Westlock Control MagPAC Modular Switches | Instronline

1. THE ULTIMATE SWITCHBOX UPGRADE The MagPAC Modular Sensor

2. 02 Introduction For decades, conventional switch technology has been the backbone of the valve industry. While reliable, these switches come with limitations such as susceptibility to wear and tear, frequent maintenance needs, and less precise diagnostics. As the industry evolves, the demand for more advanced, reliable, and efficient solutions has become vital. Welcome to the future of valve monitoring with Westlock Controls’ revolutionary MagPAC switch. In an industry where reliability and precision are essential, the MagPAC stands out as a true innovation. With an impressive 100 million cycles of operation, the MagPAC offers unparalleled durability, translating up to 8 additional years of service in high-cycle environments where valves operate as frequently as once per minute. Imagine a plant where the exact position of every valve is always known. This level of precision enhances safety, streamlines startups, and boosts diagnostic capabilities. The MagPAC’s robust design ensures that operations run smoothly, with minimal interruptions and extended service life. Its dual certification for Intrinsically Safe and Non-Incendive locations further simplifies operations, providing a versatile solution that adapts to various industrial environments. Westlock's AccuTrak and Quantum series, known for their versatility and reliability, can be equipped with the advanced MagPAC switch, offering the ultimate upgrade for your valve monitoring and control system. These series, combined with MagPAC’s cutting-edge technology, deliver exceptional performance, ensuring your plant operates at peak performance even in the most demanding industrial environments. www.westlockcontrols.com THE MAGPAC MODULAR SENSOR

3. 03 AccuTrak Switchboxes The AccuTrak series is Westlock’s industry leading switchbox mastering a compact, efficient design, seamlessly integrating switches, sensors, wiring terminals, enclosures, and local visual indicators within a single unit. This all-in-one solution is engineered to cater to a wide range of valve types, ensuring unparalleled versatility and ease of use. Designed with adaptability in mind, AccuTrak switchboxes are compatible with diverse industrial environments and adhere to various hazardous area classifications. Westlock Controls is unwavering in its commitment to safety and compliance. Our dedication to meeting the highest industry standards ensures that your operations not only run smoothly but also adhere to stringent safety protocols. By adding the MagPAC switch to AccuTrak, you gain a more robust, all-encompassing solution that enhances operational life, efficiency, and safety with intuitive LED indication for tool-free diagnostics. www.westlockcontrols.com THE MAGPAC MODULAR SENSOR

4. 04 Quantum Control Monitors Westlock’s Quantum series combines the valve monitoring of AccuTrak, plus control into a single, efficient solution. Quantum Control Monitors streamline monitoring and automation processes, featuring a pre-wired solenoid pilot valve with assorted material options, coil voltages, coil quantities, and Cv ratings to best suit your application. By integrating the MagPAC sensor and low-power solenoid valve into one switchbox, Quantum enables faster commissioning and precise control of pneumatic actuators. The modular pack gives you an additional level of diagnostics with a built-in visual indicator to the Falcon V solenoid valve, showing spool valve position with just a glance. Innovative Bifurcated Design degradation over time. These switches typically rely on simple make-and-break contact mechanisms that can suffer from oxidation and stickiness, leading to decreased performance and potential failure in high-cycle environments. The MagPAC stands out with its innovative bifurcated switch design, which delivers exceptional snap-acting breaking forces. This design effectively shields the switches from in-rush currents caused by capacitive discharge, ensuring consistent and reliable performance. Additionally, the switch contact motion emulates a wiping action, which cleans the contacts of oxidation and stickiness in low-power circuits. This feature is specifically engineered for high-capacitance feedback, guaranteeing precise performance in all conditions. discrete and position dependable www.westlockcontrols.com THE MAGPAC MODULAR SENSOR

5. 05 Sealed for Maximum Reliability The MagPAC is engineered with its switch elements hermetically sealed to offer comprehensive protection against atmospheric conditions. This robust sealing ensures maximum lifespan and reliability, safeguarding the internal components from environmental factors such as moisture, dust, and corrosive substances. The hermetic sealing MagPAC’s switch elements is particularly beneficial in demanding industrial environments. For instance, in corrosive chemical plants, the sealed design prevents exposure to harmful chemicals, ensuring long-term operational integrity. In high-temperature power plants, the MagPAC maintains its performance and reliability even under extreme heat, where conventional switches might fail. Offshore oil rigs, with their challenging conditions of saltwater exposure and varying temperatures, also benefit from the MagPAC's resilient construction, ensuring uninterrupted performance and safety. Moreover, the hermetically sealed switch elements eliminate the need for frequent maintenance and reduce the risk of failures due to environmental exposure. This translates into reduced downtime and lower maintenance costs, providing significant operational efficiencies. www.westlockcontrols.com THE MAGPAC MODULAR SENSOR

6. 06 Enhanced Field Diagnostics MagPAC sensor modules are equipped with LED indicators for intuitive field diagnostics. These exceptionally bright LEDs offer clear, individual confirmation of both switch and solenoid performance. Green and red LEDs indicate valve position, while a yellow LED shows if voltage is present in the solenoid. Additionally, with our Engineered Resin option, operators can easily view the LEDs from a distance through a transparent housing cover. With MagPAC and Quantum, an extra level of diagnostics is known through a red indicator on the solenoid valve to show spool position. When energized, the airflow shifts the spool & the indicator turns red. This enhanced visibility streamlines troubleshooting and maintenance, enabling quick identification and local diagnostics, thus minimizing downtime. Imagine a typical day in a chemical plant. The maintenance team receives a notification about a valve not responding correctly. They ultimately discover the issue lies in the IO cabinet rather than the switchbox, necessitating further investigation. Diagnosing the problem with a traditional switchbox involves deconstructing the cover and using a handheld Fluke meter to check for power, which is both time-consuming and prone to human error. With MagPAC, the team arrives at the site and simply glances at the LED indicators and spool position indicator for voltage and valve position. The MagPAC's bright LEDs and position indicator make troubleshooting straightforward: If the MagPAC’s yellow and red LEDs are on but the red indicator on the solenoid is absent, this signals a potential issue within the solenoid. This typically means no air is reaching the unit, likely due to a shut valve or a faulty coil. In such cases, coil replacement may be necessary. Fortunately, the design of the MagPAC allows for coil replacement without needing to disconnect the pneumatic lines on the valve body, simplifying maintenance and minimizing downtime. If the MagPAC’s yellow and red LEDs are on and the red indicator is present, this indicates that power is available but there is no valve movement. Maintenance technicians should listen for air blowing from the exhaust port on the solenoid. If they hear air, this points to an issue with the actuator rather than the valve, guiding them to the correct component for troubleshooting and repair. If the MagPAC’s yellow and green LEDs are on and the red indicator is present, this confirms that the system is operating normally. The yellow and green LEDs indicate the proper voltage and valve position, while the red indicator shows the solenoid is functioning correctly. This combination assures plant operators that all components are working as expected, maintaining smooth and efficient operations. www.westlockcontrols.com THE MAGPAC MODULAR SENSOR

7. 07 MagPAC’s bright LEDs are visible even in poorly lit plant areas, making routine checks quicker and more efficient. The exceptionally unique feature of a red spool indicator built into the solenoid valve, enhances MagPAC’s value as an indispensable switch pack for modern industrial environments, ensuring reliability and efficiency in valve monitoring and control. Dual Certification for Simplified Inventory One of the standout features of the MagPAC switch is its dual certification, offering both Intrinsically Safe (IS) for Class I, Division 1, and Non-Incendive (NI) for Class I, Division 2 locations. This dual certification is a game-changer for plant operations, providing unparalleled flexibility and simplifying inventory management. With these certifications, the MagPAC switch can be used safely across different hazardous locations within your plant. This means that instead of stocking multiple types of switchboxes to meet various safety requirements, you can rely on a single MagPAC switch for multiple environments. This significantly reduces the complexity of managing inventory, leading to lower storage costs, and streamlined procurement processes. The Intrinsically Safe certification ensures that the MagPAC switch can operate safely in environments where flammable gases, vapors, or dust are present, preventing potential ignition sources and enhancing overall plant safety. On the other hand, the Non-Incendive certification allows for safe operation in areas where explosive atmospheres are not likely to occur under normal operating conditions but may become hazardous in the event of an abnormal situation. www.westlockcontrols.com THE MAGPAC MODULAR SENSOR

8. 08 This versatility translates into tangible benefits for your operations. By reducing the need for different switchboxes tailored to specific hazardous areas, you not only cut down on the variety of parts required but also minimize the risk of incorrect installations. The MagPAC switch’s dual certification supports seamless integration into various parts of the plant, from high-risk zones requiring IS-rated devices to areas needing NI-rated equipment. Plug & Play Design The terminal strip's hassle-free design allows field wiring to remain in place if the MagPAC should ever need servicing. No wires need to be removed, and no screws need to be tightened—just a simple pull and plug. This feature saves time and labor by minimizing wiring errors and simplifying maintenance procedures. www.westlockcontrols.com THE MAGPAC MODULAR SENSOR

9. 09 CONCLUSION The Ultimate Switchbox Upgrade Engineered for Unbeatable Reliability The Westlock MagPAC is not just a sensor; it's a game-changer switch pack in valve monitoring and control. With its exceptional reliability, dual certification, advanced diagnostics, and user-friendly design, the MagPAC is poised to set new industry standards. Trust in Westlock Controls to deliver solutions that not only meet but exceed the demands of modern industrial environments. Embrace the future of valve monitoring with MagPAC and experience unparalleled performance, efficiency, and peace of mind. CONTACT US Phone: Email: +1-201-794-7650 globalsalessupport@westlockcontrols.com TD30006 www.westlockcontrols.com THE MAGPAC MODULAR SENSOR