ACCUTRAK ROTARY MODELS:

1040/9358/2004/9044/9468/5004
5044/2007/9479/5050
INSTALLATION AND
OPERATIONS MANUAL

Revision: A

IOM: Tech-385
Prepared By:
Herb Tucker

Date:
8/23/05

Drafting Work Order:

17072

ECN: 11714

Reviewed By: Jim Kilian

Date: 5/3/10

Approved By: Rhonda Frey

Date: 5/4/10

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: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
4/7/10

TECH-385/D.W.O. 17072

Page 1 of 8

Revision History
Revision
23 Aug, 2005 Initial release 4/7/10 rev. A
Westlock Controls Offices
USA
Westlock Controls Corp.
280 North Midland Ave.Saddle Brook, NJ 07663
Phone: (201) 794-7650 Fax: (201) 794-0913
Email: westlockinfo@westlockcontrols.com
Internet http://www.westlockcontrols.com
Westlock Service Center
6735 Exchequer Dr.
Suite 100
Baton Rouge, LA 70809
Phone: (225) 296-8118 Fax: (225) 296-5188
Email: stevesmith@westlockcontrols.com
Europe
Westlock Controls UK
Chapman Way, Tunbridge Wells
Kent, England TN23EF
Phone: 011-44-189-251-9046 Fax: 011-441-892-516279
Email: sales@westlockuk.com
Internet: http://www.westlockuk.com
South America
Westlock Equipmentos De Controles Ltda.
Rua, Sao Paulo 291
Alphaville, Barueri
Sao Paulo, CEP 06465-130
Phone: 011-55-11-7291-0930 Fax: 011-55-11-7291-0931
Email: comercial@westlock.com.br
Internet: http://www.westlock.com.br/

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
4/7/10

TECH-385/D.W.O. 17072

Page 2 of 8

1. Introduction
1.1. Product Certification
1040/9358: CSA Type 4 (Cert. #LR 81057-3)
2004: CSA Type 4 (Cert. #LR 81057-7)
9044: NEMA 4, 4X (Cert. not applicable)
9468: FMc NI/I/2/ABCD/T4 0 C<= Ta<60 Type 4X, 6P, IP67; DIP/II/2/FG/ T4
0C<=Ta<60C (Cert. #3036618C)
5004/5044: FMc IS/I, II, III/1/ABCDEFG/T6 Ta=60C Entity WD-11880,
NI/I/2/ABCD/T5 Ta=60C Entity WD-11880; Entity Parameters
Vmax=16, Imax=25, PI=345 mW, Ci=50 nF, Li=250 H (Cert.
#3008802)
2007/9479: FMc XP/I/1/CD/T6 Ta=60C, DIP/II/1/EFG/T6 TA=60C; 9479
ONLY: N/I/I/2 ABCD/T4 Ta=60C, Type 4, 4X (Cert. #3029311C)
5050: FM XP/I/1/CD/T6 Ta=50C, DIP/II/1/EFG/T6 Ta=50C, NI/I/2/ABCD/T4
Ta=50C, Type 4, 4X (Cert. #3026687)
1.2.

Warnings
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 AccuTrak model being installed is approved for the
hazardous area (see Product Certification section above or unit ID
label).
Confirm that supply power to switches is within rated specifications
listed on the unit identification label.
Protect the unit from exposure to aggressive substances or
atmospheres to ensure that hazard rating is not compromised.

1.3.

Description
AccuTrak valve position monitors are intended for use as both visual and
electrical position indicators for discrete rotary devices, most commonly
pneumatically actuated 2-way quarter-turn or 3-way valves. An AccuTrak
monitor is not limited for use in only quarter-turn valve applications, but that
application will be assumed for the purpose of this document. In addition to
the monitoring features, AccuTrak monitors may serve as wiring junctions for
accessories where additional terminals, conduit entries and wiring codes
permit.

1.4.

Principles of Operation
An AccuTrak monitor mounts to an actuator via a mounting kit, usually sold
separately. The unit shaft couples to the actuator shaft directly via NAMUR
adaptation, or via a coupling provided in the mounting kit. As the actuator
rotates the unit shaft, adjustable cams on the shaft actuate mechanical or
proximity switches inside the unit enclosure, at the limits of rotary travel set by
WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
4/7/10

TECH-385/D.W.O. 17072

Page 3 of 8

the customer. The switches are pre-wired to a terminal strip in the enclosure,
permitting easy connection of switch output to external electrical monitoring
systems or indication devices. The visual Beacon indicator on the enclosure
cover indicates 90 rotary travel between OPEN and CLOSED valve
positions, unless ordered optionally for other angular strokes or 3-way valve
applications.
1.5.

Special Features/Conditions
To avoid build-up and discharge of static electricity in a hazardous area, only
clean Westlock units with a static-free cloth dampened with water. Avoid the
use of alcohol-based cleaners.

2.

Ordering
Ordering guides for all AccuTrak product series covered by this IOM are
available through a local Westlock distributor, the current Westlock Controls
catalog literature or the Westlock Controls website at
www.westlockcontrols.com. Spare parts lists for refurbishments or repairs are
also available for common AccuTrak models.

3.

Definitions
NAMUR- This term, in the context of mounting brackets and shafts, refers to
the NAMUR VDI/VDE 3845 standard for the dimensions of actuator output
shafts and auxiliary equipment mounting hole patterns. In the context of
inductive proximity sensors, NAMUR refers to conformance of the sensor to
DIN 19 234, allowing its use with any NAMUR style amplifier/isolator.
Switch- A manual or mechanically actuated device for making, breaking or
changing the connections in an electric circuit. This term will be used also for
magnetic or inductive proximity sensors for the purpose of this document.

4.
4.1.

Installation
Mounting Instructions
Required Tools: Open-end wrenches or adjustable wrench to fit all sizes of
hex head bolts in the mounting kit.
1. Obtain a mounting kit suited for the actuator/valve, commonly available
through a local Westlock Controls distributor.
2. Attach the mounting bracket and coupler (if required) to the unit
housing with the hardware provided.
3. Attach the unit and mounting system to the actuator.
4. Ensure proper axial alignment between unit shaft, coupler and actuator
shaft. Failure to ensure alignment could result in long-term stressrelated failure of unit shaft in high cycle or high torque applications.

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
4/7/10

TECH-385/D.W.O. 17072

Page 4 of 8

MOUNTING KIT

COUPLER

NON-NAMUR
ACTUATOR

NAMUR
ACTUATOR

4.2. Calibration
Consult factory or a Westlock distributor for setting procedures of units with
six switches or four switches and transmitter.
Note 1: Switch actuation can be confirmed using a signal detection device
such as a multimeter or ohmmeter, set for continuity.
Note 2: For NAMUR P+F NJ2-V3-N type sensors, use test meter, P+F model
#1-1350 or equivalent to check sensor actuation and calibration. If the proper
meter is not available, contact the factory for additional assistance with the
test procedure.
Note 3: Adjust cams by hand by pushing/pulling the cam against the shaft
spring to disengage from the mating spline, rotating to adjust and re-engaging
firmly onto spline.
Required Tools: Signal detection device (see note 1); slotted screw drivers
for cover screws (M4, #10 or 5/16 by model)
Switch Adjustment (two switches):
1. Remove unit cover as follows: loosen (but do not remove) captive screws,
rotate cover slightly to grip corners, pull firmly.
DO NOT PRY COVER WITH TOOLS.
2. With valve in the closed position, adjust bottom cam until bottom switch
(#2) actuates.
3. Stroke valve to the open position, adjust top cam until top switch (#1)
actuates.
WESTLOCK CONTROLS CORPORATION
280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
4/7/10

TECH-385/D.W.O. 17072

Page 5 of 8

4. Cycle actuator several times to confirm proper switch indication at each

end of stoke. Finely adjust cams if necessary.
5. Skip to Field Wiring section or replace unit cover, applying approximately
20 in-lbs of torque to cover screws.
TOP CAM
PUSH DOWN, TURN
& RELEASE

BOTTOM CAM
LIFT UP, TURN
& RELEASE
MAGNUM & MAGPAC
PROXIMITY
SWITCH

MECHANICAL
SWITCH

iNDUCTIVE
PROXIMITY
SENSOR

Switch Adjustment (four switches, no CS transmitter):

Follow steps as above for the calibration of two switches but adjust the first
and third cams from the top for switches #1 and #2 and the second and fourth
cams from the top for switches #3 and #4 (see illustration below).

TOP & 3RD CAM

PUSH DOWN, TURN
& RELEASE
2ND & BOTTOM CAM
LIFT UP, TURN
& RELEASE

MAGNUM
PROXIMITY
SWITCH

MECHANICAL
SWITCH

iNDUCTIVE
PROXIMITY
SENSOR

Transmitter setting (optional CS transmitter):

For the calibration of optional current signal (CS) transmitter, see Westlock
Controls Installation/Operations Manual TECH-301, available through your
local sales representative or at www.westlockcontrols.com.
Beacon Adjustment:
Note: Skip this step if cover is flat or Beacon already displays the correct
valve status.
Required Tools: slotted screw driver for #12 screws.
WESTLOCK CONTROLS CORPORATION
280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
4/7/10

TECH-385/D.W.O. 17072

Page 6 of 8

1. For two-way OPEN/CLOSED: remove, rotate and re-fasten outer beacon

to synchronize displayed position with valve position.
2. For three-way flow paths: remove, rotate and re-fasten outer beacon
and/or inner beacon coupler to synchronize displayed flow path with
valve/actuator flow path.

OPEN

Valve in
Position

OPEN

OPEN

CLOSED

Valve in
Position

CLOSED

CLOSED

5.

Field Wiring
See the warnings section of this document for important warnings
pertaining to the wiring of AccuTrak units. Remove and replace cover
before and after wiring, per instructions given in the Switch Adjustment
section above.
Required Tools: slotted screw drivers for terminal strip screws (#2), cover
screws (M4, #10 or 5/16 by model), and grounding screw (#8 or M4 by
model); wire strippers as required for field wires.
1. Wire the AccuTrak monitor strictly according to the wiring diagram on the
inside of the enclosure cover.
2. Confirm that the ground wire is secure under the green grounding screw in
the enclosure.
3. Seal all unused conduit entries as required with suitably certified plugs
having an ingress protection rating of IP67 or better.
4. Ensure that only suitably certified cable glands are used, having an
ingress protection rating of IP67 or better.
5. Ensure that the temperature rating of all field wiring meets the service
temperature range of the application.

6.

Maintenance and Repair

Maintenance or repair of Westlock equipment must only be done by Westlock
Controls or by qualified personnel that are knowledgeable about the
installation of electromechanical equipment in hazardous areas. All parts
needed for repairs or maintenance must be purchased through a Westlock
Controls authorized distributor to maintain warrantee and to ensure the safety
and compliance of the equipment.
WESTLOCK CONTROLS CORPORATION
280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com

4/7/10

TECH-385/D.W.O. 17072

Page 7 of 8

No routine maintenance of Westlock AccuTrak units is recommended when

units are installed in environments for which they are designed. Severe
environments may warrant regular replacement of field units every two to five
years for maximum performance and safety.
Troubleshooting
Problem: No signal at the control device
Check that power supply to the loop is functioning correctly and
adequate to power all devices on the loop;
Check that power being supplied to switches is within the rated
specifications;
Check wiring integrity immediately at the connection to the control
device;
Check field wiring coming into the AccuTrak terminal strip for proper
connection and good wire preparation practices (approximately of
insulation removed and all strands intact);
Check that field wiring is no larger than 12AWG for proper fit in
terminal strip and compliance with terminal strip rating;
Check that wiring integrity is good between switches and terminal strip;
Check that cams are set to trigger switches properly in each valve
position (see Switch Adjustment section under installation);
Use multimeter set for continuity: to check for failed switch; observe
continuity between common and normally open when triggered and
between common normally closed when not triggered.
Problem: Beacon does not display the correct flow path
Reset Beacon per the Beacon Adjustment section under Calibration.
Problem: Unit appears to be binding during valve stroke or unit shaft has
broken
Carefully measure and adjust axial alignment of unit shaft, coupler and
actuator shaft to eliminate lifting or twisting of the coupler during travel.
Problem: Unit has signs of moisture ingress
Check torque on cover screws
Check gaskets and sealing surfaces for debris and clean if necessary
Check that conduit connections are properly sealed, including gland
fittings and quick-disconnect receptacles
Check that conduit pipes are properly pitched to direct condensing
moisture away from units
Check that all unused conduit entries are properly sealed with suitably
certified plugs having an ingress protection rating of IP67 or better.

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
4/7/10

TECH-385/D.W.O. 17072

Page 8 of 8