Westlock 1100 User guide

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 1 of 16
WIRELESS DEVICE
INSTALLATION AND SETUP
MANUAL
Models: all models equipped with WD module, including but not
limited to 1100, 9468, 3500, 3449, 3049, 9479, 366, 711, 764,
765, 777, 877, 2004, 2007, 2200, 2600
IOM: Tech-457
Revision: 1
Prepared By:
MarioTwardowski
Date: 2/21/12
Drafting Work Order:
19909
ECN:
Reviewed By:
Tony Paolini
Date: 6/21/12
Approved By:
Adam Buga
Date: 6/21/12
This IOM contains confidential information and is issued in confidence on the condition that it be returned on demand and not be copied,
reproduced, disclosed to others or used in manufacture of the subject matter thereof without the written consent of Westlock Controls

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 2 of 16

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 3 of 16
Revision History
Revision
19 June, 2012 Initial release
Westlock Controls Offices
USA
Westlock Controls Corp.
280 North Midland Ave.Saddle Brook, NJ 07663
Phone: [phone] •Fax: [phone]
Email: w[email protected]
Internet http://www.westlockcontrols.com
Europe
Westlock Controls UK
Chapman Way, Tunbridge Wells
Kent, England TN23EF
Phone: [phone] •Fax: [phone]
Email: sa[email protected]
Internet: http://www.westlockuk.com
South America
Westlock Equipamentos de Controle Ltda.
Sales:
Al. Araguaia, 2044 - Sl. 1101, Bloco B
Edificio CEA - Alphaville
Barueri - Sao Paulo - Brazil
06455-000
Tel: + 55 11 2588-1400
Fax: + 55 11 2588-1410
Email: com[email protected]
Internet: http://www.westlock.com.br
Operations:
Av. Antonio Bardella, 3000
Galpoes 2A e 2B - Alto da Boa Vista
Sorocaba - Sao Paulo - Brazil
18085-852
Tel: + 55 15 2102-7400
Fax: + 55 15 2102-7400

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 4 of 16
Table of Contents
1Introduction............................................................................................................................. 5
1.1 Product Certification........................................................................................................ 5
1.2 Warnings .......................................................................................................................... 6
1.3 Description....................................................................................................................... 7
1.4 Principles of Operation..................................................................................................... 7
2Order Guide............................................................................................................................. 8
3Definitions ............................................................................................................................... 8
4Installation............................................................................................................................... 8
4.1 Mounting Wireless Device to a Rotary Actuator............................................................. 9
4.2 Mounting Wireless Device to a Hand Valve.................................................................. 10
4.3 Wireless Device Operating Quadrant............................................................................. 11
5Configuration......................................................................................................................... 13
5.1 Introduction.................................................................................................................... 13
5.2 Extended ID information.................................................Error! Bookmark not defined.
5.3 Setting Operational Parameters.......................................Error! Bookmark not defined.
5.4 Calibration.......................................................................Error! Bookmark not defined.
6Field Wiring........................................................................................................................... 13
6.1 Wiring External Switches............................................................................................... 13
7Maintenance and Repair........................................................................................................ 14
7.1 Procedure to Replace the Battery Pack .......................................................................... 14
8Appendix ............................................................................................................................... 15
8.1 Appendix A-Procedure to Set Internal Switches............................................................ 15
8.2 Appendix B- Antenna Installation.................................................................................. 16

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 5 of 16
1 Introduction
1.1 Product Certification
IS / I / ABCD / T4 T=80~C
I / 0 / AEx ia IIC / T4 Ta=80~C
IS / I / ABCD / T4 T=80~C
I / 0 / Ex ia IIC / T4 Ta=80~C
II 1 G Ex ia IIC -40~C≤Ta≤ 80~C
IECEx
Ex d IIB+H2 T* Tamb -*~C TO +*~C
Ex tD A21 IP6X T5 Ta 95~C -30~C TO +75~C
Class I, Groups C& D, Class II, Groups E, F & G, Division 1 & 2
Class I, Division 1, Groups A, B, C & D, T5; Ta= -50~C TO 60~C
Class II & III, Division 1, Groups E, F & G, T5; Ta = -50~C TO 60~C; TYPE 4, 4X, 6P
Non-Incendive for Class I, Division 2, Groups A, B, C & D, T5; Ta= -50~C TO 60~C
Ex d IIB+H2 T* Tamb -*~C TO +*~C
Ex tD A21 IP6X T5 Ta 95~C -30~C TO +75~C

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 6 of 16
1.2 Warnings
Misuse of this equipment can cause bodily harm. Operations not performed as per the
instructions in this document are done at the user's own risk and liability.
To prevent bodily harm or damage to equipment, only trained, authorized personnel
should install, maintain and repair the equipment.
To prevent damage to equipment, through electrostatic charge on plastic surface of the
WD always wipe the surface with a wet cloth.
Carefully read the safety information contained in this section, and throughout this user
guide, before installing, operating, or performing any maintenance task on the
equipment.
Dispose used lithium battery in accordance with applicable State and Federal laws.

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 7 of 16
1.3 Description
This technical document provides information about the specific enclosure of a
wireless product. All other information regarding the complete wireless system
can be found on our website www.westlockcontrols.com or through our technical
sales department.
The Westlock Wireless Valve Monitoring System provides real-time information about
the status of valves installed in process plants. The data is fed directly into the
customer’s control system thereby reducing failure while increasing safety and yield.
The Wireless System is based on the ZigBee Pro standard protocol and serves as an
add-on layer, over traditional process management systems, providing enhanced
monitoring capabilities, with considerably reduced complexity. The wireless system
includes support for a wide range of standard interfaces, physical and logical, that are
common in the industry. This makes the wireless system, from the perspective of
connectivity, almost transparent for system designers and integrators, since they can
easily integrate into any of the most widely-used system architectures in the process
industry.
1.4 Principles of Operation
A Westlock Wireless Device (WD) is bracket-mounted to any type of valve or actuator.
Using the standard wireless 802.15.4/ZigBee Pro, 2.4 GHz protocol, the device
wirelessly transmits and receives messages relevant to the position status of the valve
in real time.
The WD is powered by 4 half AA Lithium batteries. In nominal operation
1
, the battery life
of the WDis above 10 years. A battery pack can be replaced in the field.
The WD includes a shaft that is fastened to the valve’s stem through a special cylinder.
It transfers the angle position of the stem to the WD. An internal WDsensor measures
the circular position of the WD shaft thus providing information about the angular
position of the stem in degrees relative to the valve.
The WD reports the valve position (angle) immediately when motion > 1.5 deg of the
valve lever is sensed and at configurable, predefined intervals. The WD temperature,
WD battery status, and other WD housekeeping information are broadcast with every
WD message. Each WDmessage is transmitted with a real time stamp. In between
transmissions the WD is in dormant status to save battery power.
The WD also consists of a Low Frequency (LF) receiver for receiving setting commands
from the Operator Device and to commission, decommission, calibrate, and setup the
unit and to perform diagnostic procedures.
1
Nominal operation is defined as 4 valve movements plus 4 keep alive messages per hour.

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 8 of 16
2 Order Guide
The WD is designed to handle a wide range of control valve applications. For complete
ordering guides consult your Westlock representative or visit
www.Westlockcontrols.com.
The following features are included in all agency approvals for Wireless products:
Wireless transmitter module
Optional proximity switches (reed type)
Optional antenna (installs in conduit entry)
3 Definitions
Westlock Gateway –An industrial computer running the WMS.
WMS –Wireless Management System
EUI –Extended Unique Identifier
HMI –Human Machine Interface
WH –Wireless Handheld
PLC –Programmable Logic Controller
PLCA –PLC Adaptor
SCADA –Supervisory Control and Data Acquisition
WG –Wireless Gateway
WR –Wireless Router
WD –Wireless Device
LF- Low Frequency
4 Installation
The Wireless Device can be mounted to an uninstalled valve or an actuator as well as
to an operating installed valve or actuator. Each valve type or actuator requires a
bracket mounting kit. If a valve or an actuator is outdated and no information can be
found, request for measurements or a site survey may be necessary in order to design
a bracket kit. Section 4.1 shows a typical actuator mount, and section 4.2 show a typical
valve mount.
The WD has an effective valve position (angle) measurement range of about 110º. On
the shaft of the WD, an axle spline indicates the position of the shaft (valve). On the
bottom of each WD there are two marks indicating a range of 90º. This is the effective
motion zone of the WD's shaft to measure the position of the quarter turn valves (see
section 4.3)

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 9 of 16
4.1 Mounting Wireless Device to a Rotary Actuator
Figure 1 shows a typical mounting of a Wireless Device to a rotary actuator.
Follow steps below for proper installation.
1. Install mounting bracket onto the actuator using four mounting screws.
2. Place an actuator coupler onto the actuator shaft in the correct orientation. Coupler
has a keyway that reflects WD’s shaft. Pay attention to the effective motion zone of
the wireless device (see Section 4.3).
3. Place wireless device on the mounting bracket in the correct orientation (see Section
4.3) and secure it with the mounting screws.
Figure 1

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 10 of 16
4.2 Mounting Wireless Device to a Hand Valve
Figure 2 shows a typical mounting of a Wireless Device to a hand valve.
Follow steps below for proper installation.
1. Remove a nut above valve handle in order to remove the handle.
2. Place a mounting bracket onto the valve and secure it with screws.
3. Place the handle back on the valve shaft and fasten the nut.
4. Attach a valve coupler to the valve shaft.
5. Place wireless device on the mounting bracket in the correct orientation (see Section
4.3) and secure it with the mounting screws.
Figure 2

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 11 of 16
4.3 Wireless Device Operating Quadrant
When installing the WD on a quarter turn valve or actuator, verify that the unit shaft is
always positioned in the range between the two marks indicating the motion zone (see
Figure 3 & Figure 4).
Figure 3
Note:
For 114W only, a special shaft is required if the reverse visual
beacon indication is desired. For all other products, outer beacon
may be rotated.

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 12 of 16
Figure 4

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 13 of 16
5 Configuration
5.1 Introduction
As part of the installation process, the Wireless Devices are configured using the WMS
(remotely) and the WH (locally). The following information is installed on the WD:
Extended ID information
Thresholds
Setting operational parameters
Calibration
Please refer to document "TECH-461 WIRELESS DEVICE OPERATION" for
detailed information on how to configure, calibrate, operate and troubleshoot
the Wireless Device. It can be found on our website www.westlockcontrols.com.
6 Field Wiring
6.1 Wiring External Switches
External switches are optional and can be wired directly into the wireless module
using terminal block. Switch operation can be visible on the software interface. See
Figure 5 for typical wiring. For correct wiring to a specific product please follow
supplied wiring diagram.
Figure 5
Note:
For 114W only, we do not offer external switches.

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 14 of 16
7 Maintenance and Repair
7.1 Procedure to Replace the Battery Pack
1. Remove (4) mounting screws that secure the battery pack as shown in Figure 6.
2. Remove battery pack. The unit will remain operating normally up to 5 minutes
without the battery pack.
3. Place new battery pack in designated area and secure it with (4) screws.
4. The device powers back automatically and it attains its previous state without any
intervention. If the device is operating in the field, it will rejoin the network and
send a status message indicating its presence.
ATEX (in Europe) approves replacement of the battery pack in the field (Zone 1). North
America standards do not permit this.
Figure 6
Dispose used lithium battery in accordance with applicable State and Federal laws.

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 15 of 16
8 Appendix
8.1 Appendix A-Procedure to Set Internal Switches
1. To set switches, lift bottom cam and turn until lower switch is activated and then
release (Figure 6 & 7). Spring will push cam back onto the splined shaft.
2. Operate the actuator to the opposite extreme, push down on the top cam and turn
until the upper switch is activated.
3. Operate actuator from one extreme to the other several times to check switch
operation.
Figure 6 Figure 7

WESTLOCK CONTROLS CORPORATION
280N MIDLAND AVENUE Ste.258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
2/3/12 TECH-457/D.W.O. 19909 Page 16 of 16
8.2 Appendix B- Antenna Installation
(If applicable) To prevent any antenna damage in shipment, it has been disassembled
from the WD. Follow steps below for proper installation:
For right angle antenna mounting (Figure 8):
1. Feed antenna cable through the right angle fitting.
2. Fasten antenna into right angle fitting.
3. Connect antenna cable with wireless module cable.
For straight antenna mounting (Figure 8):
1. Feed antenna cable through the conduit entry.
2. Fasten antenna into the conduit entry.
3. Connect antenna cable with wireless module cable.
Figure 8