Flowserve 90 User Manual

Worcester Controls
07334-F
Modular Accessory System (Series 90)
Installation, Operation and Maintenance Instructions
I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
II. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
A. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
B. Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
III. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
A. Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1. Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Operation, and Maintenance Manual, depending on which options are being used, are as follows:
Solenoid Block Options – Part number 18460 Switch Options – Part number 18472 Feedback Options – Part number 18430 Positioner/Controller Options – Part Number 18478 Heater Option – Part Number 09258
2 Modular Accessory System (Series 90) 07334-F
I. INTRODUCTION
The MODULAR ACCESSORY SYSTEM SERIES 90 (OR 90 M.A.S.) is designed to provide a wide choice of valve position feedback and pneumatic valve actuator control functions. Applications range from simple end-of-travel limit switch indication to automated control using feedback from a system parameter sensor (temperature, flow rate, etc.). Maximum ambient temperature is 110°F for models with solenoid and 160°F for models with electronics and no solenoid.
The concept behind the unit is flexibility, allowing the user to customize a M.A.S. for a particular application. For this reason, only individual installation instruction sheets pertaining to the specific options being used are combined with this Installation, Operation and Maintenance Manual. Please note – this unit is a complex device and not all options can be accommodated simultaneously. A table summarizing the available options follows. Note that the presence of the POSITIONER or CONTROLLER options changes the list of available options. Certain options also require the addition of a second terminal block which will be provided in the M.A.S. unit or kit when required.
a WARNING: The series 90 M.A.S. is an electromechanical device subject to normal wear and tear. Its life is dependent upon application and environmental conditions. Breather/Drain fittings are recommended for humid environments when moisture may condense inside the sealed M.A.S. housing.
CAUTION: Flowserve recommends that all product that must be stored prior to installation be stored indoors, in an environment suitable for human occupancy. Do not store product in areas where exposure to relative humidity above 85%, acid or alkali fumes, radiation above normal background, ultraviolet light, or temperature above 120°F or blow 40°F may occur. Do not store within 50 feet of any source of ozone.
M.A.S. MODEL: The M.A.S. product code per the appropriate options is
marked on the name plate as the M.A.S. model number, with the exception of the voltage rating (if any) and product revision level (R#). Voltage rating and R# are marked in separate locations on the nameplate.
The Product Code is Composed of:
Size . . . . . . . . . . . . . . . . Size of actuator (10, 15, 20, etc.) to which
the M.A.S. will be mounted. Will be blank if unknown.
Product Options . . . . . . See below.
Product Series . . . . . . . . 90
Action . . . . . . . . . . . . . . blank – if no solenoid
S – single-acting solenoid D – double-acting solenoid
Direction . . . . . . . . . . . . blank – if standard
R – if reverse-acting
Switch Options . . . . . . . See below.
Circuit Board . . . . . . . . . P – Positioner
C – Controller Blank if none
Input Signal . . . . . . . . . 1 – 1-5 mA
(If P or C is used) 4 – 4-20 mA
10 – 10-50 mA 13 – 0-135 ohms 1K – 0-1000 ohms
Setpoint . . . . . . . . . . . . . 4 – 4-20 mA
(If Controller) K – 0-1000 ohms
Custom Product No. . . . P, T, C, or similar number
(If special)
Product Code Examples: 20 H 90 D M2 C 4 K
10 90 S P6 T3293
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Available Options
Non-Positioner/Controller Units Positioner/Controller Units
Order Codes and Descriptions Order Codes and Descriptions
B – Breather/Drain Fitting
H – Heater
D – Dual-Feedback Potentiometer P – Single-Feedback Potentiometer 4 – 4 to 20 Milliamp Feedback
S – Single-Acting Solenoid Block
(One Three-Way Solenoid)
D – Double-Acting Solenoid Block
(One Four-Way Solenoid)
M2 – 2 SPDT Mechanical Switches M4– 4 SPDT Mechanical Switches D2 – 2 DPDT Mechanical Switches P6 – 2 AC Proximity Switches P8 – 2 DC Proximity Switches
120A – 120 Volt AC Solenoid 12D – 12 Volt DC Solenoid 24D – 24 Volt DC Solenoid
B – Breather/Drain Fitting
H - Heater
P – Single-Feedback Potentiometer 4 – 4 to 20 Milliamp Feedback
S – Single-Acting Solenoid Block
(Two Three-Way Solenoids)
D – Double-Acting Solenoid Block
(Two Three-Way Solenoids)
M2 – 2 SPDT Mechanical Switches
P6 – 2 AC Proximity Switches P8 – 2 DC Proximity Switches
120A – 120 Volt AC Solenoids 12D – 12 Volt DC Solenoids 24D – 24 Volt DC Solenoids
P – Positioner Circuit Board
(Various Input Signal Options)
C – Controller Circuit Board
(Various Input Signal and Set Point Options)
II. INSTALLATION
A. Mounting Instructions
1. Refer to Figure 1. The series 90 is designed to be mounted in-line with the major axis of the actuator. The air connections for the series 90 should be on the same end as the air connections for the actuator. The standard 39 actuator has its air connections on the right-hand end cap (with the exception of the line 0539 which has its air connections on the back) as you face the actuator nameplate. The Series 90 nameplate will be on the same side as the actuator nameplate.
2. If the actuator is double-acting, rotate the actuator shaft to its clockwise position. Spring-return actuators will be in this position already.
3. Place the mounting bracket on the actuator. Brackets to be used with Series 90 positioner or controller packages may have an optional indicating scale. This scale can be oriented on either side of the actuator (depending on customer’s preference), but normally will be located on the same side as the actuator nameplate. Secure the mounting bracket with the four (4) screws and lockwashers supplied in the kit.
4. Place the coupling over the actuator shaft. (Note: For the 05 and 1039 actuators only, shallow slot is placed over the actuator shaft). Sizes 10-40 couplings have four (4) threaded holes; two are ¹₄-20 thread for set screws and the other two are #10-32 (located 45 degrees off the center line of the coupling). The two #10-32 threaded holes must be on the same side as the indicator scale (if any) on the bracket. The size 05 coupling has two (2) ¹₄-20 threaded holes for set screws only. DO NOT tighten the set screws at this time.
5. If the mounting kit is for a positioner or controller, an optional indicating arm and locknut for the coupling may be provided. If so, install this arm into the coupling and secure with the locknut. The arm will point down and extend outside the indicating scale mounted on the bracket.
CAUTION: The actuator is in its clockwise position (per step #2). The indicating arm must be installed to allow rotation of the actuator shaft in the counter-clockwise direction.
6. Place the Series 90 unit on the bracket while inserting the shaft into the coupling slot. Be certain the holes in the bracket and 90 housing are aligned and secure with the four (4) #10­32 socket head screws and lockwashers provided.
7. The coupling set screws can be tightened after the actuator has been cycled 90 degrees.
Item
No. Qty Description
1 1 Series 90 – M.A.S. 2 1 Series 39 Actuator 3 1 Mounting Bracket 4 1 Indicating Scale – Optional
(Positioner/Controller Only) 5 2 Coupling 6 2 Set Screw 7 1 Indicating Arm – Optional
(Positioner/Controller Only) 8 1 Locking Unit – Optional
(Positioner/Controller Only) 9 4 Actuator Mounting Screw
10 4 Actuator Mounting Lockwasher 11 4 M.A.S. Mounting Screw 12 4 M.A.S. Mounting Lockwasher
13 1 ¹₄" O.D. X 31" Tubing
(Cut by User)
14 2 Straight Screw 15 2 Elbow Fitting
07334-F Modular Accessory System (Series 90) 3
Flow Control Division
Worcester Controls
Figure 1
Nameplate
4 Modular Accessory System (Series 90) 07334-F
B. Air Connections
1. Series 90 mounting kits contain two (2) elbow “quick” fittings, two (2) straight “quick” fittings, and one (1) length of ¹⁄₄" O.D. tubing. Single-acting or spring-return assembles will use one elbow and one straight fitting. Double-acting assemblies will use two elbow and two straight fittings. The length of tubing will be cut to suit the assembly (one piece for spring-return, two pieces for double-acting).
2. Refer to Figure 2. Assemble the elbow fitting(s) to the actuator. Pipe thread sealant may be used on the threads (do not allow thread sealant to contaminate the internal air passages of the M.A.S.). Fluoropolymer tape thread sealant should not be used.
Actuator Size Port Thread (NPT)
05 – 20 ¹⁄₈"
25 – 40 ¹⁄₄"
3. Refer to Figure 3. Assemble the straight fitting(s) to the Series 90 housing as shown in Figure 3. The thread sizes are labeled for reference in the figure. Pipe sealant may be used on the threads (do not allow thread sealant to contaminate the internal air passages of the M.A.S.). Fluoropolymer tape thread sealant should not be used.
4. Cut the tubing provided to as short a length as possible that will still reach comfortably from the Series 90 unit to the actuator. On double-acting versions, the tubes run parallel to each other and do not cross. The operation of the actuator can be reversed by reversing the location of the tubes at the actuator. Connect the tubes to their respective actuator and series 90 ports (ref. Figures 2, 3 and 4).
5. Refer to Figure 4 for a diagram of the Series 90 air connections in each of its four (4) configurations.
a. Connect the supply air for the actuator (80 psi
nominal/100 psi maximum) to the location labeled “SUPPLY” in the appropriate sketch.
b. Locations labeled “VENT” may be fitted with a porous
muffler (or other fitting if desired) to reduce exhaust noise. Air must be allowed to flow freely from these ports. “VENT” locations must not be plugged under any circumstances.
c. Ports labeled “NOT USED” must remain plugged with the
stainless steel pipe plugs provided.
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Figure 2 – Actuator Fitting Locations Figure 3 – M.A.S. Fitting Locations
Figure 4 – Air Connections for All M.A.S. Configurations
07334-F Modular Accessory System (Series 90) 5
III. ASSEMBLY
A. Housing Assembly
The housing consists of the base, cover, shaft, baseplate, and associated hardware. The housing is assembled as received from Flowserve. For ease of maintenance, assembly instructions will be provided here.
1. Cover
CAUTION: Use care to avoid damaging the machined flange surface of the cover.
a. Apply a light coat of Cindal 2321 lubricant (or other
bearing grease) to the shaft hole.
b. Assemble the captive type cover screws through the
flange holes. The screws must be turned through approx. ¹⁄₄" of thread until they reach the clearance diameter and remain loose in the cover. Use caution to avoid cross­threading these screws. Refer to Figure 5.
c. Check to see that the shaft seal has been installed as
shown in Figure 6.
CAUTION: When assembling cover to base, be sure wires are away from any rotating parts and are not pinched between cover and base flanges.
Relubricate the shaft hole anytime cover is removed and replaced.
To avoid damaging the cover hole finish and binding the shaft to cover, check the top of the shaft for burrs or impact damage before installing or removing cover.
2. Base
CAUTION: Use care to avoid damaging the machined flange surface of the base.
a. Check to see that the shaft seal and bearing have been
installed as shown in Figure 6.
b. Apply a light coat of bearing lubricant to the shaft hole.
c. Insert the shaft through the shaft hole in the base from
the inside. The shaft fits through this hole with minimal clearance — care must be taken to avoid damaging the bearing surfaces or causing the shaft to gall.
d. Place one of the nylon thrust washers onto the shaft end
protruding outside the base. Assemble one of the snap rings to the shaft in the groove below this thrust washer (rounded side towards thrust washer – see detail).
e. Place a second nylon thrust washer over the shaft and
into place against the shaft boss on the inside of the base. Secure the shaft in place with a second snap ring in the groove adjacent to the second thrust washer (rounded side towards thrust washer – see detail).
f. Place the third snap ring into the upper groove as shown
in Figure 6.
g. If the base is machined to accept a Breather/Drain fitting
as shown in Figure 7, then the boss on the bottom of the base near the electrical conduit connection bosses will be tapped with ³₈" NPT threads. If this boss is tapped, the Breather/Drain fitting must be installed. The use of fluoropolymer tape or other thread sealant is recommended prior to installing this fitting into the boss.
h. Plug the ³₄" NPT conduit connection on the end of the
base temporarily with the threaded plastic plug provided. This plug will be removed and discarded when the unit is installed.
i. Plug the (4) ¹₄" NPT and (1) ¹₈" NPT air connection ports
with the stainless steel pipe plugs provided. Thread sealant is not recommended prior to installing these plugs. The residue left by a thread sealing compound could foul the solenoid valve air passages. If a solenoid valve option is to be installed in the unit, some of these plugs will not be used – refer to the Solenoid Block Installation Instructions to determine which plugs can be left out.
IMPORTANT: If no solenoid is to be used, all of the ports must be plugged. Refer to Figure 7.
j. The M.A.S. uses a standard O-ring to achieve both
Watertight (TYPE 4) and Explosion-proof – (TYPE 7) ratings. Refer to Figure 8.
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Worcester Controls
Figure 5
Figure 6
6 Modular Accessory System (Series 90) 07334-F
k. Refer to Figure 9. The baseplate contains one factory-
assembled terminal strip located in the “primary” (side) location on the baseplate. A second terminal strip is required with some M.A.S. options, outlined below. The extra terminal strip will be provided with the appropriate options. Attach it to the baseplate with four #4 x ³₈" self­tapping screws provided in the “secondary” (end) location.
l. Assemble the baseplate into the base using the four
#6 – 32 screws provided. Use care when tightening these screws as the baseplate is plastic and could be damaged if over-tightened.
If options such as Switches, Potentiometer kit, etc. are to be installed, they can be assembled to the baseplate prior to installing baseplate into base.
CAUTION: Avoid contacting baseplate with solvents – damage may result.
Options Requiring Second Terminal Strip *
Feedback Potentiometers – P, D, 4
Switches – M4, D2
Positioner – All
Controller – All
* Included with option or kit if required.
m. The base is provided with an alignment pin pressed into
the flange that will allow the cover to be assembled in only one orientation (See Figures 9 and10). Be certain the cover is correctly positioned prior to tightening bolts, or damage may result.
n. M.A.S. options are supplied with wiring diagrams that
should be affixed to the inside of the cover as shown in Figure 10. Note the orientation of the terminal strips on the wiring diagrams and their location in the cover.
Flow Control Division
Worcester Controls
Figure 7
Figure 8
Figure 10
Figure 9
07334-F Modular Accessory System (Series 90) 7
3. Troubleshooting
Problem Possible Cause Solution
Shaft binds Cover not Loosen cover screws
centered and allow cover to
center on shaft.
Retighten cover screws. Inadequate Remove cover and lubrication lubricate shaft hole with
bearing grease, such as
Cindol 2321. If excessive
wear or galling is
present, shaft and
affected part of housing.
Flow Control Division
Worcester Controls
Flow Control Division
Worcester Controls
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 (and often does) 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 Installation Operation Maintenance (IOM) 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.
FLOWSERVE CORPORATION FLOW CONTROL DIVISION
1978 Foreman Drive Cookeville, Tennessee 38501 USA Phone: 931 432 4021 Facsimile: 931 432 3105 www.flowserve.com
© 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and Worcester Controls are registered trademarks of Flowserve Corporation. 07334-F 9/03 Printed in USA
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