Westlock 2600 User manual

1725 II 2GD
Installation and operating instructions for Westlock 2600 series valve position (AccuTrak) and control
(Quantum) monitors with mechanical switches, inductive proximity sensors or Magnum proximity switches
2600 SERIES ATEX AND IECEx CERTIFIED
InstallatIon and operatIng InstructIons
Copyright © Westlock. All rights reserved
1 PRODUCT DESCRIPTION
The 2600 series valve position / control monitor
provides two methods of end of travel indication
by the means of mechanical switches, inductive
proximity sensors or proximity switches and an
external visual indicator.
For applications that require position feed
back, ancillary components such as a 4-20mA
current signal transmitter or a resistive signal
feed back can be installed.
The 2600 series enclosure is available in two
materials; cast aluminum or 316 stainless
steel. The enclosure construction comprises
of a housing with a screwed cover.
The housing has the option of up to three cable
entries for connection to an external power
source via appropriate ATEX and IECEx certified
cable glands:
M20 x 1.5p, M25 x 1.5p, ½” - 14 NPT or
¾” - 14NPT.
Note: Before installation of this product, please
ensure that the product and its certification is suitable
for the intended application. This product uses various
O-ring material and an Eastar copolyester visual
indicator as standard.
If the equipment is likely to come into contact
with aggressive substances, then it is the
responsibility of the user to take suitable
precautions that prevent it from being
adversely affected, thus ensuring that the type
of protection provided by the equipment is not
compromised.
Installation of any cable entry devices,
conduit entry devices or blanking devices
shall not compromise the degree of ingress
protection level IP6X for use in the presence of
combustible dusts.
The unit has an ingress protection of IP66/67
and therefore any conduit device fitted must
maintain this.
IECEx ITS 09 0001X
ITS 11 ATEX 17438X
Ex d IIC T* Gb Tamb -*°C to +*°C
Ex tb IIIC T*°C Db Tamb -*°C to +*°C IP6X
Ambient variation: -60°C to +85°C (T4/T130°C); -60°C to +80°C (T5/T95°C);
-60°C to +65°C (T6/T80°C)
For position monitors (without a coil) the T4 ambient range may be -60°C to +110°C
Environmental parameters: 80 kPa (0.8bar) to 110 kPa (1.1bar).
Air with normal oxygen content, typically 21%.
Warning
Do not open when energized or when an
explosive atmosphere is present.
www.westlockcontrols.com VCIOM-05081-EN 17/02 Page 1 of 8
NOTE
These products have been certified with a
cable entry temperature rise of 4°C. Ensure
that this is taken into consideration when
selecting suitable cabling for the ambient
temperature in which the product is to be
used.
NOTE
These products are not intended to be
assembled directly to process pipe work etc.
that is heated or cooled to temperatures
outside of the range as indicated above.
Warning
Electrostatic hazard, clean only with
damp cloth.
AccuTrak 2600 position monitor Quantum 2600 control monitor

VCIOM-05081 Page 2 of 8Copyright © Westlock. All rights reserved
2 MOUNTING INSTRUCTIONS
2.1 Attach a mounting bracket to the housing
base with the M8 fasteners provided
with the mounting bracket. Install shaft
adaptor/ coupler, as appropriate to either
the actuator pinion or unit shaft.
2.2 To ensure that the 2600 series unit is
mounted correctly, it may be necessary
to stroke the actuator to the fully closed
position.
Warning
Before stroking the actuator at any point
during this mounting procedure, please
ensure that the process is safe to do so
and keep hands away from moving parts.
2.3 With the actuator in the correct position,
attach the 2600 series unit / bracket to the
actuator using the hardware provided in
the mounting kit.
2.4 Unscrew the cover and keep in a safe
place. Ensure that the Jack screw (socket
head cap screw) remains in the housing
(See Figure 1).
2600 SERIES ATEX AND IECEx CERTIFIED
InstallatIon and operatIng InstructIons
FIGURE 1
Standard enclosure
Beacon fixing
screw
M4
Enclosure
base
Jack screw
Visual indicator
(Beacon)
Top cam
Push down, turn and release
Bottom cam
Lift up, turn and
release
FIGURE 2
2.5 To set the switches, lift the bottom cam
and turn until the switch has activated and
then release. The spring will push the cam
back onto the splined shaft (Figure 2).
2.6 Stroke the actuator to the opposite end of
travel. Set the top cam by pushing down
and turning the cam until the switch is
activated (Figure 2).
2.7 Stroke the actuator from one end of stroke
to the other several times to check the
switch operation. If the switches require
adjustment, repeat steps 2.5 to 2.7.
2.8 Beacon setting - if fitted
Loosen the beacon fixing screw, see
Figure 1, rotate beacon window (outer
beacon) to indicate appropriate open or
closed text as corresponding to actuator
position.
2.9 Tighten beacon fixing screw sufficiently to
prevent movement of window.

VCIOM-05081 Page 3 of 8Copyright © Westlock. All rights reserved
2600 SERIES ATEX AND IECEx CERTIFIED
InstallatIon and operatIng InstructIons
Up to 2 coils
(not to scale)
2600 conduit designations
Conduit A
Conduit D
(optional configuration)
Conduit B
Conduit C
FIGURE 3
3 FIELD WIRING AND INSTALLATION
Warning
The 2600 series should always be
handled with care when the cover is
removed and wired to electrical power
source. Ensure cover lock is engaged
when replacing cover
NOTE
Before electrical installation, please read and
follow the wiring diagram located inside the
cover. The electrical ratings can be found on
the product identificationlabel.
3.1 Field wiring must be carried out in
accordance with site, local and national
electrical codes / requirements. This
includes special attention to earth bond
to the enclosure using the internal and
external earth points provided.
3.2 Installation of this product shall be carried
out by competent personnel in accordance
with the applicable code of practice such
as EN60079-14 or IEC 60079-14.
3.4 The certification applies to equipment
without cable glands. When mounting the
flameproof enclosure in the hazardous
area, only suitably rated IP66/67 ATEX and
IECEx certified flameproof glands must be
used.
3.5 All unused cable entries must be plugged
with a suitably rated IP66/67 ATEX and
IECEx certified blanking devices.
3.3 The 2600 series housing can offer up to
three of the following conduit entries
as standard; M20 x 1.5p, M25 x 1.5p,
½”- 14NPT or ¾”- 14 NPT (four conduit
entires are available as an option). These
entries are detailed on the product
identification label found on the product
housing. Please see Figure 3 for conduit
positions.

VCIOM-05081 Page 4 of 8Copyright © Westlock. All rights reserved
2600 SERIES ATEX AND IECEx CERTIFIED
InstallatIon and operatIng InstructIons
3.8 The fourth digit designates the switch / sensor type. The following table details the most
common switch / sensor types together with their electrical ratings.
Note: The series code signifies the maximum electrical rating of the product, suitable overloading
protection must be provided to prevent these values being exceeded.
3.9 The tenth digit designates the coil voltage and type. The following table details the voltage
and power ratings:
Series code/switch designation Electrical rating
26*5 Mechanical (SPDT) 15 A - 125 or 250V AC; 6 A - 24V DC
26*6 Mechanical (DPDT) 10 A - 125 or 250V AC; 10 A - 28V DC; 0.2 A - 125V DC
26*7 Inductive proximity sensors
26*9 Magnum ratings 3 A - 120V AC; 1.5 A - 240V AC or 2 A - 24V DC
Voltage / type Power rating
12V DC 0.7 W
24V DC 0.7 W
125V DC 1 W
90-120V AC 4 VA
220-240V AC 4 VA
Series code Cover type T class
Ambient temperature range aluminium
or stainless steel
264* Beacon T6 (80°C) -60°C to +65°C
264* Beacon T5 (95°C) -60°C to +80°C
264* Beacon T4 (130°C) -60°C to +85°C✤
266* No Beacon T6 (80°C) -60°C to +65°C
266* No Beacon T5 (95°C) -60°C to +80°C
266* No Beacon T4 (130°C) -60°C to +85°C✤
3.6 Thread adaptors shall satisfy the requirements of the specific type of protection.
3.7 The first two digits of the Westlock nomenclature signifies the series with the third digit
defining whether the product has a visual beacon or not.
The table below details the applicable ambient ranges:
NOTE
✤For AccuTrak position monitors without a coil, the T4 range is -60°C to +110°C.

A B
C D
VCIOM-05081 Page 5 of 8Copyright © Westlock. All rights reserved
2600 SERIES ATEX AND IECEx CERTIFIED
InstallatIon and operatIng InstructIons
5.1.2Optional features - Falcon II
5.1.2.1 No-voltage release (latching)
With the coil first energized, the palm
button is then manually moved and
latched.
The inward movement of the palm button
causes the valve to shift.
When the coil is de-energized, the
palm button and latching mechanism
are automatically tripped, allowing the
valve to return to its original position.
See Figure 4A.
5.1.2.2 Manual locking override
Manually depress palm button and rotate
clockwise for maintained condition, must
manually disengage to return to original
position. See Figure 4B.
5.1.2.3 Momentary override
Spring return momentary push type, must
hold in to actuate. See Figure 4C.
5.1.2.4 Hex drive maintained override
Insert Allen key in hex head screw and
rotate clockwise (4-5 turns) to shift spool.
Valve will stay put until hex head screw is
rotated counter clockwise (4-5 turns) back
to original position. See Figure 4D.
5 OPERATING AND MAINTENANCE
INSTRUCTIONS FOR FALCON SOLENOID
VALVES. (QUANTUM CONTROL MONITORS
ONLY)
5.1 General description
5.1.1
The Falcon II solenoid valve incorporates
elastomer static seals through which a
shaped spool moves and are manufactured
for 3 or 5 way operation. 3 way is normally
used for pilot control of the other relay
valves or for the operation of single acting
cylinders. 5 way is normally used to control
the action of double acting cylinders. The
seal spacer assembly forms individual
annular chambers opposite each valve
port and the grooved spool either closes or
allows flow between adjacent chambers,
hence the position of the spool determines
which ports are open or closed.
The spool is moved by way of a manually
or mechanically operated mechanism
normally against a return spring.
Operation may be by application or
removal of a pilot air supply acting as a
pilot piston. This form of control is utilized
for electrical actuation where integral
solenoid valves control the pilot air supply.
FIGURE 4
4 PRODUCT REPAIR AND SERVICE
4.1 Inspection of this product shall be
carried out by suitably trained personnel
in accordance with the applicable code
of practice such as EN60079-17 or
IEC 60079-17.
4.2 In the event of any repairs that may be
required such tasks must be carried out
by suitably trained/competent personnel
in accordance with the applicable code
of practice such as EN60079-19 or IEC
60079-19.
4.3 The certification of this product has
been approved based on the material of
construction as per the drawings listed
in the schedule within this certificate.
Any replacement parts that are not made
in accordance to the listed drawing will
invalidate the approval / certification.
4.4 Replacement parts must be purchased
through Westlock Controls or via an
approved Westlock Controls distributor.
3.10 The 2600 series valve control monitor has
the option for position feedback by the
means of a resistive signal (RS) or current
signal (CS) transmitter.
The RS transmitter electrical ratings are -
1 K Ohms (standard) or 5 K or 10 K Ohms
(optional).
The CS transmitter electrical ratings are -
current loop 4-20mA at 18 to 24V DC.
See separate installation & operating
instructions VCIOM-04112
3.11 Before replacing the enclosure cover,
ensure that both of the housing and cover
threads are clean and undamaged. Screw
the cover onto the housing ensuring that
it is not cross threaded and turns freely.
Continue tightening the cover until metal
to metal condition is achieved between the
bottom edge of the cover and the housing
surface.
Lock the cover as follows:
Using a 3mm A/F Allen key / wrench, rotate
the Jack screw in an anti-clockwise direction
until sufficient pressure has been applied to
the bottom edge of the cover to prevent the
cover from being removed by hand.

2
12
4
12
A
B
1
3
3
4
3
5
5
VCIOM-05081 Page 6 of 8Copyright © Westlock. All rights reserved
2600 SERIES ATEX AND IECEx CERTIFIED
InstallatIon and operatIng InstructIons
Spring return valve
Description of operation:
Solenoid de-energized - air flows from Outlet
Port 2 to Exhaust Port 3.
Solenoid energized - air flows from Inlet Port 1
to Outlet Port 2.
Spring return valve
Description of operation:
Solenoid de-energized - air flows from Inlet Port
1 to Outlet Port 2 and exhausts from Port 4 to
Port 5.
Solenoid energized - air flows from Inlet Port 1 to
Outlet Port 4 and exhausts from Port 2 to Port 3.
Dual coil valve
Description of operation:
Coil B de-energized - air flows from Inlet Port 1 to
Outlet Port 2 and exhausts from Port 4 to Port 5.
Coil A energized - air flows from Inlet Port 1 to
Outlet Port 4 and exhausts from Port 2 to Port 3.
FIGURE 5
Air line designation, ¼” NPT or BSP air ports for inlet, outlet and exhaust on 1.1 Cvvalves.
The 3.5 Cvvalve (optional) has ½" NPT or BSP ports.
5.1.5(Air line) Installation considerations
Air mains and lines should be large
enough to avoid excessive pressure
loss under conditions of maximum flow.
Air lines should be installed with as
few restrictions as possible if the cost
of compressed air is to be kept to a
minimum. Sharp turns in piping should
be avoided for more efficient air flow and
economical air power. It is advisable to
pitch the mains in the direction of air flow
so that both gravity and air flow will carry
the water to traps or water legs located at
frequent intervals.
To help in preventing condensed moisture
from reaching the point of usage, down
pipes should never be taken directly
from the bottom of air pipes or mains.
Connection should be made at the top of the
main and a long radius return bend used.
5.1.2.5. D/C - Dual coil option
5 way valves are available with a coil/pilot
valve on each end of the Falcon II valve,
coil ‘A’ and coil ‘B’.
When coil ‘A’ is energized the valve will
shift. If coil ‘A’ is then de-energized, the
valve will remain in this position.
The valve will not return to the original
state until coil ‘A’ is de-energized and coil
‘B’ is energized.
The process is the same for coil ‘B’.
Note: For dual coil valves.
The valve may be in either position upon
installation. Refer to the air flow diagrams
and energize the appropriate coil (with air)
to reset valve to the desired position.
Dual coil valves require both an electrical
signal and air pressure to operate.
See air flow diagram for air pressure
requirements.
If either or both inputs are lost the valve
will remain in it’s current position.
Both coils should never be energized
simultaneously.
5.1.3Specifications
Operating pressure: 45 - 140psig /
3.0 - 10bar
Operating media: Non lubricated
filtered air to
20 microns
5.1.4Field wiring
Complete the electrical wiring in
accordance with national and local
electrical requirements.
The ground wire should be secure under the
earth screw. Check all screws for tightness.
5.1.6Air flow
Pipe sizes are normally determined on
semi empirical lines, basis for selection
being an acceptable pressure drop e.g. not
more than 10% of the applied pressure. In
sizing pipes, consideration should be given
to likely future demands, as a system
will be inefficient if the demand outgrows
the supply. It is always better to over size
mains as this will reduce air velocity and
make water separation more effective.

VCIOM-05081
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Page 7 of 8Copyright © Westlock. All rights reserved
2600 SERIES ATEX AND IECEx CERTIFIED
InstallatIon and operatIng InstructIons
5.1.7Air service equipment
The importance of proper filtration
(20 micron) and lubrication of the air
supply to pneumatic equipment can
never be over-emphasized as a means
of decreasing friction and preventing
corrosion and wear due to moisture and
abrasive solids being present in the air
supply.
At higher pressures than recommended,
pneumatic equipment can wear
excessively with no significant increase
in output and compressed air is
consequently wasted.
There is much to be gained, therefore,
from providing pneumatic equipment with
serviced air by including suitable air line
filters, pressure regulators and lubricants
in the installation.
5.1.8Tubes and fittings
The use of copper, stainless steel, nylon
or polyethylene tube is recommended
for piping up air circuits and equipment.
As a general rule, pipe threaded fittings
should not be assembled to a specific
torque because the torque required
for a reliable joint varies with thread
quality, port and fitting materials,
sealant used, and other factors.
Maintenance
Routine maintenance is usually confined to the
periodic replenishment of Dow Corning 111
lubricant or equivalent to spool and spring.
The suggested method of assembling
pipe threaded connections is to assemble
them finger tight and then wrench tighten
further to a specified number of turns
from finger tight.
The assembly procedure given below is
for reference only, the fitting should not be
over tightened for this will lead to distortion
and most likely, complete valve failure.
1. Inspect port and connectors to ensure
that the threads on both are free of dirt,
burrs and excessive nicks.
2. Apply sealant/lubricant or PTFE tape to
the male pipe threads. With any sealant
tape, the first one or two threads should
be left uncovered to avoid system
contamination.
3. Screw the connector into the port to the
finger tight position.
4.
Wrench tighten the connector
approximately 1-2 turns (to seal) from
finger tight. Again this is only reference -
the fitting should NOT be over tightened.
FIGURE 6
Exploded assembly of 3 and 5 way 1.1CvFalcon II PARTS LIST
No. Part name
1. Pilot piston end cap
2. O-ring
3. Pilot piston
4. O-ring
5. Valve body
6. O-ring
7. O-ring
8. Bush
9. Spacer
10. Bush
11. Pilot piston seal
12. Cap screws
13. O-ring
14. O-ring
15. Cap screws
16. Spring end cap
17. Tell-tale cover
18. Spring
19. Tell-tale pin
20. Spool

VCIOM-05081
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Page 8 of 8Copyright © Westlock. All rights reserved
2600 SERIES ATEX AND IECEx CERTIFIED
InstallatIon and operatIng InstructIons
Engineering document reference
These installation and operating instructions are based on the latest engineering update,
reference ECN#13045, and form part of the certification for the 2600 series. To ensure you
have the most recent version of this IOM, please check the document library on our website
(westlockcontrols.com) to ensure this document has the latest ECN number.
Translations
Where translated the copy is taken from the original English document VCIOM-05081-EN as
checked by the relevant notified certification body and therefore the original English document
will prevail. No rights or liability can be derived from any translation.
Previous documents
VCIOM-05081 replaces all previous installation and operating instructions for the 2600 series
including VCIOM-02677/02678/04123/04124 and TECHUK-16/16Q/43/43Q.
WARNING
This symbol warns the user of possible
danger. Failure to observe this warning
may lead to personal injury or death
and/or severe damage to equipment.
ATTENTION
This symbol identifies information about
operating the equipment in a particular
manner that may damage it or result
in a system failure. Failure to observe
this warning can lead to total failure of
the equipment or any other connected
equipment.
NOTE
This symbol draws attention to information
that is essential for understanding the
operation and/or features of the equipment.
FIGURE 7
Exploded assembly of 5 way 3.5 CvFalcon
PARTS LIST
No. Part name
1Valve body
2O-ring
3Spacer
4Ball
5Bonded seal
6O-ring
7Pilot end cap
8Pilot piston
9Pilot piston sleeve
10 Ball
11 Cap screws
12 O-ring
13 O-ring
14 O-ring
15 O-ring
16 Spring end cap
17 Bush
18 Spring
19 Cap screws