Worcester Controls
Installation
Operation
Maintenance
UltraSwitch™ WXCL/WXML
FCD WCENIM2076-05
Description:
Worcester Controls UltraSwitch™ limit switch enclosures provide local and remote position indication for
automated valves. They generally feature a visual indicator with “red=closed” and “green=open” for intuitive
local position determination. The UltraSwitch™ is available with a number of limit switch options for remote
indication in a variety of electrical applications. They may also be used as a junction box for direct
installation of solenoid valves.
Installation:
UltraSwitches may be installed to valves or valve actuators with a variety of mounting hardware. For best
results, specify the NAMUR shaft option and NAMUR mounting hardware when installing to NAMUR
compliant actuator. These options allow direct coupling to actuators
without couplings, reducing dead band.
Simply bolt bracket to actuator and UltraSwitch™ to bracket, leaving bolts finger tight. For NAMUR applications
the UltraSwitch™ shaft features an integral alignment pin. This pin must engage the tapped hole in the actuator
shaft. For non-NAMUR applications, make
sure to properly install a coupler between UltraSwitch™ and actuator. Once the UltraSwitch™ is installed with
fasteners loosely tightened, stroke the actuator two or three times to align the bracket. Then tighten all fasteners.
Wiring Instructions:
UltraSwitch™ enclosures feature pre-wired switches. All user connections are made at a numbered terminal
strip. Both external bonding and internal grounding locations have been provided for use in installation. A
wiring diagram is located inside the cover and indicates which terminal numbers correspond to switch
contacts: normally open, normally closed, common, etc. Simply follow the wiring diagram and electric code to
connect switches to your system.
For field wiring: ensure that any excess wire lengths or loops are routed away from any moving parts and are
short enough, or secured to ensure a ¼” clearance between the wire and the inside surface of the switchbox
cover.
Note: for all magnetically tripped proximity switches, the top switch (top and third switches for 4-switch
versions) should only be used to indicate the clockwise position: the bottom switch (second and fourth
switches for 4-switch versions) should only be used to indicate the counter-clockwise position. Any deviation
from these settings may result in erratic indication.
Solenoids may also be wired through the UltraSwitch™ enclosure. At least two auxiliary terminals are included as
standard.
A ground screw is also included. Simply wire the solenoid to auxiliary terminals, then connect power leads to the
opposite terminal side. Be sure to properly ground the solenoid at provided ground terminal.
UltraSwitch™ XCL series enclosures include two 3⁄4" NPT conduit entries and the XML series includes two
M25x1.5 conduit entries. Installation shall be per National Electric Code, local codes, and manufacturers’
instructions. In all cases, environmental seals must be used to protect against ingress of water through the
conduit.
Special Hazardous Location Instructions:
For North America installations you must install a conduit sealing fitting within 18 inches of the enclosure to meet
NEC regulations.
For ATEX and IECEx installations an appropriately rated Cable Gland is required. Any unused conduit entry must
have a suitably rated blanking element.
Substitution of components may impair suitability for Zone 2 Increased Safety.
Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous.
Cleaning this housing by rubbing should be done in a non-hazardous area.
Potential electrostatic charging hazard, clean only with a damp cloth – danger of propagating discharge.
All grounding and bonding installation requirements must be addressed
All installation, inspection, and maintenance of the equipment should be performed by suitably trained
personnel. In addition, for ATEX, all installation, inspection, maintenance and repair must be done by suitably
trained personnel. For more information refer to EN 60079-14:1997, EN 60079-17, EN 60079-19
Replacement parts not to invalidate certification and to be only obtained direct from the manufacturer.
Adjusting Limit Switches:
Ultra Switch™ enclosures feature quick-set cams which are used to trip the limit switches. These cams are easily
adjusted without tools. Caution: disconnect power before removing cover when installed in hazardous
locations. Remove cover and set aside. Rotate actuator/valve to full clockwise (CW) position. Adjust cam(s)
associated with CW as follows:
1. Push or pull cam against spring to disengage it from splines.
2. Rotate cam CW breaking contact with switch (or moving magnet away from switch).
3. Continue rotating cam CW just until switch trips.
4. Release cam and reengage it with splines.
Rotate actuator/valve to full counterclockwise (CCW) position. Adjust cam(s) associated with CCW as described
insteps 1 through 4, except rotate cam(s) CCW.
Note: factory setting is top switch = CW (closed), second switch = CCW (open), third switch = CW, and fourth
switch = CCW.
CAUTION:
Fine Cam Adjustment:
Some cams have a fine adjustment available. These cams will have a small screw embedded into the side of the
cam. Adjusting this screw inward or outward will deform the cam, changing the trip point slightly.
Adjusting UltraDome Position Indicator:
UltraDome visual indicators are easily adjusted to match the dome’s clear windows to the rotor’s colored sections.
The dome is secured to the UltraSwitch housing with screws mounted through slotted holes. The slotted holes
allow approximately 20° adjustment of the dome. In addition, the dome can be completely removed and
reoriented in 45° and 90° increments. The rotor may be reoriented with respect to the shaft by removing the
shaftcoupler and rotating 90° before reinstalling. This may be necessary to obtain the correct orientation of
windows in a multi-way application.
Calibrating 4-20 mA Transmitter:
Setting direct/reverse action: A dip-switch setting controls the direction of increasing travel. For 4 mA in the full
clockwise position, select "D," for 4 mA in the full counterclockwise position, select "R."
Adjusting zero/span:
1. Attach a DC mA meter to +/- terminals.
2. Operate valve/switchbox to position corresponding to 4 mA.
3. Adjust feedback board zero trim pot to yield 4 mA. (Turning CW increases value, turning CCW decreases
value).
4. Operate valve/switchbox to position corresponding to 20 mA feedback.
5. Adjust feedback board span trim pot to yield 20 mA. (Turning CW increases value, turning CCW decreases
value).
6. The zero and span adjustments are interactive. Repeat steps 1 through 5 as necessary.
Note: If transmitter adjustment gets difficult (i.e., trim pots do not have desired effect) start over by "centering" the
trim pots. This is accomplished by turning in one direction for 20 turns and reversing direction for 10 turns.
Switch Option
Manufacturer
Part Number
Load Capacity
M1 – SPDT
Mechanical
Honeywell
MicroSwitch
V7-1C13D8-201
15.1A (1/2 HP) at 125/250 VAC; ½A at
125 VDC; 1/4A at 250VDC; 5A at
120Vac
MC – SPDT
Mechanical 250°F
Honeywell
MicroSwitch
V7-1C13D8-201
15.1A (1/2 HP) at 125 VAC; ½A at 125
VDC; 1/4A at 250VDC; 5A at 120Vac
MG – SPDT Gold
Mechanical
Honeywell
MicroSwitch
V7-1D19D8-201
1A at 125 VAC / 50 mA at 24 VDC
MA – 3-Position
Control
Honeywell
MicroSwitch
V7-1C13D8-201
15.1A (1/2 HP) at 125 VAC; ½A at 125
VDC; 1/4A at 250VDC; 5A at 120Vac
M3 – DPDT
Mechanical
Cherry
E19-00A
15A, 125/250 VAC 3/5HP
MB – DPDT
Mechanical
Licon
22-104
10A (1/2 HP) at 125 VAC
MD – 3-Pos.
Control w/Indication
(DA)
Licon
22-104
10A (1/2 HP) at 125 VAC
MS – 3-Pos.
Control w/Indication
(SR)
Licon
22-104
10A (1/2 HP) at 125 VAC
P4 – SPST
Proximity
Aleph
PS-6132
0.35A at 140 VAC / .25A at 200VDC
(50 W Max.)
P5 – SPDT
Proximity
Hamlin
59135-030
0.25A at 120 VAC / 0.25A at 28 VDC (3
W Max.)
PE – SPDT Sabre
Proximity
Flowserve
XA0199
1A at 120 VAC / 2A at 24 VDC
PP – SPDT Phazer
Proximity
Flowserve
XA0155
3A at 120 VAC / 2A at 24 VDC
PL – SPDT Phazer
w/LED
Flowserve
XA0154
0.5A at 120 VAC /0.3A at 24 VDC
PT – SPST BRS
Proximity
Flowserve
XA0157
3A at 120 VAC / 0.5 at 24 VDC
PX – SPST BRS
w/LED
Flowserve
XA0156
0.5A at 120 VAC / 0.3A at 24 VDC
N8 – Solid State
Proximity
Pepperl + Fuchs
NJ2-V3-N
NAMUR Sensor Output / 5-25 VDC
Supply
NP – Solid State
Proximity
Pepperl + Fuchs
SJ3.5-N
NQ – Solid State
Proximity
Pepperl + Fuchs
NJ4-12GK-N
NR – Solid State
Proximity
Pepperl + Fuchs
NJ4-12GM40-E1
PNP Sinking / 200 mA max. Current / 10-
60 VDC
NS – Solid State
Proximity
Pepperl + Fuchs
NJ4-12GM40-E2
NPN Sourcing / 200 mA max. Current /
10-60 VDC
NT - Solid State
Proximity
Pepperl + Fuchs
NJ4-12GK40-E2
NPN Sourcing / 200 mA max. Current /
10-60 VDC
NU – SPDT GO
Proximity
GO
35-13319-A1A
4A at 120 VAC / 2A at 240 VAC
N9 – Solid State
Proximity
Pepperl + Fuchs
NBB3-V3-Z4
NPN Sourcing/ 100 mA max. Current /
5-60 VDC
SN – 3-way
Pneumatic
Consult factory for
technical specifications
FZ – AS-I Bus Card
31VDC 28 mA
Switch Option Specifications:
IECEx &
Ex d IIB T5
Ex tD A21 IP 65
T5 @ -20°C ≤ Tamb ≤ +55°C,
IEC 60079-0:2004 (Ed.4)
IEC 60079-1:2003 (Ed.5)
IEC 61241-0:2004 (Ed.1)
IEC 61241-1:2004 (Ed.1
ATEX
II 2 G Ex d IIB T5
II 2 D Ex tD A21 IP 65
T5 @ -20°C ≤ Tamb ≤ +55°C,
EN 60079-0:2004
EN 60079-1:2004
EN 61241-0:2006
EN 61241-1:2004
0518
InMetro
BR Ex d IIB T5
T5 @ -20°C ≤ Tamb ≤ +55°C,
Analog Feedback Option Specifications:
Options T, D, E, S - 4-20 mA Transmitter
Voltage Supply: 6-30 VAC
Impedance: 300 Ohms at 20 mA
Options A, B, C - Potentiometer Output
Maximum Load: 1 Watt
Enclosure Ratings
NEMA 4, 4x, 7, and 9
IP67(CSA only)
Hazardous Location Approvals:
All Switch Options
Flame-proof
Mechanical Switch Options FM U.S. Canada Intrinsically Safe Switch Options
Explosion-Proof (UL/CSA/) Switch Type: MG, PE, PT, P4, N8, NQ, NP
Class I, Divisions 1, Groups C and D Class I,II,II Division 1 Groups A,B,C,D,E,F,G T5
Class II, Divisions 1, Groups E, F and G
Class II, Division 2, Groups F and G
Class III (CSA only)
Proximity / Solid State Switch Options
Explosion-Proof (UL/CSA)
Class I, Division 1, Groups C and D
Class I, Division 2 Groups A, B, C and D T3
Class II, Divisions 1, Groups E, F and G
Class II, Division 2, Groups F and G
Class III (CSA only)
NOTE: When using a sealed proximity switch (P4, P5, PP, and PL ) in North American Division 2 applications, a
sealing fitting is not required.
Product Nomenclature:
Prefix
W - Worcester Controls
SHAFT TYPE
D - Double “D” Shaft
N - NAMUR Shaft
M - 0.085 Double “D” Shaft
BODY STYLE
XCL - Aluminum Housing, Explosion-proof / Flame-proof, (2) ¾” NPT Conduit
XML - Aluminum Housing, Explosion-proof / Flame-proof, (2) M25 Conduit
INDICATOR TYPE
1 - Flat Top Cove, No Indicator
U - Standard Ultradome (Green / Red)
3 - Four Window Ultradome
C - 90’ 3-Way Ultradome
D - 180’ 3-Way Ultradome
E - 180’ 3-Way Center Blocked Ultradome
F - 120’ Thru / Divert Ultradome
H - Black / Gray / Yellow Ultradome
K - Green / Red with Ektar Ultradome
P - Stainless Steel Arrow Indicator
R - Reverse – Red = Open / Green = Closed Ultradome
W - White (=closed) / Blue (=open) Ultradome
X - Three Position Type 6 White (=closed) / Blue (=open) Ultradome
NUMBER OF SWITCH ELEMENTS
0 - 0 Switch Elements
1 - 1 Switch Element
2 - 2 Switch Elements
4 - 4 Switch Elements
SWITCH ELEMENT TYPE
00 - No Switches (empty housing)
M1 - SPDT Mechanical
MA - SPDT Mechanical with Cams for 3-Position control (see note 1)
MD - DPDT Mechanical with Cams for DA 3-Position w/ Indication (see note 1)
MS - DPDT Mechanical with Cams for SR 3-Position w/ Indication (see note 1)
MC - SPDT Mechanical – Construction for 250’ F
MG - SPDT Mechanical – Gold Contacts
M3 - DPDT Mechanical – Cherry
MB - DPDT Mechanical – Licon
P4 - SPST Proximity
P5 - SPDT Proximity
PE - Sabre SPDT Proximity
PP - Phazer II SPDT Proximity
PL - Phazer II SPDT Proximity with LED
PT - Phazer II BRS SPST Proximity
PX - Phazer II BRS SPST Proximity with LED
N8 - P&F NJ2-V3-N / NJ2-V3-N-V5 (NAMUR)
N9 - P&F NBB3-V3-Z4
NQ - P&F NJ4-12GK-N (NAMUR)
NR - P&F NJ4-12GM40-E1 (3-Wire NPN NO)
NS - P&F NJ4-12GM40-E2 (3-Wire NPN NO)
NT - P&F NJ4-12GK40-E2 (3-Wire NPN NO)
NP - P&F SJ3.5-N (NAMUR)
NU - GO SWITCH proximity
SN - 3-Way Pneumatic Valves
FN - DeviceNet Controller Card, 4 in / 2 out, with (2) type 4 switches
FZ - AS-i 2.1 Controller Card, 4in / 2 out, with (2) type 4 switches
CERTIFICATIONS
- (see note 2)
-14 - General Purpose
-17 - (CSA/UL) Class I, Div 1, CD; Class I Div 2, ABCD T3; Class II Div 1, EFG; Class II Div 2, FG;
Class III T5
-18 - UL/CSA Cl I, Div 1 Gr CD / Cl II Div 1,2 Gr EFG/ ATEX II 2G Ex d IIB T5
-19 - ATEX - II 2 G Ex d IIB T5; ; II 2 D Ex tD A21 IP 65
-25 - IECEx - Ex d IIB T5; Ex tD A21 IP 65
-26 - InMetro – BR Ex d IIB T5
-27 - Factory Mutual/CUS Intrisically Safe Class I,II,III Div 1 Gr A,B,C,D,E,F,G T5 (See Note 7)
-M1 - Metal Nameplate UL/CSA Cl I Div 1 Gr CD / Cl II Div 1,2 Gr EFG
-M2 - Metal Nameplate UL/CSA Cl I Div 1 Gr CD Div 2 Gr ABCD T3 / Cl II Div 1,2 Gr EFG
ANALOG OUTPUT OPTIONS
- (see note 3)
-0 - None
-T - 4-20mA Transmitter (40’ to 100’ travel)
-D - 180’ Travel 4-20mA Transmitter
-A - 0-1k Ohm Potentiometer
-B - 0-5k Ohm Potentiometer
-C - 0-10k Ohm Potentiometer
WIRING OPTIONS
0 - None
1 - Brad Harrison Connectors -3 pins
2 - Brad Harrison Connectors -5 pins
3 - Brad Harrison Connectors – 7 pins
H - Heavy Duty Terminal Block
P - Sealed/Potted Leads (see note 4)
MINIMUM OPEN TERMINALS OPTION
2 - 2 (standard – see note 5)
4 - 4
6 - 6
8 - 8
SPECIAL OPTIONS
0 - None
L - Lubricated (greased) cover Cover Bolts
N - No Silicone
P - 180’ Potentiometer Gears (for analog options A,B, or C)
V - Viton O-Rings
COATING OPTIONS
0 - Black Polyester Powercoat
E - White Epoxy Coated
W - White Epolon II
Part
Materials
Housing/Cover
Aluminum w/Dichromate & Polyester Powdercoat
Shaft
Stainless Steel
Cams/Splines
Nylon
UntraDome and Rotor
Polycarbonate
Terminal Block
Nylon – Buchanan TBS Series
Internal Brackets
Stainless Steel or Plated Steel
All Internal Fasteners
Stainless Steel or Plated Steel
All External Fasteners
Stainless Steel
UltraDome
Lexan or Ektar™
Rotor
Polycarbonate
Notes
1) MA switch element must be ordered with qty. (2) switch elements. MD and MS switch elements must
be ordered with qty. (4) switch element
2) Certifications:
Valid certification codes for Mechanical Switches ( options M1,MA,MD,MS,MC,MG,M3 and MB) include
-14, -18, -19, -25, -M1
Valid certification codes for Proximity Switches (options P4,P5,PE,PP,PL,PT,PX,N8,N9,
NQ,NR,NS,NJ,NP, and NU include -14,-17, -18,-19,-25, -M2
Valid certifications codes for Analog Output (options T,D,A,B,D) include -14,-18,-19,-24, -M1
3) Transmitter option available for switch options 00,M1,MG, N8 only, maximum number of switch
elements is (2)
4) When Ordering potted leads, specify the conduit (left or right), number of leads, length, and color of
wires.
5) Some models have more than (2) open terminal locations open as standards. Consult factory for
details.
6) Switch option FN(Device Net), F2, F4,(Foundation Fieldbus), SN (pneumatic switch) not approved for
ATEX or IECEx
7) Valid switch options for Intrinsically Safe (-27 code) are MG, PE, PT, P4, N8, NQ, NP
Example:
WNXCLU2M1-18-00200 = Worcester Controls brand, NAMUR shaft, XCL, Ultradome indicator, (2) SPDT
mechanical switches UL/CSA and ATEX certifications
Materials of Construction:
If the equipment is likely to come into contact with aggressive substances, then it is the responsibility of
the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the
type of protection provided by the equipment is not compromised.
Flamepath
Maximum Gap (mm)
Comment
Cover and base
0.038
Flanged joint
Operating rod and cover bushing
0.088
Cylinderical spigot joint
Cover and bushing
0.00
Interference fit
Operating rod and base bushing
0.088
Cylinderical spigot joint
Base and bushing
0.00
Interference fit
Max Safe Gaps:
GA Drawings.
Bulletin FCD WCENIM2076-05
Flowserve Corporation
Cookeville, Tennessee, USA, 38501
931 432-4021
Flowserve Flow Control UK Ltd
Haywards Heath, West Sussex, Uk
44 (0)1444 314400
Flowserve Corporation
12 Tuas Avenue 20
Singapore
68798900
Flowserve Corporation
Rua Tocantins, 128
São Caetano do Sul, SP, Brazil
55 11 2169-6300
Flowserve Corporation
Korta Gatan 9
SE-171 54 Solna, Sweden
46 (0)8 555 106 00
Flowserve Suzhou
No 35 Baiyou Road
Suzhou Industrial Part
Suzhou, China 215201
05 12628888790
To find your local Flowserve representative please
use the Sales Support Locator System found at
www.flowserve.com
Or call : 1-931-432-4021
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this
Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products
should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions. Although
Flowserve can provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must
therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products.
The purchaser/user should read and understand the (INSERT OFFICIAL USER INSTRUCTION TITLE) instructions included with the product,
and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only
and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed
as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is continually improving
and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should
any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations
or offices.
For more information about Flowserve Corporation, contact www.flowserve.com or call USA 1-800-225-6989.
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