280 N. MIDLAND AVE., STE.

258
SADDLE BROOK, NJ 07663 QUICKSTART INSTALLATION
TEL: 201-794-7650 FAX: 201-794-0913
westlockcontrols.com AND OPERATIONS MANUAL
QUANTUM ROTARY MODELS:
764/864/765/865/784/789/711/811/722/822/777/877/360/366
(Complete Installation and Operations Manual, TECH-382, available at westlockcontrols.com)
IOM: Tech-382Q Revision: D
Prepared By: Rhonda Frey Date: 12-10-12 Drafting Work Order: 24213 ECN: N/A
Reviewed By: J. Moorehead Date: 5-18-20 Approved By: Chris Irwin Date: 5-4-20
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
1. Introduction
1.1. 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 Quantum model being installed is approved for the hazardous area (consult
unit identification label).
 Ensure that approved and properly sized IS barriers are used in installations with 711, 811,
722 and 822 (confirm entity parameters from product ID label).
 Confirm that power supplied to switches and solenoid 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.
 Disconnect power to solenoids and the inlet air supply before conducting any valve service or
maintenance. Avoid the introduction of any contaminants into the valve.
 If this Quantum Control Monitor is used to maintain a designated safety integrity level, the
items that will need to be addressed can be found in the following Safety Manuals that are
available through www.westlockcontrols.com or sales contacts: Tech-487 for FalconV
solenoid valves, and Tech-478 for switches.

1.2. 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. Installation
2.1 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 and shaft with the
hardware provided (see Fig. 1).
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 stress-related failure of unit shaft in high cycle or
high torque applications.

12/10/12 TECH-382Q/EWR 20285 Page 1 of 5

 Fig. 1
Mounting the Quantum units
with accessory bracket kits

2.2. Solenoid Valve Connection and Operating Instructions

2.2.1. Standard FalconV Valve Specifications

NOTE: ALWAYS consult the Quantum product ID label for coil electrical specifications and for
pressure and temperature specifications for each unit, as they will vary with area
classification, valve options and other factors.

Specifications

Operating Pressure: 30-120 PSIG for single-coil valves; 20-120 PSIG for dual coil valves.
Operating Temperature:
General purpose and non-Incendive coils:-40° C to +75° C (-40° F to +167° F), except 125 VDC
which is -40° C to +90° C (-40° F to +194° F)
Intrinsically safe coils: -40° C to +85° C
Standard valve bodies with Viton Seals: -20° C to +93° C (-5° F to +200° F)
Low temperature valve bodies with low temperature Buna Seals: -48° C to +93° C (-55° F to
+200° F).
(Agency approvals may not encompass full operating temperature range).
Operating Media: Lubricated or dry air, filtered to 40 microns. If air line lubricators are used, please
see Appendix for information or lubricating oils and suggested brands.

For operating specifications of legacy Falcon Valves, see Tech-132.

2.2.2. Installation/Connection of FalconV Directional Control Valve

Porting Designation
1/4” NPT air ports for inlet, outlet, and exhaust
(4.3 Cv FalconV valve has 1/2” NPT air ports)

Fig. 2
Air Flow Diagrams

Spring Return 3-Way (3/2) Valve Spring Return 4-way (5/2) Valve
Description of Operation: Solenoid De-energized - Description of Operation: Solenoid De-energized -
air flows from Outlet Port 2 to Exhaust Port 3. air flows from Inlet Port 1 to Outlet Port 2 and
Solenoid Energized - air flows from Inlet Port 1 to exhausts from Port 4 to Port 5. Solenoid Energized -
Outlet Port 2. air flows from Inlet Port 1 to Outlet Port 4 and
exhausts from Port 2 to Port 3.

12/10/12 TECH-382Q/EWR 20285 Page 2 of 5

 A Dual Coil 4-way (5/2) Valve
Description of Operation: Coil B Energized -
air flows from Inlet Port 1 to Outlet Port 2 and
exhausts from Port 4 to Port 5.
Coil A Energized -
air flows from Inlet Port 1 to Outlet Port 4 and
exhausts from Port 2 to Port 3.
Note: The valve will not change state until the energized
coil is de-energized and the opposite coil is energized in
B that order.

NOTES - For Dual Coil Valves

1. The valve may be in either position upon installation. Refer to the Air Flow Diagrams (Fig. 2) and
energize the appropriate coil (with supply air present) to reset valve to the desired position.
2. Dual coil valves require both an electrical signal and appropriate air pressure to operate. If either
or both inputs are lost the valve will remain in its current position.
3. Both coils should never be energized simultaneously.
4. If using overrides on a dual coil valve, the coils must be de-energized.

2.2.3. Plumbing and Air Supply Considerations

Proper drying and filtration of air supply per specifications in section 2.2.1 is critical to prevent
premature failure of solenoid valves. If lubricators are used in the air line, use appropriate oil
distribution equipment and oil grades, such as ISO and UNI FD22. The following general valve
plumbing procedure should be followed:

1. Inspect port and connectors to ensure that the threads are free of dirt, burrs and excessive nicks.
2. Apply sealant/lubricant or Teflon tape to the male pipe threads. With any sealant or tape, the
first one or two threads should be left uncovered and care must be taken to avoid the
application of excessive sealant media to avoid system contamination.
3. Install connectors into ports and wrench tighten per the fitting manufacturer’s recommendation to
achieve an air-tight joint.

3. Calibration
Consult factory or a Westlock distributor for setting procedures of units with 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); allen key for cover screws (M5 or M8 socket head cap).

3.1. 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.
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.

12/10/12 TECH-382Q/EWR 20285 Page 3 of 5

TWO SWITCHES

3.2. Switch Adjustment (four switches, no CS/DS 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).

FOUR SWITCHES

12/10/12 TECH-382Q/EWR 20285 Page 4 of 5

 3.3. Transmitter setting (optional CS/DS transmitter):
For the calibration of optional current signal (CS) transmitter, see Westlock Controls
Installation/Operations Manual VCIOM-04112-EN. For calibration of optional 4-20 mA digital signal
(DS) transmitter, see TECH-541. Available through your local sales representative or at
westlockcontrols.com.

3.4. 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.
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.

For the 360 and 366 models:

Required Tools: set screw driver for M4 set screws and snap ring tool.
1. Remove shaft snap ring and inner beacon.
2. Disengage set screws from outer beacon, rotate and re-fasten outer and inner beacon to
synchronize displayed position with valve position.

4. Field Wiring
See the warnings section of this document for important warnings pertaining to the wiring of
Quantum 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), some cover screws (M4, #10 or
5/16), and ground screw (#8 or M4); wire strippers as required for field wires; allen keys for some
cover screws (M5 or M8 socket head cap).
1. Wire the Quantum control monitor strictly according to the wiring diagram on the inside of the
enclosure cover.
2. Confirm that ground wires are secure under grounding screws.
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.

12/10/12 TECH-382Q/EWR 20285 Page 5 of 5