Westlock 1100 User manual

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 1 of 24
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
280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
5/05/12 TECH-461/D.W.O. 19909 Page 2 of 24
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

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 5 of 24
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.

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 6 of 24
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.

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 8 of 24
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.

WESTLOCK CONTROLS CORPORATION
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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).

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 10 of 24
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