Westlock 793 User instructions

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
17/09/2012 TECHUK-55 REV 1 1 of 14
The following document details the installation, operation, setting and maintenance
instructions for the Westlock Controls Ltd -793 Rotary Pneumatic Positioner –
introduced 07/2012.
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.
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.
This symbol draws attention to information that is essential for understanding the operation
and/or features of the equipment.
Contents
1/. Mounting arrangement
2/. Pneumatic connection
3/. Setting procedure (Calibration)
4/. Field wiring (where applicable)
5/. Switch/cam setting (where applicable)
6/. Gauge block assembly
7/. Overall dimension detail
8/. Technical data
9/. Spares list

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
17/09/2012 TECHUK-55 REV 1 2 of 14
1.0 Mounting Instructions.
All positioners are designed for direct mounting to actuator and NAMUR
mounting (using appropriate Namur bracket not supplied).
See figures 1 and 2 below.
Figure 1. Direct mounting to actuator
Figure 2. Mounting using Namur bracket
The M5 internal screws in this configuration are essential as they ‘cap off’ or
seal the Housing.

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
17/09/2012 TECHUK-55 REV 1 3 of 14
1.1 For standard direct action operation (increasing signal to open actuator) ensure
that the actuator is in the CLOSED position (fully clockwise) and that the flats on
the top of the positioner shaft are at right angles to the longitudinal axis of the
actuator.
For reverse action (increasing signal to close actuator) ensure that the actuator is
in the OPEN position (fully anti-clockwise) and that the flats on the top of the
positioner shaft are parallel to the longitudinal axis of the actuator.
1.2 Before mounting the 793 unit it will be necessary to remove the top cover. To do
this, completely loosen the 4off M5 socket cap head captive screws in each
corner and remove the cover by lifting vertically. Keep the cover safe taking care
not to damage the seal detail.
1.3 Fit the positioner on the top face of the actuator according to figure 1 or 2 above.
The longitudinal axis of the positioner should be parallel to the actuator cylinder
axis. Tighten the internal fixing or blanking screws to a torque value of 18 to 22
lb. Ins.
1.4 Ensure that the feedback cam in the positioner is correctly fitted with the correct
range profile bearing against the feedback arm roller. (Positioners are stocked to
suit 3 –15 psig and direct action). For direct action, ensure that anti-clockwise
rotation of the positioner shaft, when viewed from above, will cause the cam to
compress the spring.
For reverse operation ensure that clockwise rotation of the positioner shaft, when
viewed from above, will cause the cam to compress the spring.

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
17/09/2012 TECHUK-55 REV 1 4 of 14
2.0 Pneumatic connection
2.1 Connect the air ports as shown in Fig 3 for direct operation and in Fig 4 for
reverse operation.

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
17/09/2012 TECHUK-55 REV 1 5 of 14
3.0 Setting Procedure
The positioner is pre-set for direct acting prior to leaving the factory. If re-adjustment
is necessary to suit a specific actuator, proceed using the following instructions.
With the positioner correctly mounted to the actuator, as per fig 1 or 2, and with cover
removed, connect the air supply, signal and actuator piping to the positioner as
shown in Figs 3 & 4.
3.1 Apply a signal pressure of approximately 9 psig and gradually reduce this to 3
psig. If the actuator just reaches the clockwise limit of rotation as the signal
reaches 3 psig, no adjustment is necessary.
3.2 If the actuator does not reach the clockwise limit of rotationat 3 psig, with
reference to Fig 5, loosen the locknut and turn the zero-adjusting nut 1/6 of a
turn clockwise, when viewed from above. Repeat until zero is correctly
achieved.
3.3 If the actuator reaches the clockwise limit of rotation before the signal reaches 3
psig, turn the zero-adjusting nut 1/6 of a turn anti-clockwise, when viewed from
above, and repeat until zero is correctly achieved.
3.4 Gradually increase the signal to 15 psig. If the actuator just reaches the
counter-clockwise limit of rotation as the signal reaches 15 psig, then no
adjustment is necessary.
3.5 If the actuator does not reach the counter-clockwise limit of rotation at 15 psig,
this indicates that the spring rate is too high. Loosen the hex socket set screw in
the range adjustment collar (see fig 5), hold the collar stationary using a hex
wrench (Allen key) and turn the spring slightly clockwise. The zero adjusting nut
must now be used to achieve full counter-clockwise rotation
3.6 Conversely, if the actuator reached the counter-clockwise limit of rotation before
15 psig, turn the spring slightly anti-clockwise with respect to the range
adjustment collar. Again, re-adjust the zero adjusting nut to achieve full counter-
clockwise limit of rotation. The zero and range settings are highly interactive
and steps 3.2 to 3.7 must be repeated until zero and span are acceptable.
Note; In steps 3.2to 3.7, clockwise and anti-clockwise rotations are viewed from
the adjusting nut end of the spring.

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
17/09/2012 TECHUK-55 REV 1 6 of 14
After completing the setting procedure, ensure that the hex skt set screw and the
locknut are re-tightened. (Hold zero adjusting nut so that it will not move as locknut is
tightened).

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
17/09/2012 TECHUK-55 REV 1 7 of 14
4.0 Field Wiring (when switches are present).
4.1 The terminal strip base has been designed to offer easy access for wire
termination to the terminal strip.
4.2 It is not essential to remove the terminal strip to connect the field wiring, but if
required, first remove the terminal strip retaining screw and keep safe as this
will be required to secure the terminal strip when complete.
4.3 Lift the terminal strip evenly off of the two base pins and terminate the wiring in
accordance with the wiring diagram which is located on the underside of the
cover.
4.4Reinstall by positioning the terminal strip over the two base pins and pressing
evenly in the direction of the pins.
4.5 Secure with the retaining screw removed in step 4.2.
Switch/sensor options;
Mechanical Switch –SPDT Form C.
Electrical rating –24, 48, 110 & 240 VAC / 15Amps, 24 VDC / 5 Amps,
48 VDC / 2.5 Amps.

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
17/09/2012 TECHUK-55 REV 1 8 of 14
Alternative Inductive Proximity Sensors.
P&F - NJ2-V3-N, NBB3-V3-Z4, NBB2-V3-E2
IFM - IS5026, IS5001, IS0003, IS5003, NS5002
Turck -Bi2-Q10S-AP6X, Bi2-Q10S-YOX
Telemecanique -XS7-H10PA340.
Wired as follows;
Mechanical V3 Microswitch
Inductive Proximity Sensor

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
17/09/2012 TECHUK-55 REV 1 9 of 14
5.0 Switch cam setting;(See Fig 6).
Notes; Either switch can be designated “open” or “closed”.
To determine if switch has been activated an electrical continuity tester is
recommended.
For inductive proximity switches, the appropriate power supply and measuring
instrument will be required to sense activation. See switch product literature for
recommendations.
5.1Ensure actuator/valve is in the fully clockwise position. Lift the bottom cam and
rotate clockwise until switch/sensor is activated and then release. The spring
will push the cam back onto the splined shaft.
5.2 Operate the actuator to the opposite extreme, push down on the top cam and
turn counter-clockwise until the upper switch/sensor is activated.
5.3 Operate the actuator from one extreme to the other several times to ensure
that the switches/sensors activate correctly.
FIG 6

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
516279
17/09/2012 TECHUK-55 REV 1 10 of 14
6.0 Gauge Block assembly -Retrofit or connection instructions
See Fig 6
6.1 Remove any fittings that currently occupy the positions shown in
diagram, namely: -pressure gauge x 3, supply, exhaust and actuator
“open” and “closed” ports.
6.2 With all appropriate surfaces clean and free from any damage, position
the two ‘o’ rings (item 8) on gauge manifold block (item 1) before fitting
block to existing valve block and secure using two M5 x 30 long screws
(item 4).
6.3 Reconnect pneumatic lines using new elbows (item 5) and tube (item 7)
and fit gauges (items 2 & 3) as shown with due regard to the notes
below.
Notes;
a. During installation item 6 –Dust caps, quantity 4, are to be removed and
discarded.
b. Ensure when fitting item 5 –Elbow, that the ‘o’ ring supplied with the fitting
is present.
c. The tapered thread on the gauges (items 2 & 3) should be sealed into
respective blocks using a proprietary sealant such as PTFE tape or similar.

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
516279
17/09/2012 TECHUK-55 REV 1 11 of 14
Gauge Block assembly - when fitted (or retrofitted or kit) - Fig 6

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
516279
17/09/2012 TECHUK-55 REV 1 12 of 14
Overall dimension detail

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
516279
17/09/2012 TECHUK-55 REV 1 13 of 14
Technical data
Input signal
Single range 3 –15 psi (0.2 – 1.0 bar) standard
Split range 3 –9 psi (0.2 –0.6 bar)
9 –15 psi (0.6 –1.0 bar).
Cam characteristics Linear
(Standard) Curve 1, range: 3 –15 psi = 90°
(Opt) Curve 2, range: 3 –9 psi = 65°
(Opt) Curve 2, range: 9 –15 psi = 65°
(Opt) Curve 3, range: 3 –15 psi = 65°
Other characteristics on request
Supply
Media Comp air or inert gas, dust free,
oil free with 5 micron inlet filter.
Supply pressure 30 –100 psi (150 psi max)
2 –8 bar (10 bar max)
Air consumption 0.6 cfm in balanced condition
With 60 psi (4 bar) supply.
Environmental
Environmental Temp -5° to +160°F (-20° to +70°C).
Mounting and connections
Mounting position Any orientation. No limits.
Mounting kit Direct or Namur
Air connections Supply and output G1/4. (BSPP)
Signal G1/8 (BSPP)
Materials of construction
Housing Anodised & electrostatic powder
coated aluminium alloy
Diaphragm Nitrile rubber
Valve spool Stainless steel
Cover Anodised & electrostatic powder
coated aluminium alloy
Mass
4 lbs (1.85 kg)
Options
Gauges 1 x Signal air 0 –30psi (0 – 2 bar)
2 x Supply air 0 –150psi (0 –8 bar)
Limit switches See switch section (above)

Installation, Operating & Setting Instructions.
Westlock 793 Rotary Pneumatic Positioner
With SPDT V3 Microswitches OR V3 Inductive Proximity Sensors
WESTLOCK CONTROLS LTD
22 CHAPMAN WAY, TUNBRIDGE WELLS, KENT, TN2 3EF, ENGLAND. TEL: [phone]. FAX: [phone]
516279
17/09/2012 TECHUK-55 REV 1 14 of 14
793 Positioner Spares List.