Westlock 2200 User manual

2809 II 2GD
TECH-552-ENrA
Installation and operating instructions for Westlock 2200 series valve position (AccuTrak) and control
(Quantum) monitors with mechanical switches, inductive proximity sensors or Magnum proximity switches
2200 SERIES ATEX AND IEC Ex CERTIFIED
INSTALLATION AND OPERATING INSTRUCTIONS
Copyright © Westlock Controls. All rights reserved
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 materials 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
IEC Ex ETL 17.0008X
ITS 12 ATEX 17472X
Ex db IIB +H2 T* Gb Tamb -*°C to +*°C
Ex tb IIIC T*°C Db Tamb -*°C to +*°C IP6X
Flat cover -20°C to +85°C (T4); -20°C to +75°C (T5); -20°C to +60°C (T6)
Beacon cover -30°C to +85°C (T4); -30°C to +75°C (T5); -30°C to +60°C (T6)
Stainless steel -60°C to +85°C (T4); -60°C to +75°C (T5); -60°C to +60°C (T6)
When not fitted with a coil, the T4 upper ambient temperature may be +110°C
Environmental parameters: 11.6 psi (0.8 bar) to 15.9 psi (1.1 bar)
Air with normal oxygen content, typically 21%.
1 PRODUCT DESCRIPTION
The 2200 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.
To allow this product to be used with network
communication bus protocols, the 2200 series
enclosure can house various network modules.
The 2200 series enclosure is available in both
aluminum or stainless steel and comprises two
parts, a cover and housing. The cover has three
variations, flat cover, standard beacon cover or
a high cover to suit different applications.
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Warning
Electrostatic hazard, clean only with
damp cloth.
Page 1 of 8
AccuTrak 2200 position monitor Quantum 2200 control monitor
The housing can offer a nipple mounted
solenoid coil and up to four (without coils)
of the following conduit entries; M20 x 1.5p,
1/2 - 14 NPT, or 3/4 - 14 NPT cable entries for
connection to an external power source via
appropriate ATEX and IEC Ex certified cable
glands.
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.
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
Do not open when energized or when
an explosive atmosphere is present.

TECH-552-ENrA
2200 SERIES ATEX AND IEC Ex CERTIFIED
INSTALLATION AND OPERATING INSTRUCTIONS
FIGURE 1
FIGURE 2
Twist cover 45°
then lift straight up
Top cam
Push down, turn and
release
Bottom cam
Lift up, turn and
release
2 MOUNTING INSTRUCTIONS
2.1 Attach the mounting bracket and adaptor
(if required) to the unit housing and shaft
with the fasteners provided with the
mounting kit.
2.2 To ensure that the 2200 series unit is
mounted correctly, it may necessary to
stroke the actuator to the fully closed
position.
Warning
Before stroking the actuator
in any step of this mounting procedure,
please ensure that the process is safe to
do so and that all hands are kept away
from moving parts.
2.3 With the actuator in the correct position,
attach the 2200 series unit / bracket to the
actuator using the hardware provided in
the mounting kit.
Page 2 of 8Copyright © Westlock Controls. All rights reserved
2.4 To release the cover, loosen the cover
retaining screws. Twist the cover approx
45° and lift up. See Figure 1.
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. See 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. See 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.

TECH-552-ENrA
2200 SERIES ATEX AND IEC Ex CERTIFIED
INSTALLATION AND OPERATING INSTRUCTIONS
Conduit A
(single coil
or conduit)
Conduit B
(double coil -
optional)
Conduit C Conduit D
FIGURE 3
3.5 The certification applies to equipment
without cable glands. When mounting the
flameproof enclosure in the hazardous
area, only suitably rated IP66/67 ATEX and
IEC Ex certified flameproof glands must be
used.
3.6 All unused cable entries must be plugged
with a suitably rated IP66/67 ATEX and
IEC Ex certified blanking devices.
Page 3 of 8Copyright © Westlock Controls. All rights reserved
3 FIELD WIRING AND INSTALLATION
Warning
The 2200 series should always be
handled with care when the cover is
removed and wired to electrical power
source.
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.
3.3 The 2200 position monitor can offer up to
four of the following conduit entries:
2 x M20, 2 x 3/4 - 14 NPT, 4 x M20,
4 x 3/4 - 14 NPT and 2 x 1/2 - 14 NPT + 2 x
3/4 - 14 NPT (Front).
3.4 These entries are detailed on the product
identification label found on the product
cover. Please see Figure 3 for conduit
positions.

TECH-552-ENrA
2200 SERIES ATEX AND IEC Ex CERTIFIED
INSTALLATION AND OPERATING INSTRUCTIONS
Page 4 of 8Copyright © Westlock Controls. All rights reserved
3.7 The fourth digit designates the switch / sensor type. The following table details the most
common switch / sensor types together with their electrical ratings.
3.8 The fifth digit indicates the material of the enclosure, either A (aluminum) or S (stainless steel).
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 2200 series valve position monitor has the option for position feedback by the means of
a resistive signal (RS) or digital signal (DS).
The RS transmitter electrical ratings are - 1 K Ohms (standard) or 5 K Ohms (optional).
The DS transmitter electrical ratings are - current loop 4-20mA at 9 to 30V DC.
See separate installation and operating instructions TECH-541.
3.10 The 2200 series valve control monitor has the ability to connect to bus networks via NetPAC
modules. With the network options it may be possible to assemble other switches within the
enclosure (depending on enclosure cover variation).
3.10.1 NetPAC options.
Series code/Switch designation Electrical rating
22*3 GO switch 4 A - 120 V AC; 3 A - 24 V DC; 0.5 A - 125 V DC
22*5 Mechanical (SPDT) 15 A - 125 or 250 V AC; 6 A - 24 V DC
22*6 Mechanical (DPDT) 10 A - 125 or 250 V AC; 10 A - 28 V DC; 0.2 A - 125 V DC
22*7 Inductive proximity sensors
22*9 Magnum ratings 3 A - 120 V AC; 2 A - 24 V DC
3.6 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.
3.11 Digit 10 of the Westlock nomenclature signifies the coil voltage with the following voltage
and type available, 24V DC or 120, 240V AC or V DC except when NetPAC options are
specified, restricting coil voltage to 24 V DC only.
3.12 Before replacing the enclosure cover, ensure that both of the housing and cover flange
surfaces are clean and undamaged. Tighten the cover screws hand tight using a standard
6mm A/F Allen key ensuring there are no gaps.
NetPAC option I.O.M.
AS-I Actuator Sensor Interface TECH-316
Device Net TECH-309
Modbus TECH-214
Profibus DP TECH-488
Foundation Fieldbus* TECH-482
* Note that Foundation Fieldbus is not available with solenoid valve.

TECH-552-ENrA
2200 SERIES ATEX AND IEC Ex CERTIFIED
INSTALLATION AND OPERATING INSTRUCTIONS
Page 5 of 8Copyright © Westlock Controls. All rights reserved
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.
5.1.2Optional features - Falcon
5.1.2.1 Manual locking override
Manually depress palm button and rotate
clockwise for maintained condition, must
manually disengage to return to original
position.
5.1.2.2 Momentary override
Spring return momentary push type, must
hold in to actuate.
5 OPERATING AND MAINTENANCE
INSTRUCTIONS FOR FALCON SOLENOID
VALVES (QUANTUM CONTROL MONITORS
ONLY)
5.1 General description
5.1.1 The FalconV solenoid valve is an air piloted,
solenoid - operated directional control valve
incporporating a shaped spool packed with
elastomeric seals and moving through a
gated body. Valves are manufactured for 3- or
4-way operation. 3-way is normally used for
pilot control of the other relay valves or for the
operation of single acting cylinders. Valves
are available with flow rating of 1.4 C
v
in
aluminum and 316 stainless steel., as well as
with a flow rating of 4.3 C
v
in aluminum.
In a typical, normally closed, spring-return
FalconV valve, the spool controllling the
direction of air flow is moved by pressurized
pilot air acting on a piston when the coil
is energized. The spool is returned to the
normally closed position by a spring when
the coil is de-energized, and the piston is
vented internally to the body of the exhaust
port(s).
The spool may be manually moved to
control air flow direction with override
options. The pilot air supply is normally
tapped internally from the air supplied
to Inlet port 1 and power is supplied
separately to coils. External pilot options
allow a separate source of pilot air to be
plumbed directly to the valve pilot end cap
for applications in which the process is
supplied to port 1 is below the minimum
pilot pressure required by the FalconV
valve.

2
1
3
2
4
13
5
TECH-552-ENrA
2200 SERIES ATEX AND IEC Ex CERTIFIED
INSTALLATION AND OPERATING INSTRUCTIONS
Page 6 of 8Copyright © Westlock Controls. All rights reserved
5.1.3Specifications
Operating pressure: 30 - 120psig for single
coil valves; 20 - 120 psgi for dual coil valves.
Operating media: Lubricated or dry
air, filtered to 40 microns. Iff air line
lubricators are used, please see Appendix
for information on lubricating oils and
suggested brands.
5.1.4Field wiring
Complete the electrical wiring in
accordance with national and local electrical
requirements.
The ground wire should be secure under
the ground screw. Check all screws for
tightness.
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.
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.
FIGURE 5
Air line designation, 1/4 NPT or BSP air ports for inlet, outlet and exhaust on 1.4 Cvvalves.
The 4.3 Cvvalve (optional) has 1/2 NPT or BSP ports.
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.

TECH-552-ENrA
2200 SERIES ATEX AND IEC Ex CERTIFIED
INSTALLATION AND OPERATING INSTRUCTIONS
Page 7 of 8Copyright © Westlock Controls. All rights reserved
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. 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.
Maintenance
Routine maintenance is usually confined to
the periodic replenishment of Dow Corning III
lubricant or equivalent to spool and spring.

TECH-552-ENrA
2200 SERIES ATEX AND IEC Ex CERTIFIED
INSTALLATION AND OPERATING INSTRUCTIONS
Page 8 of 8Copyright © Westlock Controls. All rights reserved
Engineering document reference
These installation and operating instructions are based on the latest engineering update,
reference ECN# 13537 and EWR# 24042, and form part of the certification for the 2200 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 EWR number.
Translations
Where translated the copy is taken from the original English document TECH-552-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
TECH-552 replaces all previous installation and operating instructions for the 2200 series
including VCIOM-05080/02692/02676/04121/04122 and TECHUK-01/01Q/42/42Q.
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.