SPX Waukesha Cherry-Burrell W-Series User manual

W-Series Control Top Manual
Read and understand this manual
prior to installing, operating or servicing this equipment.

Table of Contents
April 2005 95-03077 Page 3
Waukesha Cherry-Burrell Warranty ...............................................................................4
Shipping Damage or Loss ....................................................................................................4
Warranty Claim ....................................................................................................................4
Safety ....................................................................................................................................5
Care of Stainless Steel ........................................................................................................6
Stainless Steel Corrosion ......................................................................................................6
Elastomer Seal Replacement Following Passivation ...........................................................6
Introduction ........................................................................................................................7
General Information .............................................................................................................7
Models and Specifications ...................................................................................................7
Materials ................................................................................................................7
Operating Parameter ............................................................................................................. 7
Temperature ...........................................................................................................7
Nitrile .....................................................................................................................7
Thermal range of application: ................................................................................ 7
Chemical Resistance: ............................................................................................. 7
Installation and Operation .................................................................................................8
Solenoids .............................................................................................................................. 8
Parker Solenoid Configuration ..............................................................................8
Exceptions ..............................................................................................................8
Solenoid Operation ................................................................................................8
Air\Solenoid Valve Port Connections: W60/W80/W90 Series Valves ..............................9
Air/Solenoid Valve Port Connections: W70 Series Mixproof Valves .................................10
Clippard Solenoid Configuration .........................................................................................10
Exceptions ..............................................................................................................10
Wiring Instructions: Switches and Solenoids ......................................................................11
Wiring Instructions: Pin Connectors ....................................................................................21
Wiring Instructions: As-i and Device Net Modules ............................................................28
Maintenance ........................................................................................................................32
Important Safety Tips ...........................................................................................................32
Detaching Port Connections: ................................................................................. 32
Inspection ............................................................................................................................. 32
Maintenance Intervals ..........................................................................................................32
Disassembly ......................................................................................................................... 32
Assembly .............................................................................................................................. 32
Switches ............................................................................................................................... 33
Micro Switch ..........................................................................................................33
Proximity Switch ...................................................................................................33
Switch Adjustment .................................................................................................33
Parts Lists ............................................................................................................................34
Parker Solenoid: AC/DC and Long Stroke AC/DC ............................................................. 34
Parker Solenoid: DC and Long Stroke with Asi Card,
Westlock and Interlink Device Net Card ..........................................................................36
Parker Solenoid: AC Mixproof Non Seat Lift ..................................................................... 38
Clippard Solenoid: Asi, Terminal Block, Westlock and Interlink Device Net Card ........... 40
No Solenoid: Standard, Long Stroke, Mixproof, and PMO .................................................42
Exterior Mount Proximity Switch ........................................................................................ 44
Valve Mount Proximity Switch ............................................................................................ 45
Troubleshooting ..................................................................................................................46

Warranty Waukesha Cherry-Burrell
Page 4 95-03077 April 2005
Waukesha Cherry-Burrell Warranty
Seller warrants its products to be free from defect in materials and workmanship for a period of one (1) year from the date
of shipment. This warranty shall not apply to products which require repair or replacement due to normal wear and tear or
to products which are subjected to accident, misuse or improper maintenance. This warranty extends only to the original
Buyer. Products manufactured by others but furnished by Seller are exempted from this warranty and are limited to the
original manufacturer’s warranty.
Seller’s sole obligation under this warranty shall be to repair or replace any products that Seller determines, in its
discretion, to be defective. Seller reserves the right either to inspect the products in the field or to request their prepaid
return to Seller. Seller shall not be responsible for any transportation charges, duty, taxes, freight, labor or other costs. The
cost of removing and/or installing products which have been repaired or replaced shall be at Buyer’s expense.
Seller expressly disclaims all other warranties, express or implied, including without limitation any warranty of
merchantability of fitness for a particular purpose. The foregoing sets forth Seller’s entire and exclusive liability, and
Buyer’s exclusive and sole remedy, for any claim of damages in connection with the sale of products. In no event shall
Seller be liable for any special consequential incidental or indirect damages (including without limitation attorney’s fees
and expenses), nor shall Seller be liable for any loss of profit or material arising out of or relating to the sale or operation
of the products based on contract, tort (including negligence), strict liability or otherwise.
Shipping Damage or Loss
If equipment is damaged or lost in transit, file a claim at once with the delivering carrier. The carrier has signed the Bill of
Lading acknowledging that the shipment has been received from WCB in good condition. WCB is not responsible for the
collection of claims or replacement of materials due to transit shortages or damages.
Warranty Claim
Warranty claims must have a Returned Goods Authorization (RGA) from the Seller before returns will be accepted.
Claims for shortages or other errors, exclusive of transit shortages or damages, must be made in writing to Seller within
ten (10) days after delivery. Failure to give such notice shall constitute acceptance and waiver of all such claims by Buyer.

Waukesha Cherry-Burrell Safety
April 2005 95-03077 Page 5
Safety
READ AND UNDERSTAND THIS MANUAL
PRIOR TO INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT
Waukesha Cherry-Burrell recommends users of our equipment and designs follow the latest Industrial Safety Standards.
At a minimum, these should include the industrial safety requirements established by:
1. Occupational Safety and Health Administration (OSHA), Title 29 of the CFR
Section 1910.212- General Requirements for all Machines
2. National Fire Protection Association, ANSI/NFPA 79
ANSI/NFPA 79- Electrical Standards for Industrial Machinery
3. National Electrical Code, ANSI/NFPA 70
ANSI/NFPA 70- National Electrical Code
ANSI/NFPA 70E- Electrical Safety Requirement for Employee Workplaces
4. American National Standards Institute, Section B11
Attention: Servicing energized industrial equipment can be hazardous. Severe injury or death can result from electrical
shock, burn, or unintended actuation of controlled equipment. Recommended practice is to disconnect and lockout
industrial equipment from power sources, and release stored energy, if present. Refer to the National Fire Protection
Association Standard No. NFPA70E, Part II and (as applicable) OSHA rules for Control of Hazardous Energy Sources
(Lockout-Tagout) and OSHA Electrical Safety Related Work Practices, including procedural requirements for:
• Lockout-tagout
• Personnel qualifications and training requirements
• When it is not feasible to de-energize and lockout-tagout electrical circuits and equipment before working on or near
exposed circuit parts
Locking and Interlocking Devices: These devices should be checked for proper working condition and capability of
performing their intended functions. Make replacements only with the original manufacturer’s renewal parts or kits.
Adjust or repair in accordance with the manufacturer’s instructions.
Periodic Inspection: Industrial equipment should be inspected periodically. Inspection intervals should be based on
environmental and operating conditions and adjusted as indicated by experience. At a minimum, an initial inspection
within 3 to 4 months after installation is recommended. Inspection of the electrical control systems should meet the
recommendations as specified in the National Electrical Manufacturers Association (NEMA) Standard No. ICS 1.3,
Preventative Maintenance of Industrial Control and Systems Equipment, for the general guidelines for setting-up a
periodic maintenance program.
Replacement Equipment: Use only replacement parts and devices recommended by the manufacturer to maintain the
integrity of the equipment. Make sure the parts are properly matched to the equipment series, model, serial number, and
revision level of the equipment.
Warnings and cautions are provided in this manual to help avoid serious injury and/or possible damage to equipment:
DANGER: marked with a stop sign.
Immediate hazards which WILL result in severe personal injury or death.
WARNING: marked with a warning triangle.
Hazards or unsafe practices which COULD result in severe personal injury or death.
CAUTION: marked with a warning triangle.
Hazards or unsafe practices which COULD result in minor personal injury or product or property damage.

Care of Stainless Steel Waukesha Cherry-Burrell
Page 6 95-03077 April2005
Care of Stainless Steel
Stainless Steel Corrosion
Corrosion resistance is greatest when a layer of oxide film is formed on the surface of stainless steel. If film is disturbed or
destroyed, stainless steel becomes much less resistant to corrosion and may rust, pit or crack.
Corrosion pitting, rusting and stress cracks may occur due to chemical attack. Use only cleaning chemicals specified by a
reputable chemical manufacturer for use with 300 series stainless steel. Do not use excessive concentrations, temperatures
or exposure times. Avoid contact with highly corrosive acids such as hydrofluoric, hydrochloric or sulfuric. Also avoid
prolonged contact with chloride-containing chemicals, especially in presence of acid. If chlorine-based sanitizers are used,
such as sodium hypochlorite (bleach), do not exceed concentrations of 150 ppm available chlorine, do not exceed contact
time of 20 minutes, and do not exceed temperatures of 104°F (40°C).
Corrosion discoloration, deposits or pitting may occur under product deposits or under gaskets. Keep surfaces clean,
including those under gaskets or in grooves or tight corners. Clean immediately after use. Do not allow equipment to set
idle, exposed to air with accumulated foreign material on the surface.
Corrosion pitting may occur when stray electrical currents come in contact with moist stainless steel. Ensure all electrical
devices connected to the equipment are correctly grounded.
Elastomer Seal Replacement Following Passivation
Passivation chemicals can damage product contact areas of WCB equipment. Elastomers (rubber components) are most
likely to be affected. Always inspect all elastomer seals after passivation is completed. Replace any seals showing signs of
chemical attack. Indications may include swelling, cracks, loss of elasticity or any other noticeable changes when
compared with new components.

Waukesha Cherry-Burrell Introduction
April 2005 95-03077 Page 7
Introduction
Numerical call outs in illustrations reflect item numbers in Parts Lists beginning on page 34. Alphabetical call outs
represent pre-assembled or customer provided parts not found in Parts Lists
For valve information, please refer to the specific publication assigned to the type of valve you have. For additional
product information please see our web site at http://www.spxprocessequipment.com/sites/wcb/literature.htm.
General Information
Information in this manual should be read by all personnel involved in installation, setup, operation and maintenance of
W-series control modules.
NOTE: In this manual,’stem-raised’ is understood to be when the valve stem is fully retracted into the actuator.’Stem-
lowered’ is understood to be when the valve stem is fully extended out from the actuator.
Models and Specifications
Control Modules are used with pneumatically actuated valves to protect and deploy stem feedback switches and/or air
solenoid valves. NEMA 4X enclosures mount on top of valve actuator. An indicator stem extends into the control top to
provide a position-measurement surface for feedback switches.
Two basic types of control modules are: W-series 3-piece and the Set and Forget control modules. This manual covers
the 3-piece control top.
Materials
Operating Parameter
Temperature
W-series control manuals are designed to work in the
temperature range of 32°F to 180°F (0° - 82°C). W-series
control modules are intended for normal exterior cleaning
procedures.
Operating temperature and environment determine the
materials used for seals. The following materials are
available for seals in the temperature range listed:
Nitrile
Thermal range of application:
• -32° to 275° F (-30°F to 225°F)
Chemical Resistance:
• Acids in 2-5% concentration up to 212°F (100°C)
• Caustics in 2% concentration up to 105°F (41°C)
•Oilsandfats
Nitrile seals comply with FDA standards.
Figure 1 : W-series 3-piece materials
AStainless steel base
B(1) pair of 2 switch mounting and
adjustment poles
CSee through acrylic lens
DO-ring seals
EStainless Steel cap
FAcorn nuts
GIndicator stem

Installation and Operation Waukesha Cherry-Burrell
Page 8 95-03077 April2005
Installation and Operation
Control module bases are configured differently for
different solenoids. For W60/W80/W90 valves without
solenoids, the porting on the base is typically limited to:
wiring inlet, module vent, air-in, and exhaust.
Solenoids
Parker Solenoid Configuration
•AC/DC
• 4-way action
• Single Seat valves W60/W80/W90
• allows for air boost
• Ports on base are numbered
• Same configuration used for MAC solenoids
Exceptions
1. W60/W80 and W68/W88 Series 3-Position, Air-to-
Raise Valves uses two Clippard Solenoids
2. Mix Proof Non Seat Lift uses AC Parker Solenoid
Solenoid Operation
Solenoids direct air pressure to ports in the base of the
control top to control the valve. For the solenoid to work
correctly and achieve the required valve condition,
specific ports must be open or plugged. Table 2,
demonstrates the appropriate configurations for a W60/
W80/W90 Shutoff Valves. Prior to startup, perform a
functional test on each valve by applying compressed air.
For W70 Series Mixproof valves see page 10.
* Highlighted rows are most common valve conditions
1N.O. stands for Normally Open
2 N.C. stands for Normally Closed
Figure 2 - Control Top Base Ports
VALVE CONDITION PORT 1 PORT 2 PORT 3 PORT 4 PORT 5
2N.O.1valve closes when N.O.
solenoid is de-energized Plug Open Plug Plug Plug
3N.C.2valve opens when N.O.
solenoid is de-energized Connect to
port in yoke Plug Open Plug Plug
*4 N.C. valve opens when N.C.
solenoid is energized Plug Plug Open Connect to port in yoke Plug
*5 N.O. valve closes when N.C.
solenoid is energized Plug Plug Plug Plug Open
6
N.C. valve with air boost
opens or Air-to-Air valve
opens when N.C. solenoid is
energized
Plug Open Plug Connect to
port in yoke Plug
7
Normally open valve with air
boost closes or Air-to-Air
valve closes when N.C.
solenoid is energized
Connect to
port in yoke Plug Plug Plug Open
TABLE 2: CONTROL MODULE SOLENOID ARRANGEMENTS W60/W80/W90 SERIES

Waukesha Cherry-Burrell Installation and Operation
April 2005 95-03077 Page 9
Air\Solenoid Valve Port Connections: W60/W80/W90 Series Valves
Use 1/4" flexible tubing with a fitting to 1/8" NPT at valve connections.
Figure 3 - Air Line Connection for Parker Solenoid Valves
Figure 4 - Air Line Connections for 2 Solenoid, 3-Position Air-to-Raise Actuators

Installation and Operation Waukesha Cherry-Burrell
Page 10 95-03077 April2005
Air/Solenoid Valve Port Connections: W70 Series Mixproof Valves
Clippard Solenoid Configuration
• DC only
• 3-way action
• Mix Proof valves
• Air boost requires (2) solenoid. Ports on base line up
with lettered solenoid locations
Exceptions
1. W60/W80 and W68/W88 Series 3-Position, Air-to-
Raise Valves uses two Clippard Solenoids (see page)
2. Mix Proof Non Seat Lift uses AC Parker Solenoid
All functions of W-70 mix proof valves are pneumatically
controlled using a 72 to 100 psi (4.9 to 6.9 bar) clean air
supply.
Up to three air supplies controlled by solenoid valves
supply air to valve actuator (Figure 6). For non seat lift
valves, ports A and C are not provided on the actuator.
ON = Solenoid energized (OPEN).
OFF = Solenoid de-energized (CLOSED).
Solenoids are normally closed (N.C).
Air connections are 1/8 NPT
.
W70 Series Solenoid/Valve Position
Condition SolenoidA Solenoid B Solenoid C
Closed OFF OFF OFF
Open OFF ON OFF
Upper Seat
Cleaning OFF OFF ON
Lower Seat
Cleaning ON OFF OFF
Figure 5 Control Top Base Ports
Figure 6 - Solenoid Valve Port Connections

Waukesha Cherry-Burrell Installation and Operation
April 2005 95-03077 Page 11
Wiring Instructions: Switches and Solenoids
DANGER: To avoid electrocution, all electrical work should be done by a registered electrician following
industry safety standards. All power must be off and locked out.
PAGE, FIGURE SOLENOID VOLTAGE SWITCH
Micro Proximity
Page 12, Fig. 7 Parker (optional) AC X
Page 12, Fig. 8 Parker (optional) DC X
Page 13, Fig. 9 Parker (optional) AC 2-Wire
Page 14, Fig. 10 Parker (optional) DC 2-Wire
Page 15, Fig. 11 Parker (optional) DC 3-Wire
Page 15, Fig. 12 1 Clippard DC X
Page 16, Fig. 13 2 Clippard DC X
Page 16, Fig. 14 3 Clippard DC X
Page 17, Fig. 15 Parker (optional) DC 3-Wire
Page 17, Fig. 16 1 Clippard DC 2-Wire
Page 18, Fig. 17 2 Clippard DC 2-Wire
Page 18, Fig. 18 3 Clippard DC 2-Wire
Page 19, Fig. 19 1 Clippard DC 3-Wire
Page 19, Fig. 20 2 Clippard DC 3-Wire
Page 20, Fig. 21 3 Clippard DC 3-Wire

Installation and Operation Waukesha Cherry-Burrell
Page 12 95-03077 April2005
Figure 7 - Wiring Diagram for AC Micro-Switches (Parker Solenoid optional) Figure 8 - Wiring Diagram for DC Micro-Switches (Parker Solenoid optional)

Waukesha Cherry-Burrell Installation and Operation
April 2005 95-03077 Page 13
Figure 9 - Wiring Diagram for 2-Wire AC Proximity Switches
(Parker Solenoid optional)

Installation and Operation Waukesha Cherry-Burrell
Page 14 95-03077 April2005
Figure 10 - Wiring Diagram for 2-Wire DC Proximity Switches
(Parker Solenoid optional)

Waukesha Cherry-Burrell Installation and Operation
April 2005 95-03077 Page 15
Figure 11 - Wiring Diagram for 3-Wire DC (PNP/NPN) Proximity Switches (Parker Solenoid optional)
Figure 12 - Wiring Diagram for 1 Clippard Solenoid Valves with DC Micro-Switches

Installation and Operation Waukesha Cherry-Burrell
Page 16 95-03077 April2005
Figure 13 - Wiring Diagram for 2 Clippard Solenoid Valves with DC Micro-Switches
Figure 14 - Wiring Diagram for 3 Clippard Solenoid Valves with DC Micro-Switches

Waukesha Cherry-Burrell Installation and Operation
April 2005 95-03077 Page 17
Figure 15 - Wiring Diagram for 3-Wire DC Proximity Switches (Parker Solenoid optional)
Figure 16 - Wiring Diagram for 1 Clippard Solenoid Valves with 2-Wire DC Proximity Switches

Installation and Operation Waukesha Cherry-Burrell
Page 18 95-03077 April2005
Figure 17 - Wiring Diagram for 2 Clippard Solenoid Valves with 2-Wire DC Proximity Switches
Figure 18 - Wiring Diagram for 3 Clippard Solenoid Valves with 2-Wire DC Proximity Switches

Waukesha Cherry-Burrell Installation and Operation
April 2005 95-03077 Page 19
Figure 19 - Wiring Diagram for 1 Clippard Solenoid Valves with 3-Wire DC Proximity Switches
Figure 20 - Wiring Diagram for 2 Clippard Solenoid Valves with 3-Wire DC Proximity Switches

Installation and Operation Waukesha Cherry-Burrell
Page 20 95-03077 April2005
Figure 21 - Wiring Diagram for PMO 3 Clippard Solenoid Valves with 3-Wire DC Proximity Switches

Waukesha Cherry-Burrell Installation and Operation
April 2005 95-03077 Page 21
Wiring Instructions: Pin Connectors
PAGE, FIGURE CONNECTION VOLTAGE SWITCH SOLENOID TERMINAL/
NETWORK
Micro Proximity
Page 22, Fig. 22 5 Pin AC/DC X2-Wire --
Page 22, Fig. 23 5 Pin AC/DC X2-Wire --
Page 22, Fig. 24 6 Pin AC/DC X2-Wire Parker
Page 22, Fig. 25 7 Pin AC/DC X2-Wire Parker
Page 23, Fig. 26 4 Pin AC/DC X2-Wire --
Page 23, Fig. 27 5 Pin AC/DC X2-Wire --
Page 23, Fig. 28 6 Pin DC X2-Wire Parker
Page 23, Fig. 29 6 Pin DC 3-Wire --
Page 24, Fig. 30 6 Pin DC 2-Wire --
Page 24, Fig. 31 6 Pin DC 3-Wire 1 Clippard
Page 25, Fig. 32 6 Pin DC 3-Wire 2 Clippard
Page 25, Fig. 33 8 Pin DC X2-Wire 3 Clippard
Page 26, Fig. 34 8 Pin DC 3-Wire 1 Clippard
Page 26, Fig. 35 8 Pin DC X2-Wire 2 Clippard
Page 27, Fig. 36 8 Pin DC 3-Wire 2 Clippard
Page 28, Fig. 37 4 Pin DC 2-Wire Parker AS-i Slave
Module
Page 28, Fig. 38 4 Pin DC 2-Wire Clippard AS-i Slave
Module
Page 29, Fig. 39 5 Pin DC 3-Wire Parker DeviceNet
Page 30, Fig. 40 5 Pin DC 3-Wire Clippard DeviceNet