Westlock 1100 User manual

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WIRELESS VALVE MONITORING SYSTEM
WIRELESS DEVICE
OPERATING 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-461
Revision: 5
Prepared By: R. da Mata
Date: 03/2012
Drafting Work Order:
19909
ECN:
Reviewed By: xxxxx
Date: xxxxx
Approved By: xxxxx
Date: xxxxx
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
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www.westlockcontrols.com
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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
22 Chapman Way, Tunbridge Wells
Kent, England TN23EF
Phone: [phone] •Fax: [phone]
Email: [e-mail]
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: [e-mail]
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
Revision History
Document
Version
Date
Author
Changes
2
07/2011
Rogerio da Mata
First Draft
3
1/12/12
MKT
REPLACING/ADDING VIEWS
4
4/25/12
Rogerio/Mario
Main IOM split into 6 sections
5
5/05/12
Rogerio/Mario
Overall review and clean up
6
8/30/12
Rogerio
Overall review and clean up

WESTLOCK CONTROLS CORPORATION
280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
5/05/12 TECH-461/D.W.O. 19909 Page 3 of 24

WESTLOCK CONTROLS CORPORATION
280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
5/05/12 TECH-461/D.W.O. 19909 Page 4 of 24
TABLE OF CONTENTS
Revision History.................................................................................................................................. 2
TABLE OF CONTENTS ......................................................................................................................... 4
1Introduction ................................................................................................................................ 5
1.1 Scope of Manual............................................................................................................................................................. 5
1.2 Definitions, abbreviations, acronyms and terms................................................................................................. 5
1.3 Warnings............................................................................................................................................................................ 5
1.4 Product certifications and approvals....................................................................................................................... 6
1.4.1 Applicable Documents ............................................................................................................................. 6
1.5 FCC Compliance.............................................................................................................................................................. 6
1.6 Warranty Information ................................................................................................................................................... 7
1.7 System Principles of Operation................................................................................................................................. 8
1.7.1 Introduction.................................................................................................................................................. 8
1.7.2 Wireless Device (WD)................................................................................................................................ 9
1.7.3 Wireless Router (WR) ................................................................................................................................ 9
1.7.4 Wireless Gateway (WG) ............................................................................................................................ 9
1.7.5 Wireless Handheld (WH)........................................................................................................................10
1.7.6 Wireless Management System (WMS)..............................................................................................10
1.7.7 WMS Server................................................................................................................................................11
1.7.8 Connectivity Server..................................................................................................................................11
1.8 System Specifications..................................................................................................................................................11
2Wireless Device (WD) ............................................................................................................... 12
2.1.1 Wireless Device Overview......................................................................................................................12
2.1.2 Wireless Device LEDS and Indicators ................................................................................................12
2.1.3 WD Specifications ....................................................................................................................................13
2.1.4 WD Installation..........................................................................................................................................14
2.1.5 Powering Up and Shutting Down the WD ......................................................................................17
2.1.6 Configuration.............................................................................................................................................18
3WD Troubleshooting and maintenance................................................................................... 20
3.1.1 Device Does not Power Up ...................................................................................................................20
3.1.2 Device Is not Presented in the WMS.................................................................................................21
3.1.3 Device Presents Invalid Angle Readings ..........................................................................................21
3.1.4 Device Performs Continuous Resets (LEDs Constantly Flashing in Sequence) ..................21
3.1.5 WH/WD Communication Is Temporarily Suspended..................................................................22
3.1.6 Representation on the WD Is Unusually Slow ...............................................................................22
3.1.7 WD Reacts but Does not Return an Acknowledgement to WH..............................................22
3.1.8 The WD Name or Setting Is not Displayed on the WMS...........................................................22
3.1.9 Valve Dynamics are not Shown in the WMS ..................................................................................23
3.1.10 WD Returns to WMS after Deletion from Table............................................................................23
3.1.11 Faulty WD Calibration Results .............................................................................................................23
3.1.12 WD Information is not Presented in HMI/PLC...............................................................................23
3.1.13 Battery Replacement ...............................................................................................................................24

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1 Introduction
1.1 Scope of Manual
This manual includes principles of operation, specifications, installation, setup, configuration,
operation, troubleshooting, and maintenance information on the Wireless Device (WD), the
heart of the Westlock Wireless Valve Monitoring System (WVMS).
1.2 Definitions, abbreviations, acronyms and terms
ACK –Acknowledgement Message
Wireless Gateway –An industrial computer running the WMS Server
WMS –Wireless Management System
EUI –Extended Unique Identifier
HMI –Human Machine Interface
WH –Wireless Handheld
WG –Wireless Gateway
WD –Wireless Device
WR –Wireless Router
OPC DA –OLE for Process Control Data Access
PLC –Programmable Logic Controller
Connectivity Server –a ruggedized industrial computer for I/O integration
SCADA –Supervisory Control and Data Acquisition
1.3 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.

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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.
Warranty
Westlock warrants that the Westlock Wireless Valve Monitoring System is free of defective
materials and faulty workmanship. If warranted goods are returned to Westlock during the
period of coverage, Westlock will repair or replace, at its option, without charge those items it
finds defective. The foregoing is buyer’s sole remedy and is in lieu of all other warranties,
expressed or implied, including those of merchantability and fitness for a particular purpose. In
no event shall Westlock be liable for consequential, special, or indirect damages. Additional
warranty information is provided in Chapter 1.6.
1.4 Product certifications and approvals
1.4.1 Applicable Documents
ATEX Directive (94/9/EC): the Westlock Wireless Valve Monitoring System complies with
the ATEX directives. The EC type examination certificates for the WD and the T/WR are
attached herein.
Electro Magnetic Compatibility (EMC) (2004/108/EC): the Westlock Wireless Valve
Monitoring System complies with the EMC directives.
Radio and Telecommunications Terminal Equipment Directive (R&TTE) (1999/S/EC): the
Westlock Wireless Valve Monitoring System complies with the EMC directives.
CE EMC marking: the Westlock Wireless Valve Monitoring System complies with the
European Union marking directives.
1.5 FCC Compliance
The Westlock Wireless Valve Monitoring System complies with Part 15 of FCC Rules and
other local regulations like IC/CE/RTTE/ANATEL. Operation is subject to the following two
conditions: (1) This device may not cause harmful interference and (2) this device must accept
any interference received, including interference that may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference in a residential installation. This equipment generates,
uses, and can radiate radiofrequency energy and, if not installed and used in accordance with
these instructions, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the user
will be required to correct the interference at his/her own expense.
Intentional or unintentional changes or modifications must not be made to the WD or other
components unless under the express consent of the party responsible for compliance. Any such
modifications could void the user’s authority to operate the equipment and will void the
manufacturer’s warranty.

1.6 Warranty Information
Westlock reserves the right to make corrections, modifications, enhancements, improvements,
and other changes to its products and services at any time and to discontinue any product or
service without notice. Customers should obtain the latest relevant information before placing
orders and should verify that such information is current and complete. All products are sold
subject to Westlock's terms and conditions of sale supplied at the time of order
acknowledgment.
Westlock warrants performance of its hardware products to the specifications applicable at the
time of sale in accordance with Westlock's standard warranty. Testing and other quality control
techniques are used to the extent Westlock deems necessary to support this warranty. Except
where mandated by government requirements, testing of all parameters of each product is not
necessarily performed.
Westlock assumes no liability for applications assistance or customer product design.
Customers are responsible for their products and applications using Westlock components. To
minimize the risks associated with customer products and applications, customers should
provide adequate design and operating safeguards.
Westlock does not warrant or represent that any license, either express or implied, is granted
under any Westlock patent right, copyright, mask work right, or other Westlock intellectual
property right relating to any combination, machine, or process in which Westlock products or
services are used. Information published by Westlock regarding third-party products or
services does not constitute a license from Westlock to use such products or services or a
warranty or endorsement thereof. Use of such information may require a license from a third
party under the patents or other intellectual property of the third party, or a license from
Westlock under the patents or other intellectual property of Westlock.
Resale of Westlock products or services with statements different from or beyond the
parameters stated by Westlock for that product or service voids all express and any implied
warranties for the associated Westlock product or service and is an unfair and deceptive
business practice. Westlock is not responsible or liable for any such statements.
All company and brand products and service names are trademarks or registered trademarks
of their respective holders.

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The equipment contains communication devices. Any changes or modifications made to the
equipment without the written consent of WESTLOCK, and its resellers or distributors, can
nullify the user's authority to operate this equipment.
The user assumes all risks associated with the use and handling of the equipment, and
specifically acknowledges that WESTLOCK, and its resellers or distributors, will not be liable for
any damages of any kind, including personal injury or property damages resulting from use of
the equipment.
1.7 System Principles of Operation
1.7.1 Introduction
The Westlock Wireless Valve Monitoring System, or Westlock WVMS, provides real-time
information about the status of valves. The data is fed directly into the customer’s control
system thereby reducing failure while increasing safety and yield. The WVMS 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 WVMS includes support for a wide range of standard interfaces, physical and
logical, that are common in the industry. This makes the WVMS, from the perspective of
connectivity, almost transparent for system designers and integrators, since they can easily
integrate the WVMS into any of the most widely-used system architectures in the process
industry.
The Westlock Wireless Valve Monitoring System has the following main functionalities:
Manual Valve Operation Monitoring: Many process valves are activated manually by
field operators who receive instructions from the control room. Such manual processes are
vulnerable to human error and can result in substantial damage and poor yield. The WVMS
provides the plant with an efficient, cost-effective solution to monitor installed devices.
Actuated Valve Operation Monitoring: Although actuated process valves are activated
remotely, many do not have any feedback on the operation and, in cases of actuation
failure, a false perception of the valve position may be reported. The WVMS complements
the actuated operation with a full monitoring feedback.
Actuated Valve Maintenance: Wear and tear of actuated valves can result in a broken
shaft (causing an excessively fast response), or in shaft deterioration that slows down the
valve's movement. The dynamic profile of actuated valves during transactions must
consistently remain within a pre-set range. Whenever these limits are breached, an alarm is
generated.
Partial Stroke Monitoring: Static valves that remain in the same position for long periods
of time may lose their operational flexibility. To facilitate periodic “instruction” of such a
valve to move, the Partial Stroke Test (PST) is initiated, either by the control system or
manually. Valve positioning monitoring allows such a PST to be recorded and stored for
audit and evidence.

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1.7.2 Wireless Device (WD)
A Westlock Wireless Device (WD) is bracket-mounted to any type of valve or actuator and –
using the standard wireless IEEE802.15.4/ZigBee Pro, 2.4 GHz protocol –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, the battery life of the WD is
above 10 years. A battery pack can be replaced in the field if allowed by local regulations.
The WD includes a shaft that is fastened to the valve’s stem through a special adapter. It
transfers the angle position of the stem to the WD. An internal WD sensor measures the
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 of the valve lever is sensed or every 15 minutes (configurable). The WD temperature,
WD battery status, and other WD housekeeping information are broadcast with every WD
message. Each WD message is transmitted with a real time stamp. In between transmissions the
WD is in sleep status to save battery power. The WD also includes a Low Frequency (LF)
receiver for receiving setting commands from the Wireless
Handheld and to commission, decommission, calibrate, and
setup the unit and to perform diagnostic procedures.
1.7.3 Wireless Router (WR)
Each WR collects and routes data from nearby WRs and up to
32 associated WDs, and transmits the information towards the
control center by hops from WR to WR.
The WR acts as a relay that retransmits the messages received
from a remote WR, through the ZigBee wireless network, until
they reach a WG (see below for details). Data transfer
redundancy and self-healing is assured by automatic routing of
the wireless devices through a mesh topology and providing
multiple WGs for each wireless network.
1.7.4 Wireless Gateway (WG)
The Wireless Gateway (WG) is the last-hop that transfers
collected data from WRs and WDs to the Wireless Management
System. Several WGs can be connected, via TCP/IP, to the
Wireless Management System (thus ensuring full redundancy
and avoiding a single point of failure).

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1.7.5 Wireless Handheld (WH)
The Wireless Handheld (WH) is a hand-held device that enables the field operator to
communicate with a selected field device (WD/WR/WG) using low frequency channel (LF)
and ZigBee. Such one-on-one communication provides the field operator a transportable and
effective control panel for independently perform various operation and maintenance tasks. The
WH delivers messages to operators, reports on performance and is used to support installations,
configuration and diagnostics.
1.7.6 Wireless Management System (WMS)
The Wireless Management System (WMS) is a software application that processes collected
data from WGs, monitors it, and delivers it to various typical clients at the process control
management system. Such clients may be in various levels of the process control from the high
level HMI and down to the line controllers (PLCs). The Wireless Management System supports
such typical clients and data/indication and uses generic interface converters to provide the
required interface accordingly.
Figure 1: Westlock Wireless Valve Monitoring System –Block Diagram

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1.7.7 WMS Server
The WMS Server is the central software server on the TCP/IP network. It maintains the
wireless network, performs data logging, and publishes sensor information to clients and to the
plant monitoring and control systems (PLC, SCADA, etc.)
1.7.7.1 WMS Clients
GUI Client: Provides a view of sensor data and network status and allows configuration
of remote sensors and alarms.
Connectivity Client: Forwards Wireless Device data and status to the third party PLC,
DCS and SCADA. Supported protocols are Modbus RTU, Modbus TCP and OPC DA.
1.7.8 Connectivity Server
The Connectivity Server is a ruggedized computer that supplies real-time data to PLCs/HMIs
that reside on the plants dedicated network. The Connectivity Server gathers relevant data from
the WDs and transfers it via MODBUS RTU/TCP and/or OPC DA real time to PLCs/HMIs.
The Connectivity Server is seamlessly situated on the WVMS between the WMS and WGs and
extracts the requested device information from the data stream. From this position in the
WVMS the Connectivity Server also acts as a redundant network manager –keeping the
WVMS alive in case of WMS unavailability.
1.8 System Specifications
The following table provides general system specifications.
Function
Explanation
Wireless Communication
Two way Radio –IEEE 802.15.4 –at 2.4 GHz.
Communication Protocol
ZigBee Pro version.
Message Hops
Up to 15 hops from WD to WR to WR till it reaches a WG.
Main function
Angle measurement of valve stem position.
Update Rate
WD transmits its status immediately when valve moved more
than 1.50 degrees or every 15 minutes (configurable).
Latency
Less than 0.1 sec in average (assuming one hop)
Interface to Existing
Process Control Systems
The Connectivity Server is designed to deliver data collected
from the process line to any typical client or format commonly
used in the traditional process control systems. This starts with
OPC for the HMI / SCADA systems and down to the valve
status report fed directly to the PLC in using the popular
MODBUS protocol.
Operating Temperature
-400 C to 800 C (WD/WR)
-400 C to 700 C (WG)
WD/WR/WG sealing
Typically IP66 grade (WD depends on enclosure)

2 Wireless Device (WD)
Before reading this chapter it is recommended to read this sequence of specific IOMs: WH,
WG/R, WMS. This will prepare you to easily understand the terminology, functions and
operations described hereafter.
2.1.1 Wireless Device Overview
Figure 2: Wireless Device Internal Antenna Mounted on Actuator
The Westlock Wireless Device (WD) is the sensing component of the Westlock Wireless Valve
Monitoring System. It is installed on top of a valve or actuator and consists of a stem attached
mechanically to the valve or actuator axle. The WD includes sensors that measure the angle
which corresponds to the opening status of the valve (in degrees and opening percentage). The
valve status is transmitted by an internal bi-directional transceiver that is based on the standard
ZigBee Pro protocol. A dedicated Low Frequency (LF) receiver, in the WD, supports advanced
maintenance, calibration, and provisioning procedures by the Wireless Handheld (WH).
The WD provides real-time information about a valve’s status directly into the control system
thereby reducing failure and risk while increasing safety and yield.
2.1.2 Wireless Device LEDS and Indicators
The WD has 4 internal LEDs for diagnostic. The LEDs are visible by removing the cover or
beacon or through the transparent cover, as shown in the following picture:

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LED
Color
Description
TX
Green
Indicates ZigBee transmission is taking place.
CLOSE
Red
Indicates that the valve is not fully open.
OPEN
Green
Indicates that the valve is not fully closed.
ONLINE
Amber
Indicates that the WD is registered on the network and has a
WG recipient address.
During special operations such as: ON, OFF, calibrate and LF commands from the Handheld
(WH), a flashing sequence of LEDs is activated. (Online Open Close).
All LEDs' blink every 30 seconds (configurable by WMS between 3 and 100 seconds) to
indicate that is alive.
The green Tx LED blinks every transmission (15 minutes for housekeeping, configurable).
Additionally, at every change in the valve's position > 1.5 deg (angle):
oOPEN green LED blinks if fully open.
oOPEN and CLOSE LEDs blink for a “partially open” valve.
oOPEN and CLOSE LEDs stay off for an “undefined position” of the valve.
oCLOSE red LED blinks if fully closed.
2.1.3 WD Specifications
The specifications for the WD are provided in the following table.
Feature
Explanation
Wireless Communication (RF)
Mode
Two way Radio –IEEE 802.15.4 –2006 at 2.4 GHz.
Communication
Protocol
ZigBee Pro
WD max Tx Power
+3dBm, adjustable
WD Antenna
Internal +2 dBi peak. Optional external antenna F-SMA connector
(WD mounted or remote)
Communication range
WD to WG/WR
Open space: about 70m
Indoors at obstructed environment: about 25 m.
Latency
Less than 0.1 sec in average (assuming one hop)
Approach
Measurement
Angle of measurement of valve stem position.
Update Rate
Transmits its status immediately when valve has moved more than
1.50 degrees or every 15 minutes (configurable).
Sense Movement
Duration
Between 30 msec to 10 minutes (user selectable in discrete steps)
Sector
Quarter turn: -10.0 to +100.0 degrees
Resolution
0.10 degrees
Accuracy
±1.0 degrees

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Feature
Explanation
Message timing
Each message is sent by the WD with a real time stamp.
Low Frequency (LF)
Characteristics
125kHz (3 channels): Short range receiver continuously open,
even when WD is turned OFF: WD on/off, calibration,
identification, commissioning, test, etc.
Sensitivity
~3 mV each channel
Data Rate
1,366 bps
Modulation
OOK Manchester
LF Range (with WH)
~10 cm to 1 meter
General
Additional WD Data
WD internal temperature, battery voltage and unit's house-keeping
parameters.
Battery
A battery pack containing 4 Lithium ½ AA batteries. Field
replaceable where allowed by local regulations.
Battery Life
10 years under nominal conditions: four valve position changes
per hour and 20 millisecond sampling rate.
Valve Transition
Measurement
(optional)
After 1.50 degree move of valve, WD collects up to 64 readings of
valve position every 5 ms up to 9.8 sec (user selectable in discrete
steps) and all readings transmitted as a packet.
WD software upgrade
Both ZigBee Pro stack and MCU application can be upgraded
through the ZigBee link (Download Over Radio).
Case Material
Internal canister made of clear Polycarbonate
Operating
Temperature
-40C to +80C
Sealing rating
Depends on enclosure
2.1.4 WD Installation
The Westlock Wireless Device can be mounted on operating installed valves using an
appropriate bracket. Each valve type requires a unique mechanical design for the specific
bracket and Westlock has a large installed base and extensive experience manufacturing and
customizing such brackets. During site survey, Westlock determines the type of brackets
required for the installed valves on the process line.
Most brackets consist of two parts. One part connects the fixed part of the WD to the fixed part
of the valve, and the other connects the rotating part of the WD to the rotating part of the valve
(stem/shaft). Actuators with a NAMUR interface usually do not require the rotating part.
Specific installation instructions are provide in accordance with the provided WD brackets.

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The WD has an effective valve position (angle) measurement range of about 110º. On the stem
of the WD, an axle spline indicates the position of the stem (valve). On the bottom of each WD
there are two etched marks indicting a range of 90º. This is the effective motion zone of the
WD's stem to measure the position of the quarter turn.
To avoid erroneous behavior, when installing the WD on a quarter turn valve or on an actuator
verify that the axle spline is always positioned between the two etched lines (the motion zone).
All WDs are factory calibrated such that the motion zone of the position measurement range is
centered. Do not remove the lower PCB from its casing, or factory calibration may be lost.
1. When installing the WD on a quarter turn valve or actuator, verify that the axle spline is
always positioned in the range between the two etched marks indicating the motion zone.
2. Perform the calibration procedures in order to ensure that the relative positions of the WD
and the valve are correct.
3. After mounting the WD on a valve or an actuator, calibrate the WD to set the open and
closed boundaries of the valve/actuator. Calibration is performed by the WH
communicating with the WD (refer to specific WH IOM). This process must be performed
locally using the WH via LF. This ensures the accuracy of the configuration.
If installation is performed on an active line, partial calibration can also be implemented. When
either the OPEN or CLOSED angle is set, the WD will automatically suggest the corresponding
other angle as 90 degrees away. To achieve partial calibration, reset previous calibration angles
prior to setting the current angle (RESET CAL function by WH).
The WD can also report a custom valve angle which has been preset in the process line to
facilitate a position report which is defined as CUSTOM. This third state provides the user
with the ability to return to a predefined setting for a particular valve. For example, the user sets
the valve to a capacity setting which will be reported upon by the WD to the WH and/or WMS
when the WD is within the tolerance values of the Custom state. This angle is always measured
from the 0 angle, regardless of valve angle notation (open or closed). The CUSTOM angle can
be set either on the WH (CAL > Set Custom by WH) or using the WMS.

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WD must be powered on before calibration can take effect.
Figure 3 - WD antenna pattern
The WD should be installed, when possible, at least 1 m from the ground and 0.5 m from any
vertical surface.

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2.1.5 Powering Up and Shutting Down the WD
The WD is delivered in a shutdown state for safety reasons and to save battery. While in this
state, the motion sensing capabilities and the wireless radio are shutdown, and the device is
ready to receive the LF command to power up and join a wireless ZigBee network.
1. To power up and join the device to a wireless network that has already been formed by
a WG, use the WH as described in the specific WH IOM sending the JOIN (or JOIN
ALL) command to the WD.
When the WD powers-up, a distinct flashing sequence of the LEDs is visible. The operation
normally takes a few seconds. During this sequence, the WD validates that the battery has
sufficient power for the initial process. If this is not the case, the power-up sequence might take
longer (during which the LEDs are still flashing), until the power levels are stable.
If the power on sequence takes longer than 4 minutes, replace the battery pack. If power up
does not complete, contact your local distributor. For additional information, refer to
Troubleshooting chapter.

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Once powered up, the WD will automatically join the network that the WH is joined to (see
more information in the WH specific IOM). If the network does not exist (or the WH is not
joined to any network) the WD will look for any other ZigBee Pro network that conforms to the
set of configuration passed by the WH. If no such network exists, the WD will keep trying to
join the same network at slower intervals until the network is found / formed or until the WD is
shutdown.
2. To shutdown the WD, use the WH as described in the specific WH IOM and send the
LEAVE (or LEAVE ALL) command. Once the WD receives the LEAVE command, it will
flash its LEDs send an acknowledgement to the WH and shutdown.
The shutdown sequence normally takes a few seconds. However, if the WD has messages to
send, it will keep sending these messages until completed or until 60 seconds have passed.
Then a second sequence of LED flashing will occur and the WD will leave the network and
shutdown. When shutdown, movement of the WD stem is not sensed by the WD and the LEDs
do not blink as a consequence to the movement.
The WMS and Connectivity Server are aware of these events and reflect the change in the
database. When the WD powers up and joins the network, it also appears in the WMS tabular
display (if not already present) and becomes ONLINE. When shutdown, the WD informs the
WMS (and Connectivity Server) of this event prior to shutting down, and the WMS presents
the WD as offline and SHUTDOWN.
2.1.6 Configuration
2.1.6.1 Introduction
As part of the installation process, the Wireless Devices are configured using either the WMS
(remotely) or the WH (locally). The following information is installed on the WD:
Extended ID information
Thresholds
Setting operational parameters
Calibration
2.1.6.2 Extended ID information
A Network Name (an alias of eight alphanumeric characters) is set via the WH. The WD and
WG/WR remember this name and this prevents a device from accidentally joining another
network in its vicinity.
The unique factory set ID is the MAC address. In addition to that user friendly IDs –more
easily remembered and understood by technicians –such as the valve name and serial number
can be used. To manually select a specific device, for a one-on-one LF session with the WH,
perform the following options:

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1. Locate the label near the WD battery pack with its unique 6-characters ZigBee MAC
address, like ZB: 174E6D.
2. On the WH, in the WD mode (selected using Device NetKey button), type in the MAC
address by using the Up/Down keys to select the character and the Tab key to select the
character location.
3. When done press Enter. The selected device will open a one-on-one LF communication
session with the WH Thresholds
The WD continuously measures various status parameters such as the dynamic movement of
the valve, room temperature and battery voltage. These measurable parameters are normally
limited to a threshold or range.
Exceeding a threshold generates an alarm in the WD which is delivered with the normal status
message to the WMS (and from there to the HMI/PLC). These thresholds and/or ranges are
configurable as part of the system configuration using the WMS application client.
2.1.6.3 Setting Operational Parameters
Operational parameters set by the WMS and WH define the behavior of the WD. For example:
How often the WD should transmit a keep-alive signal to WMS.
How often the WD should poll for pending messages (receive from the WMS).
How often the WD should blink the LEDs.
How fast the WD stem should be sampled for valve dynamics (signature).
Changing operational parameters can affect the battery life of the WD and/or the sensing
capabilities of the motion sensor.
2.1.6.4 Calibration
After mounting the WD on a valve or an actuator, the WD should be calibrated to set the open
and closed boundaries of the valve/actuator. This process must be performed locally using the
WH via LF. This ensures the accuracy of the configuration. Calibration, from the WH point of
view, is discussed in the WH specific IOM.
In order to achieve a successful calibration of the WD on the installed valve/actuator, follow
these simple steps:
1. Verify that the WD is powered and joined to the same network of the WH.
2. Open an LF session between the WD and the WH.

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3. Navigate to the CAL menu in the WH and key in the following commands. Make sure that
each command is acknowledged before moving to the next one.
oRemove previous calibration using RESET CAL.
oWhere applicable make sure the valve is completely open and set the open angle using
SET OPEN option.
oWhere applicable make sure the valve is completely closed and set the closed angle
using SET CLOSE option.
oIf required set the custom angle using SET CUSTOM option.
oApply the new settings using APPLY option.
The order of calibration SET OPEN before SET CLOSED or vice versa is not important.
Perform the above steps at your convenience.
The WD can also be run from default values or partial calibration. This is pertinent when an
installation is performed on a “hot line”. A complete calibration process can be completed at a
later time (after the valve has changed its state).
When completing a partial calibration, do not send RESET CAL, otherwise the previous
calibrated angle will be erased.
3 WD Troubleshooting and maintenance
3.1.1 Device Does not Power Up
1. Verify that the device has an installed battery pack.
2. Using the WH, send a Join/Join All command to the WDs from a distance of 10 cm to 1 m.
Sending a command when the WH is too close (< 10 cm) to the WD will saturate the WD
receivers and the transaction will be aborted. Keep the WH between 10 cm and 1 m.
3. When a successful transaction occurs, the LEDs flash in sequence for a few seconds. If
necessary remove the WD cover to see the LEDs.