Westlock ICOT 5400 User manual

WESTLOCK CONTROLS CORPORATION
280 N MIDLAND AVENUE STE 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
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ICOT 5400 AND ICOT 6400
(REVISION 4)
FOUNDATION FIELDBUS
INTELLIGENT VALVE POSITIONER
TECHNICAL MANUAL
IOM:
TECH538
Revision: -
Prepared By:
William Ferraz
Date:
02/27/2017
Drafting Work Order:
23160
ECN:
Reviewed By:
Frank Oster; Chris Irwin;
Leiser de Souza; Rogerio da
Mata; Raj Patel
Date:
03/23/2017
Approved By: Jason
Moorehead
Date:
11/01/2017
This document 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 N MIDLAND AVENUE STE 258, SADDLE BROOK, NJ 07663 TEL: [phone] FAX: [phone]
www.westlockcontrols.com
5/12/2017 TECH-538/D.W.O. 23160 Page 2 of 189
Revision History
Revision
12/05/2017
Initial release
Westlock Controls Locations
USA
Phone: [phone] •Fax: [phone]
Europe
Phone: [phone] •Fax: [phone]
South America
Phone: + 55 11 2588-1400 •Fax: + 55 11 2588-1410
Asia
Phone: [phone] •Fax: [phone]
Internet: http://www.westlockuk.com

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SUMMARY
1Introduction........................................................................................................................7
2Warnings..........................................................................................................................17
3Mechanical and Pneumatic Installation (Valve Setup) ......................................................18
4Power / Network and Field wiring – Direct Mount............................................................31
5Power / Network Field wiring – Remote Mount – ICoT 5400.............................................35
6Power /Network and Field wiring – Remote Mount – ICoT 6400 .......................................36
7Setting of switches on a rotary ICoT (5400 only) ...............................................................38
8System Integration and Operation....................................................................................39
9Maintenance and Repair ................................................................................................105
10 Appendix A – ICoT 6000 Series Local Display Menu Tree..............................................128
11 Appendix B – Foundation Fieldbus Network ................................................................129
12 Appendix C – Wiring in classified areas (ICoT 5400).....................................................179
13 Appendix D – Device Compatibility Relevant Data ...................................................... 181
14 Appendix E – Option to use a remote 4-20mA position sensor or potentiometer .........182
15 Appendix F - References .............................................................................................. 183
16 Appendix G – General Arrangement Drawings ............................................................184

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Table of Figures
Figure 1-1 – Valve Automation Key Elements.................................................................. 7
Figure 1-2 – Standard Flow Manifold – front view .......................................................... 11
Figure 1-3 – High Flow Manifold – front view ................................................................. 11
Figure 1-4 – ICoT Positioner connected to a pneumatic valve ....................................... 16
Figure 3-1 - Bracket / Coupler Mounting ........................................................................ 18
Figure 3-2 - Rotary – Direct – Condition 1...................................................................... 19
Figure 3-3 - Rotary – Direct – Condition 1...................................................................... 19
Figure 3-4 - Rotary – Direct – Condition 2...................................................................... 20
Figure 3-5 - Rotary – Direct – Condition 2...................................................................... 20
Figure 3-6 – Examples of a Final Assembly ................................................................... 21
Figure 3-7 - Rotary – Remote – Condition 1................................................................... 22
Figure 3-8 - Rotary – Remote – Condition 2................................................................... 23
Figure 3-9 – Linear Actuator Assembly Drawings – IcoT 6000 ...................................... 25
Figure 3-10 – Linear Actuator Assembly Drawings – IcoT 5000 .................................... 26
Figure 3-11 – Mounting the position sensor housing for the remote positioner on a linear
actuator .......................................................................................................................... 27
Figure 3-12 – ICoT 6000 and Standard Flow manifold designation ............................... 28
Figure 3-13 – ICoT 6000 and High Flow Manifold designation....................................... 28
Figure 3-14 - Cover Lock................................................................................................ 30
Figure 4-1 - ICoT 5400 Bus connection pins (Electrical connection).............................. 31
Figure 4-2 - ICoT 6400 Bus connection pins (Electrical connection).............................. 31
Figure 4-3 – Example of ICoT 6400 Foundation Fieldbus network topology .................. 32
Figure 4-4 – Example of ICoT 5400 Foundation Fieldbus network topology .................. 33
Figure 5-1 – Diagram of the connection between the ICoT 5400 positioner and the
remote mounted position sensor enclosure.................................................................... 35
Figure 6-1 – Terminal board mounting screws ............................................................... 36
Figure 6-2 – Lifting up the terminal board....................................................................... 36
Figure 6-3 – J3 & J4 connectors on the bottom of terminal board.................................. 37
Figure 6-4 – Diagram of the connection between the ICoT 6400 junction box and the
actuator mounted position sensor enclosure.................................................................. 37
Figure 7-1 – Switches use in the rotary ICoT5400 ......................................................... 38
Figure 8-1 – SW4 Detail (ICoT 5400) ............................................................................. 40
Figure 8-2 – SW2 Detail (ICoT 6400) ............................................................................ 40
Figure 8-3 – Westlock ICoT FF EDD Folder................................................................... 41
Figure 8-4 – ICoT FF registration page at FF................................................................. 42
Figure 8-5 – – ICoT AO block in fault state condition ..................................................... 47
Figure 8-6 – ICoT Local Display..................................................................................... 52
Figure 8-7 – Magnetic tool usage ................................................................................... 52
Figure 8-8 – Position of the ICoT6400 buttons............................................................... 52
Figure 8-9 – Position of the ICoT5400 keypad buttons .................................................. 53
Figure 8-10– Password screen ...................................................................................... 53
Figure 8-11 – Magnetic tool usage ................................................................................. 54
Figure 8-12 – ICoT5400 DIP switch SW4...................................................................... 55
Figure 8-13 – ICoT6400 DIP switch SW2...................................................................... 55
Figure 8-14 – Menu example ........................................................................................ 56
Figure 8-15 – LCD Menu Error Message example ........................................................ 56
Figure 8-16 – Main Menu Flow Chart ............................................................................ 56

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Figure 8-17 – Automatic calibration (ACAL) routine ....................................................... 57
Figure 8-18 – Manual calibration (MCAL) routine........................................................... 60
Figure 8-19 – Positioner’s parameters configuration Menu Tree - Part I........................ 64
Figure 8-20 – Positioner’s parameters configuration Menu Tree - Part II....................... 65
Figure 8-21 – Valve flow characteristics......................................................................... 66
Figure 8-22 – Valve Type shown on the left side of the local display ............................ 66
Figure 8-23 – Positioner’s parameters - stroke configuration routine ............................ 69
Figure 8-24 – Change address routine.......................................................................... 71
Figure 8-25 – Device Identification menu page of the ICoT ........................................... 72
Figure 8-26 – Configure/Setup menu available in the ICoT............................................ 73
Figure 8-27 – Device Diagnostics menu available in the ICoT ....................................... 74
Figure 8-28 – Process Variables menu available in the ICoT....................................... 74
Figure 8-29 – ICoT Methods .......................................................................................... 75
Figure 8-30 – Transducer block in manual mode message............................................ 76
Figure 8-31 - “ATTENTION” message............................................................................ 76
Figure 8-32 – “Calibration Enabled” message................................................................ 77
Figure 8-33 – “Auto Calibration Finished with success” message.................................. 77
Figure 8-34 – Characterization function ......................................................................... 81
Figure 8-35 – Valve flow characteristics......................................................................... 81
Figure 8-36 – Actuator Type function ............................................................................. 82
Figure 8-37 –Flop Enable function ................................................................................. 83
Figure 8-38 – Characterization function ......................................................................... 84
Figure 8-39 – Deviation Deadband function ................................................................... 85
Figure 8-40 – Final Value function ................................................................................ 86
Figure 8-41– Final Value Hi / Lo Cutoff function............................................................. 87
Figure 8-42 – STEP1 - Select the positioner .................................................................. 89
Figure 8-43 – STEP2 - Select the "Device Root Menu".................................................. 89
Figure 8-44 – STEP3 - Select the "Calibration".............................................................. 89
Figure 8-45 – STEP4 - Select "3-1 Positioner Calibration"............................................. 89
Figure 8-46 – STEP5 - Select "Auto Calibration" ........................................................... 89
Figure 8-47 – STEP6 - Follow the screen instructions ................................................... 89
Figure 8-48– ICoT FF on line in the NI Conf Tool .......................................................... 93
Figure 8-49 – AI-PID-AO Application Example on NI Conf Tool..................................... 95
Figure 8-50 – NI Configuration Tool Download Options ................................................. 95
Figure 8-51 – NI Conf Tool in Monitoring mode ............................................................. 96
Figure 8-52 – ICoT FF on line in the DeltaV Explorer tool.............................................. 97
Figure 8-53 – Place in standby command ...................................................................... 97
Figure 8-54 – ICoT in Standby mode ............................................................................. 98
Figure 8-55 – Commissioning ICoT in the P02 Network................................................. 98
Figure 8-56– Configure/Setup command to configure the Transducer block ................. 99
Figure 8-57– Minimum Configuration for the Transducer block...................................... 99
Figure 8-58 – Creating a Control Module ..................................................................... 100
Figure 8-59– Opening the new Control Module with the Control Studio tool ................ 100
Figure 8-60 – Application Example with Signal Generator Function Block on DeltaV
System ......................................................................................................................... 101
Figure 8-61 – Application Example with Signal Generator on DeltaV System.............. 101
Figure 8-62 – Download Button.................................................................................... 102
Figure 8-63 – Download Options.................................................................................. 103
Figure 8-64 – On-Line Button....................................................................................... 103

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Figure 8-65 – On-Line Mode in DeltaV System............................................................ 104
Figure 9-1– ICoT Local Display showing device in normal operation........................... 105
Figure 9-2 – Polarities of Magnetic Feedback Assemblies........................................... 109
Figure 9-3 – Stroke Length and Failure Direction......................................................... 109
Figure 9-4 – ICoT Firmware Version in Local Display .................................................. 111
Figure 9-5 – ICoT function block list shown by a FF Host system................................ 114
Figure 9-6 – Diagram for the positioner’s onboard filter replacement........................... 124
Figure 9-7– Diagram for the spool piece removal ........................................................ 125
Figure 9-8– Diagram for the air filter and spool piece removal..................................... 126
Figure 9-9 – Handling Electronic Canister.................................................................... 127
Figure 10-1 – ICoT Local Display Menu Tree............................................................... 128
Figure 11-1 – Example of a Function Block Application: AI-PID-AO ........................... 130
Figure 11-2 – Block relationship diagram ..................................................................... 131
Figure 11-3 – Field Diagnostics Alarm Schematic........................................................ 133
Figure 11-4 – ICoT EDD Menu Tree ............................................................................ 165
Figure 11-5 – Westlock ICoT FF EDD Folder............................................................... 166
Figure 11-6 – ICoT FF registration page at FF............................................................. 167
Figure 11-7 – Unzipped ICoT EDD Files in Windows Explorer .................................... 168
Figure 11-8 – “Add Device Type” command in DeltaV Explorer................................... 168
Figure 11-9 – Browsing ICoT EDD Files ...................................................................... 169
Figure 11-10 – Message of “Add Device Type” command is successful ...................... 169
Figure 11-11 – ICoT EDD Files imported in the DeltaV System................................... 169
Figure 11-12 – Compatible FF standard libraries ......................................................... 170
Figure 11-13– Incompatible FF standard libraries........................................................ 170
Figure 12-1 – Wiring Instructions – IS installations - FISCO ........................................ 179
Figure 12-2– Control Drawing - FISCO ........................................................................ 180
Figure 16-1 – Dimensional drawings – Standard Manifold ........................................... 184
Figure 16-2 – Dimensional drawings – Standard Manifold – top view.......................... 184
Figure 16-3 - Dimensional drawings – High Flow Manifold .......................................... 185
Figure 16-4 - Dimensional drawings – High Flow Manifold – top view ......................... 185
Figure 16-5 Dimensional drawings – Beacon............................................................... 186
Figure 16-6 – Dimensional drawings – Standard Manifold ........................................... 186
Figure 16-7 – Dimensional drawings – Standard Manifold – Bottom view.................... 187
Figure 16-8 – Dimensional drawings – High Flow Manifold.......................................... 187
Figure 16-9 – Dimensional drawings – High-Flow Manifold – top view ........................ 188

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1Introduction
The Westlock ICoT
The Westlock ICoT – Intelligent Valve Positioner is an advanced performance positioner with features
that include high accuracy, ease of set-up with one-touch auto-tune calibration, linear or rotary mounting
and non-contact feedback for the positioner, integral feedback position transmitter, and comprehensive
diagnostics. The ICoT provides a unique combination of accuracy, flexibility, easy maintenance, low air
consumption, and low power consumption.
The ICoT has no linkages, levers or connecting rods from the positioner to the controlled element. Valve
position sensing is performed totally by non-contacting means based upon a rugged magnetic sensor.
Note: consult Westlock for other position sensor options like ruggedized potentiometers or 4-20mA
output position sensors like LVDT, guided wave, magnetostrictive etc.
The ICoT can also be mounted remotely (up to a distance of 200 feet) from the device it is controlling.
The ICoT local LCD configuration tree is so comprehensive that a hand held is rarely needed during
configuration, field maintenance, and operation.
The ICoT LCD indicates valve position, set-point, calibration status, alarms status, and whether the ICoT is
in local or fieldbus control. Error messages are displayed on the local LCD display and communicated to
the Host system via fieldbus.
The ICoT on board LED’s provide further diagnostic and quick information about communication status
and other errors.
What this document contains
In the following pages of this document basic information about four different processes involved in the
installation, operation as well as the configuration of the ICoT valve positioner are described:
•Mechanical and Pneumatic Installation (Valve Setup): The valve assembly is generally divided in
three parts: the valve, the actuator and the positioner. The positioner’s brackets, tubbing and
fittings as well as the flow capacity have to match the physical characteristics of the actuator,
valve, and the process.
•Power supply and Field wiring: When HART, PROFIBUS PA and FOUNDATION Fieldbus
technologies are used, in order to enable the exchange (communication) of the SP and PV1values
between the positioner and host systems, the ICoT user should not only power the positioner but
also install the communication interfaces and other devices.
•System Integration: The host system (from the positioner configuration point of view) can be a
PC computer, a pre-configured workstation, a control system, a DCS or a hand held. Here is
where the device drivers (called DDs or EDDs) are going to be installed.
•Calibration Instructions: There are three different ways to start and monitor the calibration of
the ICoT Positioner. Local display and pushbuttons (not requiring network communication), using
a Handheld Communicator, and using Host Control System user interface.
2
1SP (Set point or desired position), PV (Process variable or measured position)
2This is an illustration only. Control Systems architecture, components and topology may vary.

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Available Enclosure Materials and Options
The ICoT enclosures are designed to offer the best fit in multiple environments. The user can select the
enclosure material that is most suitable for the application:
•Aluminum (low copper content) – Explosion/Flame Proof (ICoT 6000)
•Stainless Steel (316) – Explosion proof (ICoT 6000)
•Stainless Steel (316) – General applications, intrinsically safe (ICoT 5000)
•Engineering resin - General applications, intrinsically safe (ICoT 5000)
The ICoT also offer different options of manifolds, which make available different flow capacities or CV.
The manifold material can also be in Aluminum or Stainless Steel. (See section 1.7).
The physical dimensions of both enclosure and manifolds are in Appendix G – General Arrangement
Drawings.
Product Certifications and Ratings – ICoT 6400
IECEx FMG 13.0033X
Ex d IIB T5 Gb Ta
-50°C to +85°C; IP66
Ex tb IIIC T100°C Db Ta
-50°C to +85°C; IP66
FM13ATEX0081X
II 2 G Ex d IIB T5 Gb Ta
-50°C to +85°C; IP66
II 2 D Ex tb IIIC T100°C Db Ta
-50°C to +85°C; IP66
FM Project ID: 3047816
XP/ I /1/ CD/ T5 Ta -50°C to +85°C;
DIP/ II, III/ 1/ EFG T5 Ta -50°C to +85°C;
I/ 1/ AEx d IIB/ T5 Ta -50°C to +85°C;
21/ AEx tb IIIC/ T100°C Ta -50°C to +85°C;
Type 4X, IP65/IP66
NCC 16.0138 X
Ex d IIC T6 Gb
-20°C ≤ Ta ≤ +40°C

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Product Certifications and Ratings – ICoT 5400
EC Ex FMG 06.0002x
Ex ia IIC T4
(Tamb = -40°C to +80°C)
FM09 ATEX 0028
Ex ia IIC T4 II 1 G
(Ta = -40°C to +80°C)
II3 DT 75~C
FM Project ID: 3017233
IS / I,II,III / 1 / ABCDEFG / T4 Ta = 80°C —
WD-11704; Entity; Type 4X,
I / 0 / AEx ia / IIC / T4 Ta = 80°C —
WD-11704; Entity; Type 4X,
IPA / I,II,III / 2 / ABCDEFG / T4 Ta = 80°C;
Type 4X
NCC 16.0148 X
Ex ib IIC T4 Gb IP66
(- 40 °C ≤ Ta ≤ + 85 °C)
NCC 16.0137 X
Ex nA IIC T4 Gc IP66
(-20°C ≤ Ta ≤ +85°C)

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Environmental:
While the approval agencies list the ICoT over a certain temperature range and with certain gas/dust
groups, their approval is based on it not creating a hazardous condition. As with all devices, functional
operational symptoms or reduced device life expectancy may be seen with the device as environmental
conditions get closer to the extremes. Such conditions may include shorter life expectancy at high
temperatures, sticky/frozen pneumatic spool at low temperatures or corrosive liquids/gasses
contaminating gaskets, seals, filters or spools. Contact Westlock for tips and actions that may help is such
situations. Also, Contact Westlock for hazardous areas. It does not include pneumatic assembly.
General purpose application ratings:
•Recommended electronics Operating/Storage: -40˚C to +85˚C (-40 ˚F to +185 ˚F),
•Pneumatic assembly with dry air operating -15 ˚C to +85˚C (+5 ˚F to +185 ˚F).
Recommended dew point at least +10 ˚C (18 ˚F) below desired operating temperature.
•Relative Humidity: 0 to 95% non-condensed.
•Vibration: 2 g, 10Hz to 1000 Hz.
•Shock: 18 g, 3 axis, 100 bumps each axis.
•References: IEC61514-2, IEC 60068-2-29/27, IEC 61298-3, IEC 60068-2-1/2.

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Flow Capacity
ICoT Positioner standard flow manifold design is suitable for actuator swept volumes of a
minimum of 40 inch3 (0.65 liters) to a maximum of 600 inch3(9.80 liters) for proper auto
calibration functionality. This is to be used as a general guideline only.
Figure 1-2 – Standard Flow Manifold – front view
ICoT Positioner High Flow manifold design is suitable for actuator swept volumes of a minimum
200 inch3 (3.2 liters) to a maximum of 1000 inch3(16.30 liters) for proper Auto Calibration
functionality. Again, this is to be used as a general guideline only.
Figure 1-3 – High Flow Manifold – front view
Whatever the flow capacity is available in the model used the actuator/valve package dynamics would
dictate the success of the auto calibration routine and could be compromised by the following:
instrument air supply volume capacity, actuator sizing, tubing size, and actuator/valve health.

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Technical Specification / Special Features
ICoT 5400
•FF specific3:
oITK version: 6.1.2
oPHY compliance: FF-830 FS2.0
oMANUFAC_ID: 0x574343
oDEV_TYPE: 0x1100
oDEV_REV: 0x04
oDD_REV: 0x024
oNoof Blocks: 1xRB, 1xTB, 1xAI, 1xAO, and 1xPID
oBlock execution time:(AI:52ms, AO:55ms; PID:100ms)
oDevice class: BASIC
oMore at: http://www.fieldcommgroup.org/
•Electrical input:
oConnector: J7 (pins 7 and 8)
oGrounding: H1 Conn. nut (don’t connect cable shield)Operating voltage: 9 to 32 VDC
(Max 35 VDC overvoltage protected)
oPolarity insensitive
oMaximum current consumption from the bus: 12.5 mA
•Real Time Clock:
oAdjusted using Diagnostic Transducer Block
oBack-up: Supercapacitor
oBack-up life: 7 days @ 20oC (68oF)
•Optional potentiometer sensor input (POT version):
oConnector: J5
oRecommend Industrial ruggedized 1kOhm to 10kOhms
oMaximum wire length: using shielded twisted cable 3M (10 feet)
•Optional 4-20mA sensor input (TOG version):
oConnector: J5
oAny sensor with a 4-20mA output and update rate at least 10 Hz
oMaximum wire length: using shielded twisted cable 15M (50 feet)
- limited by pneumatic tubing
3The device was tested against the ICoT FF firmware revision number 4.2. For newer revisions consult
Westlock.
4For reference only. Check the actual device or consult Westlock for more information.

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•Environmental:
oOperating/Storage: -40˚C to +85˚C (-40˚F to +185˚F).
Valid for general purpose application only. Contact Westlock for hazardous areas.
Pneumatic assembly depends on media dew point.
oRelative Humidity: 0 to 95% non-condensed.
oVibration: 2 g, 10Hz to 1000 Hz.
oShock: 18 g, 3 axis, 100 bumps each axis.
oReferences: IEC61514-2, IEC 60068-2-29/27, IEC 61298-3, IEC 60068-2-1/2.
•Ingress Protection rating (base models):
o5400 Eng. Resin Housing: IP66
o5400 Aluminum Housing (consult): IP66
oContact Westlock on other models.
•Electro-Magnetic Compatibility (EMC):
Table 1: ICoT 5000 Series – EMC Immunity Test
Immunity Test
Standard
Level
Class5
Electrostatic Discharge - ESD
IEC 61000-4-2
Direct ±4kV, air ±8kV
A
Electric Fast Transient Burst – EFTB
IEC 61000-4-4
±2kV
A
Lightning Surge - SURGE
IEC 61000-4-5
±1kV
A
Power Frequency Magnetic Field – PFMF
IEC 61000-4-8
30A/m 50Hz and 60Hz
A
Radiated Immunity – RI
IEC 61000-4-3
20 V/m 80MHz-1GHz
3 V/m 1GHz-2.7GHz
B
Conducted Immunity - CI
IEC 61000-4-6
IEC 61326
3Vrms 150kHz-80MHz
A
Table 2: ICoT 5000 Series – EMC Emissions Test
Emissions Test
Standard
Level
Class
Radiated Emissions – RE
CISPR 11
Class A QP 3m
A
Conducted Emissions - CE
CISPR 22
Class A
A
5Class A: device does not exhibit noticeable interference. Class B: device may exhibit temporary
interference or with loss of function, but self-recovers.

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ICoT 6400
•FF specific6:
oITK version: 6.1.2
oPHY compliance: FF-830 FS2.0
oMANUFAC_ID: 0x574343
oDEV_TYPE: 0x1100
oDEV_REV: 0x04
oDD_REV: 0x027
oNoof Blocks: 1xRB, 1xTB, 1xAI, 1xAO and 1xPID
oBlock execution time:(AI:52ms, AO:55ms; PID:100ms)
oDevice class: BASIC
oMore at: http://www.fieldcommgroup.org/
•Electrical input:
oConnector: J1 (pins 1 and 2)
oGrounding: J1 pin 5 (cable shield not connected)
oOperating voltage: 9 to 32 VDC (Max 35 VDC overvoltage protected)
oPolarity insensitive
oMaximum current consumption from the bus: 12.5 mA
•Real Time Clock:
oAdjusted using Diagnostic Transducer Block
oBack-up: Supercapacitor
oBack-up life: 7 days @ 20oC (68oF)
•Optional potentiometer sensor input (POT version):
oConnector: J5
oRecommend Industrial ruggedized 1kOhm to 10kOhms
oMaximum wire length: using shielded twisted cable 3M (10 feet)
•Optional 4-20mA sensor input (TOG version):
oConnector: J5
oAny sensor with a 4-20mA output and update rate at least 10 Hz
oMaximum wire length: using shielded twisted cable 15M (50 feet)
- limited by pneumatic tubing
6The device was tested against the ICoT FF firmware revision 4.2. For newer revisions consult Westlock.
7For reference only. Check the actual device or consult Westlock for more information.

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•Environmental:
oOperating/Storage: -40˚C to +85˚C (-40˚F to +185˚F).
Valid for general purpose application only. Contact Westlock for hazardous areas.
Pneumatic assembly depends on media dew point.
oRelative Humidity: 0 to 95% non-condensed.
oVibration: 2 g, 10Hz to 1000 Hz.
oShock: 18 g, 3 axis, 100 bumps each axis.
oReferences: IEC61514-2, IEC 60068-2-29/27, IEC 61298-3, IEC 60068-2-1/2.
•Ingress Protection rating (base models):
o6400 Aluminum Housing: IP66
o6400 SST Housing : IP66
oContact Westlock on other models
•Electro-Magnetic Compatibility (EMC):
Table 3: ICoT 6000 Series – EMC Immunity Test
Immunity Test
Standard
Level
Class8
Electrostatic Discharge - ESD
IEC 61000-4-2
Direct ±4kV, air ±8kV
A
Electric Fast Transient Burst – EFTB
IEC 61000-4-4
±2kV
A
Lightning Surge - SURGE
IEC 61000-4-5
±1kV
A
Power Frequency Magnetic Field –
PFMF
IEC 61000-4-8
30A/m 50Hz and 60Hz
A
Radiated Immunity – RI
IEC 61000-4-3
10 V/m 80MHz-1GHz
3 V/m 1GHz-2.7GHz
A
Conducted Immunity - CI
IEC 61000-4-6
10Vrms 150kHz-80MHz
A
Table 4: ICoT 6000 Series – EMC Emissions Test
Emissions Test
Standard
Level
Class
Radiated Emissions – RE
CISPR 11
Class A QP 3m
A
Conducted Emissions - CE
CISPR 22
Class A
A
8Class A: device does not exhibit noticeable interference. Class B: device may exhibit temporary
interference or with loss of function, but self-recovers. Reference standards: IEC 61514-2, IEC61326,
IEC61000-6-4, IEC61000-6-2.

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Principles of Operation
The ICoT FF (5400 and 6400) continuously controls the position of a valve based on the fieldbus input
signal. The ICoT senses the valve position via a non-contact magnetic sensor (or other optional sensor in
the TOG/POT versions) and controls the valve positioning through a pressure transducer.
The next picture shows a typical application drawing of an ICoT 5400/6400 positioner assembled on a
linear actuator and valve.
Figure 1-4 – ICoT Positioner connected to a pneumatic valve
The ICoT FF is also a two wire, polarity insensitive instrument that receives both signal and power from
the bus. Current consumption of the ICoT FF is 12.5mA with an operating voltage of 9 – 32 Vdc.
See Section 1.8 (Technical Specification / Special Features)for more information about technical
specification.
The ICoT FF allows calibration and access to on-line diagnostic information via FF compatible hand-held
terminal or through configuration software present in host configuration systems.
A set of hermetically sealed non-contact limit switches is an option that can be integrally supplied with
the ICoT FF9.
9The limit switches are not connected to any internal logic of the ICoT so they cannot be accessed
through a DI function block or any other block.

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2Warnings
Warning symbols used in this document
Below there are the symbols used in this document:
This symbol warns the user of possible danger. Failure to heed 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 heed 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.
ICoT Installation and Operation Warnings
•The ICoT series contain aluminum and is a potential risk of ignition by impact or
friction. Care must be taken into account during installation and use to prevent
impact or friction.
•Never remove enclosure cover or make/break electrical connections with power
connected to the unit.
•Perform all wiring in accordance with site and local codes and the National Electric
Code ANSI-NFPA-70 (US) or the Canadian Electric Code Part I (Canada) for the
appropriate area classifications.
•Confirm that the ICoT model being installed is approved for the hazardous area
(consult unit’s identification label).
•Protect the unit from exposure to aggressive substances or atmospheres to ensure
that hazard rating is not compromised.
•Disconnect power to the ICoT and shut off the inlet air supply before conducting any
valve service or maintenance. Avoid the introduction of any contaminants into the
valve.
•Before using these products with fluids/compressed gases other than air or for
non-industrial applications, consult the factory. This product is not intended for use
in life support systems.
•Installation in poorly ventilated confined areas, with any potential of gases other
than oxygen being present, can lead to a risk of personnel asphyxiation.
•Do not operate radio transmitters at less than 1 meter from the device.

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3Mechanical and Pneumatic Installation (Valve Setup)
The correct configuration, installation and assembly is crucial not only to get the best performance from
the positioner, but also to avoid damaging the positioner as well as other parts like the actuator and
other accessories attached to them. Please follow the following instruction carefully.
Rotary Actuator - Direct Mounting.
Step 1.
Mount the bracket and inner beacon coupler on the actuator. If the actuator shaft has a tapped hole,
fasten using proper flat head screw. If actuator does not have a tapped hole, fasten using set screws on
side of coupler. See Figure 2-1
Figure 3-1 - Bracket / Coupler Mounting
Bracket
Flat
Head
Screw
Set
Screw
Inner
Beacon
Coupler
Actuator
Accessory
Mounting
Shaft

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Step 2.
Press fit the inner beacon to the inner beacon coupler. The inner beacon needs to be properly oriented.
Use the symbols on the top of the inner beacon to mount as shown in Condition 1 or Condition 2.
The reference used for the magnet position is the ICoT, not the actuator. Please note that the magnet
orientation is with reference to the positioner manifold.
Condition 1: Actuator fails in a clockwise direction.
Spring Return
Output Port 2 is plugged
Output Port 1 is piped to turn the actuator counter
clockwise
Double Acting
Output Port 2 is piped to turn the actuator clockwise
Output Port 1 is piped to turn the actuator counter
clockwise
Magnet position (with actuator in clockwise position)
Placed at 6:00 (bottom)
Placed at 3:00 (right)
Figure 3-2 - Rotary – Direct – Condition 1
(ICoT 6000)
`
Figure 3-3 - Rotary – Direct – Condition 1
(ICoT 5000)
SUPPLY
PORT
2
PORT
1
BEACON
SYMBOLS
PORT
2
PORT
1
BEACON
SYMBOLS
SUPPLY

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Condition 2: Actuator fails in a counter clockwise direction.
Spring Return
Output Port 2 is plugged
Output Port 1 is piped to turn the actuator clockwise
Double Acting
Output Port 2 is piped to turn the actuator counter
clockwise
Output Port 1 is piped to turn the actuator clockwise
Magnet position (with actuator in counter clockwise
position)
Placed at 9:00 (left side)
Placed at 6:00 (bottom side)
Figure 3-4 - Rotary – Direct – Condition 2
(ICoT 6000)
Figure 3-5 - Rotary – Direct – Condition 2
(ICoT 5000)
SUPPLY
PORT
2
PORT
1
BEACON
SYMBOLS
PORT
2
PORT
1
BEACON
SYMBOLS
SUPPLY