FALCON SOLENOID VALVE

OPERATING AND MAINTENANCE

MANUAL

IOM: Tech-132 Revision: D

Prepared By: L.Coolbeth Date: 7/12/96 Drafting Work Order:19848 ECN: 12044

Reviewed By: J. Kilian Date:12/20/11 Approved By: R. Frey Date:12/20/11

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
8/14/09 TECH-132/D.W.O. 11500 Page 1 of 10
Revision History

Revision
Rev.A 1/14/05: Rev. B 8/14/09: Rev. C 10/27/11: Rev. D 12/16/11

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
8/14/09 TECH-132/D.W.O. 11500 Page 2 of 10
1. Product Certification

The Falcon valves themselves carry no hazardous area approvals. Refer to approvals
of the Westlock unit on which the valves are installed.

2. Warning

Be sure to disconnect power to solenoids and pressurized air supply before conducting
any valve service or maintenance. Avoid introducing particles or chemical contaminants
into valves.

3. Description

The Falcon solenoid valve is an air piloted solenoid valve system incorporating
elastomer static seals through which a shaped spool moves and are manufactured for 3
or 4 way operation. 3 way is normally used for pilot control of the other relay valves or
for the operation of single acting cylinders. 4 way is normally used to control the action
of double acting cylinders.

4. Principles of Operation

In a typical, normally closed, spring-return Falcon valve, the spool controlling the
direction of air flow is moved by pressurized pilot air acting on a piston when the coil is
energized. The spool is returned to the normally closed position by a spring when the
coil is de-energized, and the piston is vented to atmosphere.

The spool may be manually moved to control air flow direction with override options.

The pilot air supply is normally tapped internally from the air supplied to Inlet port 1 and
power is supplied separately to coils.

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
8/14/09 TECH-132/D.W.O. 11500 Page 3 of 10
 Fig. 1 Fig. 2

Fig. 3 Fig. 4
5. Optional Features

N - No-Voltage Release (Latching)

The palm button is manually moved and latched. The inward movement of the palm
button causes the valve to shift. Open position will be sustained and latch will
automatically disengage when air and voltage are applied. When the coil is de-
energized, the valve will return to its original position. (1.2 Cv Valves only) See Fig. 1

R - No-Voltage Release (Non-Latching)

With the coil first energized, the palm button is then manually moved. The inward
movement of the palm button causes the valve to shift.
When the coil is de-energized, the palm button automatically returns to its original
position. (1.2 Cv and 3.5 Cv Valves only) See Fig. 2

L - Manual Locking Override

Manually depress palm button and rotate clockwise for maintained condition;
must manually disengage to return to original position. See Fig. 3
Coils must be de-energized before operating manual override.
M - Momentary Override
Spring return momentary push type; must hold in to actuate. See Fig. 3
Coils must be de-energized before operating manual override.

H - Hex Drive Maintained Override

Insert allen key in hex head screw and rotate clockwise (4-5 turns) to
shift spool. Valve will stay put until hex head screw is rotated counter
clockwise (4-5 turns) back to original position. See Fig. 4
Coils must be de-energized before operating manual override.

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
8/14/09 TECH-132/D.W.O. 11500 Page 4 of 10
E - External Pilot
The 1/8” NPT external pilot connection requires a separate auxiliary
pressure line to the valve. This feature should be used when the controlled
pressure supplied to inlet port 1 is below the minimum 45 psi operating pressure.

D/C - Dual Coil Option

Four way valves are available with a coil/pilot valve on each end of the
Falcon valve, coil “A” and coil “B”. When coil “A” is energized the valve
will shift. If coil “A” is then de-energized, the valve will remain in this
position. The valve will not return to the original state until coil “A”
is de-energized and coil “B” is energized. The process is the same
for coil “B”.

NOTES - For Dual Coil Valves

1. The valve may be in either position upon installation. Refer to the Air Flow
Diagrams (Fig. 5) and energize the appropriate coil (with air) to
reset valve to the desired position.

2. Dual coil valves require both an electrical signal and air pressure to operate. See
Air Flow Diagram for air pressure requirements. If either or both inputs are lost the
valve will remain in it’s 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.

Specifications
Operating Pressure: 45-120 PSIG
Operating Temperature: -4° F to 176° F
(Agency approvals may not encompass full operating temperature range).
Operating Media: Lubricated or dry air, filtered to 20 microns.

6. Order Guide

Spare Falcon valve assemblies and stand-alone valves for use outside an integrated
Westlock control monitor can be purchased through your regular sales contact. To
specify a Falcon valve as an integrated part of your Quantum or Intellis control monitor,
please consult the product ordering guides also available from your sales contact or on
the Westlock website at www.westlockcontrols.com under the control monitor of your
choice.

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
8/14/09 TECH-132/D.W.O. 11500 Page 5 of 10
Exploded Assembly of
0.5 Cv 3 way Falcon

Exploded Assembly of
1.2 Cv 3 way Falcon

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
8/14/09 TECH-132/D.W.O. 11500 Page 6 of 10
 Exploded Assembly of
0.5 Cv 4 way Falcon

Exploded Assembly of
1.2 Cv 4 way Falcon

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
8/14/09 TECH-132/D.W.O. 11500 Page 7 of 10
 7. Installation

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

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. A 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.

Dual Coil 4-way (5/2) Valve

Description of Operation: Coil B Energized -
air flows from Inlet Port 1 to Outlet Port 2 and
Fig. 5 exhausts from Port 4 to Port 5.
Air Flow Diagrams Coil A Energized -
B 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
that order.

PLUMBING AND AIR SUPPLY CONSIDERATIONS

Air mains and lines should be large enough to avoid excessive pressure loss under
conditions of maximum flow. Air lines should be installed with as few restrictions as
possible if the cost of compressed air is to be kept to a minimum. Sharp turns in piping
should be avoided for more efficient air flow and economical air power. It is advisable to
pitch the mains in the direction of air flow so that both gravity and air flow will carry the
water to traps or water legs located at frequent intervals.

To help in preventing condensed moisture from reaching the point of usage, down pipes
should never be taken directly from the bottom of air pipes or mains. Connection should
be made at the top of the main and a long radius return bend used.

The importance of proper filtration (20 Micron) of the air supply to pneumatic equipment
can never be over-emphasized as a means of preventing wear due to abrasive solids
being present in the air supply. At higher pressures than recommended, pneumatic
equipment can wear excessively or undergo seal damage with no significant increase in
output and compressed air is consequently wasted. Therefore, provide pneumatic
equipment with serviced air by including suitable air line filters, and pressure regulators
in the installation at minimum. If lubricators are used in the air line, use appropriate oil
grades, such as ISO and UNI FD22. The performance and life of pneumatic valves may
be affected by air supply conditioning methods.

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
8/14/09 TECH-132/D.W.O. 11500 Page 8 of 10
AIR FLOW

Pipe sizes are normally determined on semi empirical lines, the basis for selection being
an acceptable pressure drop (e.g. not more than 10% of the applied pressure). In sizing
pipes, consideration should be given to likely future demands, as a system will be
inefficient if the demand outgrows the supply. It is always better to over size mains as
this will reduce air velocity and make water separation more effective.

TUBES AND FITTINGS

The use of copper, stainless steel, nylon or polyethylene tube is recommended for
piping up air circuits and equipment. As a general rule, pipe threaded fittings should not
be assembled to a specific torque because the torque required for a reliable joint varies
with thread quality, port and fitting materials, sealant used, and other factors. The
suggested method of assembling pipe threaded connections is to assemble them finger
tight and then wrench tighten further to a specified number of turns from finger tight. The
assembly procedure given below is for reference only, the fitting should not be over
tightened for this will lead to distortion and most likely, complete valve failure.

1. Inspect port and connectors to ensure that the threads on both 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. Screw the connector into the port to the finger tight position.

4. Wrench tighten the connector aproximately 1 - 2 turns (to seal) from finger tight.
again this is only reference - the fitting should NOT be over tightened.

8. Field Wiring

Complete the electrical wiring in accordance with local and National Electrical Codes.
The ground wire should be secure under the green screw. Check all screws for
tightness. If the installation is in a hazardous area, all electrical leads must be sealed
with an approved compound, in accordance with local and National Electrical Codes
unless the switches are hermetically sealed. (NEC 5051-5)
Always check the nameplate to make sure the approval ratings coincide with the
application.

CAUTION: To prevent ignition of hazardous atmospheres, replace cover before

actuating the electrical circuits. Keep cover tightly closed when in operation.

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
8/14/09 TECH-132/D.W.O. 11500 Page 9 of 10
9. Maintenance and Repair

Routine maintenance is usually confined to the periodic replenishment of Dow

Corning 111 lubricant or equivalent to spool and spring if needed. Repair and overhaul
kits are available for soft seals replacement or replacement of all internal parts in the
event of catastrophic contamination of the valve. Consult your sales contact for details.

WESTLOCK CONTROLS CORPORATION

280 MIDLAND AVENUE, SADDLE BROOK, NJ 07663 TEL: 201-794-7650 FAX: 201-794-0913
www.westlockcontrols.com
8/14/09 TECH-132/D.W.O. 11500 Page 10 of 10