TECH 533r EN PDF
TECH 533r EN PDF
TECH 533r EN PDF
OPERATING MANUAL
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
12/20/2017 TECH-533/ D.W.O. 22902 Page 1 of 20
Revision History
Revision
12/20/2017
Initial release
USA
Phone: (201) 794-7650
Europe
Phone: +44-1892-516277
Asia
Phone: +65 676 858 00
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
12/20/2017 TECH-533/ D.W.O. 22902 Page 2 of 20
Table of Contents
1 Introduction.................................................................................................................... 4
1.1 Product Certification ................................................................................................ 4
1.2 Warnings ................................................................................................................. 4
1.3 Description .............................................................................................................. 5
1.4 Principles of Operation ............................................................................................ 5
1.5 Special Features ....................................................................................................... 6
2 Order Guide .................................................................................................................... 6
3 Definitions ...................................................................................................................... 8
4 Installation ..................................................................................................................... 8
4.1 Mounting................................................................................................................. 8
4.2 Calibration ............................................................................................................. 10
5 Field Wiring .................................................................................................................. 10
6 Maintenance and Repair............................................................................................... 16
7 Appendix ...................................................................................................................... 17
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
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1 Introduction
ATEX IECEx
154155 1725
Enclosure Material 17.70130633 SIRA IECEx CSA 17.0012X
17ATEX2181X
Class I, Div. 1, Groups A,B,C & D, T4;
Resin/ Class I, Zone 0, AEx/Exia IIC T4 Ga; II 1G
Ex ia IIC T4 Ga Ex ia IIC T4 Ga
Stainless Steel Type 4X, IP65
-40 to +85°C
Class I, Div. 1, Groups A,B,C & D, T4;
Class II, Div. 1, Groups E,F & G; Class III; II 1G/II 2D
Ex ia IIC T4 Ga
Class I, Zone 0, AEx/Ex ia IIC T4 Ga; Ex ia IIC T4 Ga
Aluminum Class II, Zone 21, AEx/Ex tb IIIC T87 Db; Ex tb IIIC T87 Db
Ex tb IIIC T87 Db
Type 4X, IP65
-40 to +85°C
1.2 Warnings
WARNING: The aluminum housing Model K20 Ex ia is at potential risk of ignition by impact or
friction therefore, care must be taken into account during installation to avoid this problem.
Wires must be rated at least 105°C with minimum 0.25mm thickness shall be used for external
connections.
Fils doivent être évaluées au moins 105°C minimum 0,25 mm d’épaisseur doivent être utilisés
pour les connexions externes.
WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD- Clean the equipment only with a
damp cloth to prevent static charge build-up on the resin enclosure or beacon.
ATTENTION: Maximum supply pressure is 120 PSI. Supply air must be clean, dry, oil free
instrument air per ANSI / ISA-7.0.01- 1996 or BS ISO 8573-1:2010.
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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1.3 Description
The K20 is a 4-20mA electro-pneumatic valve positioner/controller. Position measuring
is performed by off-set, shaft driven, state of the art Hall Effect Sensor. The positioner
comes standard with 4-20mA feedback transmitter. In addition there are options for
feedback limit switches, Mechanical, proximity & inductive proximity type.
Calibration
Arrow keys
Keys
Fault LED
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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1.5 Special Features
Front panel
Auto Calibration
Direct and reverse acting (set for low or high loop current closes valve)
Transmitter will output 4mA for valve closed, 20mA for valve open with current
Increasing linearly with opening percentage.
Two switch calibration for 4mA and 20mA without need to set loop currents
Low position calibration
High position calibration
Auto tuning automatically selects loop parameters for best operation
Allowed range of actuators in terms of open/close times
250ms to 2 – 10 minutes, upper limit can be adjusted via Long CAL
Manual tuning
o Set Drop Off on/off
o Set Gain, Zero and Span positions
o LCD displays loop current, valve position.
Integrated Transmitter
The transmitter operates from the same sensor input as the main unit, but is powered by
a separate loop. It shows the current position of the valve by sinking between 4mA and
20mA with 4mA being 0% open and 20mA being 100% open.
If the main section of the K20 fails and so ceases to provide position updates to the
Transmitter or the position sensor fails on the main section, so that the current valve
position is unknown, the Transmitter will put out a current of 3.5mA or 21.5mA
(selectable), to indicate this failure. This “fail” current will be put out within 200ms of the
actual failure. If the main unit detects an error >10% of position, the transmitter will
output fault current and the Fault LED starts blinking.
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
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2 Order Guide
ELECTRO-PNEUMATIC POSITIONER
K Series Positioner (Intrinsically Safe and Non-Incendive)
SEE DATASHEET FOR HAZARDOUS RATINGS OF BASE MODELS
Base Model
K20 Electro-Pneumatic Positioner ( 4-20 mA Input )
| Shaft Output
| S Standard (Double-D with 1/4" Flats)
| D Direct mount to Keystone 79U or MRP Actuators
| N NAMUR
| | Hazardous Area Certification
| | IS Intrinsically Safe and Non-Incendive
| | | Housing Material
| | | E Engineered Resin Enclosure (Clear Cover w/ Visible LCD)
| | | S 316 Stainless Steel CF8M (Adder for 316SS Manifold also required)
| | | A Aluminum Enclosure
| | | | Supply Pressure
| | | | H STD flow High Pressure (40 - 120 psi)
| | | | L STD flow Low Pressure (15 - 45 psi)
| | | | V High Flow (40 - 120 psi, for larger actuators)
| | | | | Manifold Material
| | | | | 0 Anodized Aluminium
| | | | | 1 Stainless Steel (Required for 316SS Enclosure)
| | | | | | Conduit Entry *
| | | | | | B (1) M20 x 1.5 **
| | | | | | C (1) 3/4-14 NPT *** (Recommended with switch options)
| | | | | | D (1) M25 x 1.5 ** (Recommended with switch options)
| | | | | | | Limit Switch Options
| | | | | | | 0 None
2 x SPDT Mechanical Switches with Gold Plated Contacts
| | | | | | | B
( Not Suitable for Class I, Div 2 )
| | | | | | | I 2 x Inductive Sensors P&F Model NJ2-V3-N
| | | | | | | T 2 x SPDT Magnum Proximity switches with Tungsten Contacts
| | | | | | | R 2 x SPDT Magnum Proximity switches with Rhodium contacts
| | | | | | | | Position Transmitter Output
| | | | | | | | B 4-20mA Transmitter
| | | | | | | | | Pneumatic Connections
| | | | | | | | | N 1/4" NPT (3/8" NPT with high flow option)
| | | | | | | | | B 1/4" BSP (3/8" BSP with high flow option)
1/4" NPT w/Aluminum Filter-Regulator
| | | | | | | | | F
Assembly (3/8" NPT with High Flow option)
1/4" NPT w/ Stainless Steel Filter-Regulator
| | | | | | | | | S
Assembly (Not available with High Flow option)
| | | | | | | | | |
V V V V V V V V V V
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
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3 Definitions
4 Installation
4.1 Mounting
Choice of Mounting:
Bracket
Coupler
(Not required for Namur
option)
Actuator
Figure 1
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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Mod Mount
Bracket
(Included with D option)
Actuator
Figure 2
Mounting for Shaft Option Direct Mount to Keystone 79U or MRP Actuators
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
12/20/2017 TECH-533/ D.W.O. 22902 Page 9 of 20
4.3 Calibration
There are 3 auto calibrate modes (all modes auto calibrate the Transmitter)
o Auto Calibration for 4mA to 20mA.
o Calibration for Low current calibration other than 4mA.
o Calibration for High current calibration other than 20mA.
Press SEL Key until the Display shows “AUTO CAL” then press Key.
Auto calibration will occur for 4mA low current and 20mA high current.
4.3.2 Auto Calibration for Low current Calibration other than 4mA (Split Range)
The Low calibration refers to the input current value that drives the valve into the fail
position.
The Transmitter Function is being automatically calibrated during this procedure.
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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4.3.3 Auto Calibration for High current Calibration other than 20mA (Split Range)
High calibration refers to the input current value that drives the valve into the Span
position.
The Transmitter Function is being automatically calibrated during this procedure.
All Manual Calibration Steps will timeout after 2 minutes, discarding any changes if no
key is pressed during that time.
At the end of any procedure, changes can be kept by saving the changes.
To Save the changes press and hold the Key until the display shows:
HOLD
TO SAVE
SAVED Changes made to this point are saved.
Or you can Exit without saving, this discards the changes that were entered.
To enter Manual Calibration, Press the SEL Key until MAN CAL is shown on the the display
will show FWGN xx.
Repeatedly pressing the SEL switch will cycle through what can be changed.
FWGN xx
RVGN xx
DR ENABL or DR DISAB based upon what is set
ZERO xx
SPAN xx
DIR ACTG or REV ACTG based upon what is set
TX FT LO or TX FT HI based upon what is set
REG CAL
RESTORE FACTORY DEFAULT
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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4.4.1 Forward Gain (FWGN XX) is the gain applied when opening the valve.
o The LCD shows “FWGN xx” where xx is the current gain.
o Pressing the DOWN Key decreases the gain
o Pressing the UP Key increases the gain
4.4.1 Reverse Gain (RVGN XX) is the gain applied when closing the valve.
The LCD shows “FWGN XX” press the CAL Key again and the LCD shows “RVGN XX”.
RVGN xx changes can now be made.
Pressing the DOWN Key decreases the gain
Pressing the UP Key increases the gain
4.4.2 Drop off (DR ENABL or DR DISAB) - Enables or Disables Drop off at end of travel
The LCD shows “RVGN XX” press the CAL Key again and the LCD shows either “DR ENABL
or DR DISAB” . DR ENABL or DR DISAB can now be selected.
Pressing the DOWN or UP Key toggles this setting.
4.4.3 Zero Position (ZERO XX) - Adjusts the electronic stop away from (increasing values) or
towards (decreasing values) from the physical closed position. 0 being nominally the
position of the hard stop zero and 100 being about 90 degrees away from it
The LCD shows “DR ENABL or DR DISAB” press the CAL Key again and the LCD shows
“ZERO xx”. ZERO XX changes can now be made.
Pressing UP Key increases the zero position of the valve away from the hard stop.
Pressing DOWN Key moves the zero position closer to the hard stop.
4.4.4 Span Position (SPAN XX) - Adjusts the electronic stop away from (increasing values)
or towards (decreasing values) from the physical open position. 0 being nominally
the position of the hard stop Span Zero and 100 about 15 degrees away from it
Pressing DOWN Key reduces the span position of the valve away from the hard stop
Pressing UP Key moves the span position closer to the hard stop.
4.4.5 Direct / Reverse Acting (DIR ACTG / REV ACTG) - Direct Acting means that the valve
opens with increasing loop current, Reverse Acting means that it closes with increasing
loop current. This function can be selected after the auto calibration is complete.
Pressing the DOWN or UP Key toggles this setting.
4.4.6 Transmitter Fault Current (TX FT LO or TX FT HI) - This specifies the Monitor Transmitter
Fault current as either LO 3.5mA or HI 21.5mA. This is always available but only effective
if the unit has a Transmitter.
The LCD shows “DIR ACTG or REV ACTG” press the SEL Key again and the LCD shows “TX
FT LO or TX FT HI”. TX FT LO or TX FT HI can now be selected.
Pressing the DOWN or UP Key toggles this setting.
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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4.4.7 Calibration Timeout (REG CAL or LONG CAL): Time for the first move in calibration will
be set at a maximum of 30 seconds for REG CAL and all subsequent time outs are keyed
off the time it takes to go from closed to open, to create much shorter subsequent time
outs for smaller valves. The initial 2 minute time out can be lengthened in the Manual
Calibration routine Long CAL.
This should normally be left at REG CAL. If however the valve is likely to take more than
30 seconds to open or close, switching to LONG CAL allows 100 seconds.
The LCD shows “TX FT LO or TX FT HI” press the SEL Key again and the LCD shows “REG
CAL or LONG CAL”. REG CAL or LONG CAL can now be selected.
Pressing the DOWN or UP Key toggles this setting.
4.4.8 Saving or discarding changes:
At the end of any procedure, changes can be kept by saving the changes. To Save the
changes by pressing and holding the Key until the LCD shows:
HOLD
TO SAVE
SAVED Changes made to this point are saved.
Releasing after a shorter time will cause the changes to be discarded.
LCD will show “DISCRDED”
Or you can Exit without saving, this discards the changes that were entered.
All Manual Calibration Steps will timeout after 2 minutes, discarding any changes if no
Key is pressed during that time.
When the LCD displays “AUTO CAL” and you do not want to perform this operation. Do
nothing. Within 15 seconds the function displayed is canceled and the LCD display
reverts back to opening percentage “xx %”
If starting an Auto Calibration by mistake. Wait 5 seconds and press again. LCD
shows “CALIBRATION CANCELED”. The LCD display will revert to opening percentage
“xx %” after 20 seconds.
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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4.5 Setting the Cams.
To release the cover, loosen the cover retaining screws using a 4mm A/F Allen Key. Lift the cover and twist
approx. 45° and remove. See Figure 2 below.
Figure 5
To set switches, lift the bottom Touch Set cam and turn until the switch has activated and then release. The
spring will push the Touch Set cam back onto the splined shaft. See figure X.
To set switches, lift the bottom Touch Set cam and turn until the switch has activated and then release. The
spring will push the Touch Set cam back onto the splined shaft. See figure X.
Before stroking the actuator, please ensure that the process is safe to do so and that all hands are
kept away from the moving shaft / cams.
Stroke the actuator to the opposite end of travel. Set the top Touch Set cam by pushing down and turning
the Touch Set cam until the switch is activated. See figure X.
Before stroking the actuator, please ensure that the process is safe to do so and that all hands are
kept away from the moving shaft / cams.
Stroke the actuator from one end of travel to the other several times to check the switch operation.
If the switches require adjustment, repeat as required.
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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5 Field Wiring
Wires must be rated at least 105°C with minimum 0.25mm thickness shall be used for external
connections.
Wiring Diagrams:
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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6 Maintenance and Repair
The positioner’s onboard filter should be replaced regularly or whenever it gets clogged.
See diagram below for location of the filter. Note: the following instructions are for
Standard Flow. For High Flow please contact the factory.
Important: The positioner’s onboard filter is not a substitute for normal instrument air
preparation. Supply air to the positioner should conform to ISA Standard S7.3 - Quality for
Instrument Air.
Important: The filter’s original color is chalk white. If the filter is discolored, its replacement
should be performed more often. A discolored filter may also indicate the need for an
evaluation of the air-supply quality. A filter/regulator with a 5 micron or better element,
just prior to the positioner, is therefore recommended.
MS10222
Filter Figure 11
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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7 Appendix
Appendix: A
Controlled Diagram
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280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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Appendix: B
TRANSDUCER ERROR
When preforming an Auto Calibration if the LCD shows “TRANSDUCER ERROR” within 2 minutes.
The transducer is not connected to the K20.
UNABLE TO CLOSE
When preforming an Auto Calibration and within 2 minutes the LCD displays “UNABLE TO
CLOSE”. The air supply is not connected or turned on.
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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Appendix: C
Dimensions:
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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Appendix D:
Westlock K20 Quick Start Guide
-AUTO CALIBRATION INSTRUCTIONS-
PRESS AND RELEASE [SEL]. DISPLAY WILL SHOW 'AUTO CAL'. PRESS AUTO CAL WILL BEGIN WITH 4MA AS
LOW CURRENT AND 20MA AS HIGH CURRENT.
-LOW CURRENT-
SET LOOP CURRENT TO IDLE VALUE. PRESS AND RELEASE [SEL] UNTIL 'LOW' SHOWS IN DISPLAY.
PRESS CALIBRATION WILL BEGIN.
-HIGH CURRENT-
SET LOOP CURRENT TO OPEN VALUE. PRESS AND RELEASE [SEL]UNTIL 'HIGH' SHOWS IN DISPLAY.
PRESS CALIBRATION WILL BEGIN.
-FORWARD GAIN-
PRESS AND RELEASE [SEL] UNTIL 'FWGN' SHOWS IN DISPLAY. ADJUST VALUE USING OR .
-REVERSE GAIN-
PRESS AND RELEASE [SEL] UNTIL ‘RVGN’ SHOWS IN DISPLAY. ADJUST VALUE USING OR .
-DROP OFF-
PRESS AND RELEASE [SEL] UNTIL 'DR ENABL' OR 'DR DISAB' SHOWS IN DISPLAY. PRESS OR TO
ENABLE/DISABLE DROP OFF.
-ZERO ADJUST-
PRESS AND RELEASE [SEL] UNTIL 'ZERO' SHOWS IN DISPLAY. PRESS OR TO ADJUST THESE VALUES.
-SPAN ADJUST-
PRESS AND RELEASE [SEL] UNTIL 'SPAN' SHOWS IN DISPLAY. PRESS OR TO ADJUST THESE VALUES.
PRESS AND RELEASE [SEL] UNTIL 'REG CAL' OR 'LONG CAL' SHOWS IN DISPLAY. PRESS OR TO SELECT
CALIBRATION TIME.
WESTLOCK CONTROLS
280N MIDLAND AVENUE, STE.258, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
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