Flowserve WXCL User Manual

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: