand and consistently cost effective. The integration of these three major network

standards with various manufacturers of PLC’s and DCS systems is readily accomplished through the implementation

of off-the shelf gateway interfaces.

Standard Network Protocols

AS-interface®

Ver 2.1The AS-Interface® protocolwas developed by a consor-tium of major Europeancompanies. Designed specif-ically for use in low levelautomated systems. AS-i cancommunicate via a gatewayto most higher level bus sys-tems such as DeviceNet,Modbus and Profibus.

Twisted pair for communications and power.


6/segment if bus powered & IS 12/segment if bus powered & non-IS 32/segment if neither bus powered nor IS

96 discrete

18-24mA max.with Piezo operator32mA max. with ULP coil


Publisher/subscriber

Manchester encoding

Trunk & drop. zero drop, tree, star

31.25 kbps

Yes

Yes


The initial specification for

Foundation Fieldbus, drafted

in 1987, was a joint effort of

the IEC and the ISA to create

an international fieldbus

standard.

DeviceNet®

Allen-Bradley is the origi-nator of the DeviceNet®

protocol. DeviceNet is anopen device network stan-dard based upon provenController Area Network(CAN) technology.

*For added I/O capability, please consult factory.





TOP VIEW

SIDE VIEW

ACTUATOR

Mounting Plate3/16"

4.76mm

3.30

3.30

1.53

1.50

3.86SEE NOTE

1.36

.68

1/2" NPT

1/2" NPT

3.751.00

.74

1.49

3.75

3.24

NOTE: For units withvisual indicators, overallheight is dependentupon stroke of actuator.



DIMENSIONAL DATA

Model 7399, 7699, 7799Engineered Resin (Nylon)Nema 4, 4x, NonincendiveClass I, Groups A, B, C & DClass II, Groups F & G, Division 2 only

LOW POWER SOLENOID TECHNOLOGY

¤

VALVE POSITION SENSORSUtilized for full open/close position detection and predictive diagnosticfunctions, each proximity sensor is hermetically sealed against theintrusion of explosive gases, moisture, and corrosion.

TECHNICAL SPECIFICATIONS & ORDERING GUIDE

SOLENOID VALVESFalcon low power solenoid valves operate at 24 VDC, 20 mA, .5 watt. The low power feature (20 mA) allowsfor a major reduction in power supply requirements. When utiliz-ing the AS-interface protocol, power and communications may be transmitted on the same two wire cable.

NOTE: For dual coil applications, please consult factory.For Manual Override suffix part number with MO

Use abovelisting

for ordering solenoid

FoundationFieldbus73*

DeviceNet76

AS-interface77

Card A2 Inputs1 Output

A

DeviceNet Scanner for Allen-Bradley PLC5 DS71

DeviceNet Scanner for Allen-Bradley SLC DS47

AS-i/Profibus 1060

AS-i/DeviceNet 1078

AS-i/Modbus 1104

AS-i/Interbus-S 1079

NetworkProtocol Enclosure Network

Card Solenoid Gateway Interface

ORDERING GUIDE

EngineeredResin

99RS

EngineeredResin w/JunctionHousing99XS

No-Voltage Release (Latching) NNo-Voltage Release (Non-Latching) RFalcon Manual Maintained Override LFalcon Momentary Override MExternal Pilot ELockout K

EXAMPLE: S-7399RSAFS02100N

SOLENOID (MANUAL OVERRIDE OPTIONS)

Web Site: www.westlockcontrols.com

WESTLOCK Westlock Controls Corp.280 Midland AvenueSaddle Brook, NJ 07663201-794-7650 • Fax: 201-794-0913



CV Body 3-Way

Brass 2100

Alum. 3100

303 S.S. 4100

316 S.S. 5100

Brass 2200

Alum. 3200

303 SS 4200

316 S.S. 5200

Brass 2300

Alum. 3300

303 S.S. 4300

316 S.S. 5300

Alum. 3400

4-Way

2500

3500

4500

5500

2600

3600

4600

5600

2700

3700

4700

5700

3800

COILS

FSO24 VDC

0.5 watts




ZUO24 VDC

1.0 watts




.3 Cv

.5 Cv

1.2 Cv

3.5 Cv

*COILS - 7300 PRODUCTS ONLY

BKO7.2 VDC

0.014 watts

NEMA 4, 4x, NonincendiveClass I, Groups A, B, C, DClass II, Grps. F, G, Div. 2


accutrak rotary sec. 04 · 2014. 3. 4. · accutrak rotary valve position monitors " accutrak...

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