Flowserve DFC17 User Manual

Worcester Actuation Systems

WCAIM2026

DataFlo Digital Electronic Controller DFC17

Installation, Operation and Maintenance Instructions

MODELS:

10 - For

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Boards Mounted Inside 10-23 75 Actuators.

25 - For

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Boards Mounted Inside 25/30 75 Actuators.

Setpoint Inputs:

DFC17-1K (120A, 240A, or 24D) 1000 ohm Resistance

Setpoint Input

DFC17-13 (120A, 240A, or 24D) 135 ohm Resistance

Setpoint Input

DFC17-1 (120A, 240A, or 24D) 1 to 5 mA Setpoint Input

DFC17-4 (120A, 240A, or 24D) 4 to 20 mA Setpoint Input

DFC17-10 (120A, 240A, or 24D) 10 to 50 mA Setpoint Input

DFC17-5V (120A, 240A, or 24D) 0 to 5 VDC Setpoint Input

DFC17-XV (120A, 240A, or 24D) 0 to 10 VDC Setpoint Input

Voltages:

120A - 120 VAC Power Circuits

240A - 240 VAC Power Circuits

24D - 24 VDC Power Circuits

DataFlo

Digital Electronic Controller DFC17 Installation, Operation and Maintenance Instructions WCAIM2026

TABLE OF CONTENTS

Page

1.0 GENERAL 4

1.1 Basic Design 4

1.2 Environmental Considerations 4

1.2.1 Temperature 5

1.2.2 Humidity 5

1.2.3 Input Circuit Noise Protection 5

2.0

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ELECTRONIC POSITIONER CIRCUIT BOARD 5

2.1 General 5

2.2 Circuit Board Configurations 8

2.3 LED Indicators 8

2.4 Controls (Override) 8

2.5 AC Power Control 8

3.0 WIRING OF DIGITAL CONTROLLER AND SERIES 75 ELECTRIC ACTUATOR 8

3.1 Actuator Power 8

3.1.1 Wire Size 8

3.1.2 Termination and Voltage 8

3.1.3 Minimum Fuse Ratings 8

3.2 Input Signal Connections 9

3.2.1 Milliamp 9

3.2.2 Resistive 9

3.2.3 DC Voltage 9

3.3 4–20 mA (4–75) Position Indicator Option Connections 9

4.0 OPERATION OF THE DIGITAL CONTROLLER 12

4.1 Run Mode 12

4.1.1 Run Mode Menu 12

4.1.2 Mode Change Key Sequence 12

4.1.3 Alarm Displays 12

4.2 Calibration Mode 12

4.2.1 Calibration Mode Menu 12

4.2.2 Key Sequences for Calibrating Setpoint Lower Limit 12

4.2.3 Key Sequences for Calibrating Setpoint Upper Limit 12

4.2.4 Key Sequences for Calibrating Clockwise Position 12

4.2.5 Key Sequences for Calibrating Counter-clockwise Position 14

4.2.6 Key Sequences for Calibrating Analog Process #1 Lower Input Signal 14

4.2.7 Key Sequences for Calibrating Analog Process #1 Upper Input Signal 14

4.2.8 Key Sequences for Calibrating Single-Channel RTD Process Module 14

4.2.9 Key Sequences for Calibrating Optional Two-Channel RTD Process Module 15

4.2.10 Key Sequences for Calibrating Thermocouple Process Module 16

4.2.11 Key Sequences for Calibrating Cycle Time 17

4.3 Program Mode 17

4.3.1 Program Mode Menu 18

4.3.2 Instructions for Editing Parameters 18

4.3.3 Default Values for Process Control (factory installed) 18

4.4 Manual Setpoint Mode 18

4.5 Manual Position Mode 18

4.6 Positioner Mode 18

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WCAIM2026

DataFlo

Digital Electronic Controller DFC17 Installation, Operation and Maintenance Instructions 3

4.7 Auto-Tuning Safety Considerations 21

4.7.1 Things to Know Before Tuning 21

4.7.2 Safety Concerns During Operation 21

4.8 Controller Setup 21

4.8.1 General Setup 21

4.8.2 Tuning the Controller Automatically (Open-Loop Tuning) 21

4.8.3 Tuning the Controller Manually 22

4.8.4 Some Guidelines for Control Parameters 22

5.0 TECHNICAL DATA 23

5.1 Allowable Supply Voltage Range 23

5.2 Analog Input Circuit Specifications 23

5.3 Output Circuit Specifications 23

5.4 Input Circuit Load Resistances 23

6.0 TROUBLESHOOTING 24

6.1 General 24

6.1.1 Cam Adjustment 24

6.1.2 Check Fuse F1 24

6.1.3 Check Basic Actuator for Proper Operation 24

6.1.4 Check for Noise Problems 24

6.1.5 Replace Circuit Board 24

6.2 Symptom Table 25

6.3 Troubleshooting Guidelines 26

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DataFlo

Digital Electronic Controller DFC17 Installation, Operation and Maintenance Instructions WCAIM2026

1.0 GENERAL

1.1 Basic Design

The Worcester/McCANNA

DataFlo

Digital Electronic Controller (DFC17) was designed for use with the Worcester/McCANNA Series 75 electric actuators. However, it may also be used with other actuators or electrically operated rotary devices, provided the specified load parameters as given in Section 5.3 are not exceeded.

CAUTION: This controller is sensitive to electrical noise; please see Section 1.2

PLEASE READ THIS SECTION

A. The 4–20 mA Setpoint signal input circuit of both the AC

and DC Digital Controller board is protected with a 62 mA fuse (F1). The fuse is used to protect the input circuit from an excessively high voltage. The fuse used in the input circuit is a Littlefuse PICO II very fast-acting fuse rated at 62 mA.

All DC Digital Controller boards also use a standard 1

4",

250 volt, 3 amp fuse (F2) to protect the circuit board and the power source in case of a fault in the DC motor driver integrated circuit on the circuit board.

CAUTION: It is important that the DC voltage power source be connected properly to the actuator’s terminal strip. Terminal one (1) of this strip is to have the negative or common wire connected to it. Terminal two (2) is to have the positive wire connected to it.

Note: All wiring to terminal strip should be inserted only

to mid-point of terminal strip.

For 240 VAC Digital Controller only, limit switches do not directly control the motor(s). Therefore, the actuator will not stop when the limit switches trip. Use care not to drive the actuator past its normal limits.

B. The Digital Controller board requires both a setpoint input

signal and a process input signal.

C. The Digital Controller board can be set up in several ways

for normal operation. The board is designed to control in 90° quadrants only (with alternate potentiometer gearing, 180° of rotation is available). The number of quadrants over which the board will control is determined by the number of teeth on the feedback pot pinion gear.

D. Quite often when we receive an actuator for repair, we

find that the only thing wrong with the unit is that the feedback potentiometer is out of calibration. It is very important that the feedback pot be properly calibrated for correct operation of the Controller board. It is also very important that the actuator shaft not be rotated out of the quadrant for which the feedback potentiometer has been calibrated. Whenever you have a problem with the Controller calibration, always check the feedback potentiometer calibration first. See paragraph 6.3.6 in the troubleshooting section.

1.2 Environmental Considerations

CAUTION: The

DataFlo

Digital Electronic Controller is sensitive to electrical noise on signal, process, or supply lines and in the environment. For maximum controller sensitivity, the electrical noise level should be as low as possible. Follow installation and calibration guidelines carefully and use shielded wire as stated in paragraph 1.2.3.

Flowserve recommends that all products which 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 temperatures above 120°F or below 40°F may occur. Do not store within 50 feet of any source of ozone.

Temperature and humidity are the two most important factors that determine the usefulness and life of electronic equipment.

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Quadrants of Operation

WCAIM2026 DataFlo Digital Electronic Controller DFC17 Installation, Operation and Maintenance Instructions 5

1.2.1 Temperature

Operating solid state electronic equipment near or beyond its high temperature ratings is the primary cause for most failures. It is, therefore, very important that the user be aware of and take into consideration, factors that affect the temperature at which the electronic circuits will operate.

Operating an electronic device at or below its low temperature rating generally results in a unit operating poorly or not at all, but it will usually resume normal operation as soon as rated operating temperatures are reached. Low temperature problems can be easily cured by addition of a thermostatically controlled heater to the unit’s housing.

The Worcester/McCANNA

DataFlo

Digital Electronic Controller is rated for operation between -40°F (with heater and thermostat) and 160°F. When using the Controller inside the Worcester/McCANNA 75 Series actuators, a maximum ambient temperature of 115°F is required to ensure the circuit board maximum temperature of 160°F is not exceeded.

Temperature Ranging allows the user to specify the actual process temperature conditions within the stipulated range of the measuring element, i.e., RTD or thermocouple. The control range can be as little as 50°C or 100°C respectively, or to the full range of the measuring device. For temperatures above 600°C, consult factory.

1.2.2 Humidity

Most electronic equipment has a reasonable degree of inherent humidity protection and additional protection is supplied by the manufacturer, in the form of moisture proofing and fungicidal coatings.

Such protection, and the 3 to 4 watts of heat generated by the circuit board assembly, will generally suffice for environments where the average relative humidity is in the area of 80% or less and ambient temperatures are in the order of 70°F average. Where relative humidity is consistently 80 to 90% and the ambient temperature is subject to large variations, consideration should be given to installing a heater and thermostat option in the enclosure. The heater should not increase the enclosure temperature to the point where the circuit board assembly temperature rating of 160°F is exceeded.

In those instances where the internal heater would bring the circuit board’s operating temperature near or above its maximum rating, the user might consider purging the enclosure with a cool, dry gas. The initial costs can usually be paid off quickly in the form of greatly extended equipment life, low maintenance needs, and much less process downtime.

1.2.3 Input Circuit Noise Protection

Shielded wiring should be used for all setpoint and process signal input circuit wiring regardless of length.

With separately housed Controllers, the wiring from the feedback potentiometer to the remote Controller, would be considered as signal input wiring

and should also be

shielded wire

The shields should never be used in place of one of the input wires, and the shields should be grounded to equipment housings at one end of the wiring run only. Grounding both ends of shielding can eliminate the shielding benefits because of current ground loops. If two or more shielded cables come to the Controller from different locations, ground the shields at the Controller.

2.0

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ELECTRONIC

CONTROLLER CIRCUIT BOARD

2.1 General

Figure 1 defines the location of major components and wires from the Controller Board to terminal strip connections. The Digital Controller Board is factory wired to the terminal strip either per Figure 2, Figure 3, or Figure 4, as found in Section 3.0, depending on power circuit voltage.

The feedback potentimeter leads are factory connected to the terminal block (TB1) on the Digital Controller Board.

2.2 Circuit Board Configurations

The Controller circuit board is factory supplied in one of several possible configurations:

A. The Controller circuit board will accept one of the

following setpoint signal inputs, depending on the circuit board ordered:

• 4–20 mA

• 1–5 mA

• 10–50 mA

• 0–5 VDC

• 0–10 VDC

• 135 ohm pot

• 1000 ohm pot

In addition, the setpoint value can be set remotely via the RS 485 interface, or locally with the circuit board switches. When the setpoint is entered locally, all other means of entering the setpoint are temporarily disabled.

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DataFlo

Digital Electronic Controller DFC17 Installation, Operation and Maintenance Instructions WCAIM2026

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Figure 1 – Digital Electronic Controller Circuit Board, 120/240 VAC

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Digital Electronic Controller DFC17 Installation, Operation and Maintenance Instructions 7

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Figure 1 – Digital Electronic Controller Circuit Board, 24 VDC

DataFlo

Digital Electronic Controller DFC17 Installation, Operation and Maintenance Instructions WCAIM2026

B. The Controller circuit board will accept one of the

following process signal inputs, depending on the circuit board ordered:

One of the following analog inputs:

4–20 mA

1–5 mA

10–50 mA

0–5 VDC

0–10 VDC

135 ohm pot

1000 ohm pot

One 100 ohm Platinum RTDs – NOTE: A single channel is standard. A two channel is available as a custom product and must be hard wired to the red and two black leads from circuit board identified as signal 2.

A single J, K, T, or E type Thermocouple

NOTE: Field changes to the Controller board are not advised. Consult Flowserve before attempting any modification.

2.3 LED Indicators

Light emitting diodes (LED) marked LD1 (CW) and LD2 (CCW) are in the output circuits and when lit indicate which direction the actuator is trying to drive. A third LED, LD3, is used to indicate when an alarm condition exists. If LD3 is lit, the alarm that caused it to light must be determined by looking at the liquid crystal display (LCD) and finding the alarm parameter with the UP or DN switch.

2.4 Controls (Override)

There are no adjustable controls provided on the circuit board because none are necessary. All parameters are set through the programming switches (keys) or the RS485 interface. Local pushbutton control is provided at the actuator by simultaneously pressing the SEL and UP switches (keys) for three seconds. At this point the UP and the DN switches (keys) can be used to manually position the actuator shaft. Pressing the SEL switch for three seconds will return the Controller to the run mode.

2.5 AC Power Control

The AC output circuits are controlled by solid state switches (triacs Q3, Q4), which will provide trouble-free operation for the life of the equipment they are used with,

AS LONG AS THEY ARE

OPERATED WITHIN THEIR RATINGS

The ratings for the solid state switches used in the Worcester

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Digital Electronic Controller are listed in part 5.3.

3.0 WIRING OF DIGITAL CONTROLLER AND SERIES 75 ELECTRIC ACTUATOR

See wiring diagrams located under actuator cover and/or Figures 2 through 4 for customer connections.

3.1 Actuator Power

CAUTION: Wiring should be inserted only to mid-point of terminal strip.

3.1.1 Wire Size

Power to the Controller and from the Controller to the actuator should be with wire no smaller than #18 gauge and with insulation rated for the particular application. The #18 gauge wire size is sufficient for all Worcester Series 75 actuators. When using the Controller with other makes of actuators, check the manufacturer’s current rating to determine the correct wire size.

3.1.2 Termination and Voltage

Power connections are made to terminals 1 and 2 of the terminal strip. The AC neutral or common, or DC negative wire should be connected to terminal #1 and the AC “Hot” or DC positive wire to terminal #2. Note that the AC Controller requires a minimum of 110 VAC, and a maximum of 130 VAC for the 120 VAC version and a 220 VAC minimum, 250 VAC maximum for the 240 VAC version.

Grounding wires should be connected to green colored grounding screw (if present) on actuator base or to any base plate mounting screw in the actuator.

3.1.3 Minimum Fuse Ratings

See Minimum Fuse Rating table when overcurrent protection is used in motor power circuit.

Minimum Fuse Rating for Overcurrent Protection

Actuator Size Voltage Fuse Rating

10-23 120 VAC 5 A 25/30 120 VAC 10 A 10-23 240 VAC 3 A 25/30 240 VAC 5 A 10-23 24 VDC 5 A

NOTE: This table shows the minimum rating to prevent inrush current from blowing the fuse.

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Digital Electronic Controller DFC17 Installation, Operation and Maintenance Instructions 9

3.2 Input Signal Connections

NOTES: The Digital Controller setpoint input signal circuit is

protected by

16 amp fuse, F1 (See Figure 1 and Paragraph A of

Part 1.1).

A label on the circuit board indicates the controllers setpoint and process signal configurations. See Section 5.2 for input signal specifications.

After input signal connections have been made, securely tighten all terminal screws. Keep wiring away from all rotating parts and ensure it will not be pinched when the actuator cover is installed.

3.2.1 Milliamp

DFC17-1, DFC17-4, DFC17-10 (Milliamp Setpoint Input Signal for Digital Controller)

For a milliamp setpoint signal input, the more positive or “High” signal lead should connect to actuator terminal 11. The less positive or “Common” lead should connect to actuator terminal 10. [Terminal 10 is (), Terminal 11 is (+).]

The Controller is available for use with the following signals: 1 to 5, 4 to 20, and 10 to 50 milliamps. The Controller board is factory calibrated for one of the three milliamp signal ranges and field changes are not advised.

Part 5.4 gives the nominal resistance load, which the Controller presents to the control circuit for the three signal ranges.

Comparison of resistance measurements made at terminals 10 and 11 (on the yellow and blue wires from the circuit board) against the resistances shown in Part

5.4 provides a quick way to determine the milliamp range for which a particular board is calibrated. If fuse F1 is blown, an open circuit will be indicated.

NOTE: If the circuit board has an orange wire (See Figure 1) attached to it, the board is set up for a Potentiometer Setpoint Input. See paragraph 3.2.2.

3.2.2 Resistive

DFC17-13, DFC17-1K (Potentiometer Setpoint Input for Digital Controller)

NOTE: The Setpoint Input Potentiometer is not the Feedback Potentiometer, but is an additional Potentiometer provided with the Controller, and externally located by the end user. The acceptable potentiometer values are 135 ohm for the DFC17-13 board and 1000 ohms for the DFC17-1K board.

For a potentiometer setpoint input signal, the usual connections will be as shown in Figures 2 through 5 with a “Low” setpoint command being generated when the potentiometer is rotated to its full CCW position and a “High” setpoint command when it is in the full CW position.

If the setpoint command signal is derived from other than a rotary potentiometer, it is only necessary to keep in mind that a “Low” (full CCW) setpoint signal is called for when the command potentiometer presents the least resistance between terminals 10 and 11 and the most resistance between terminals 11 and 12. A “High” (full CW) setpoint signal would be the reverse condition; the least resistance between terminals 11 and 12 and the most resistance between terminals 10 and 11.

If the “Setpoint Command” potentiometer is reasonably linear, the setpoint will be approximately 50% when the potentiometer shaft is halfway through its travel.

3.2.3 DC Voltage

DFC17-5V, DFC17-XV (Direct Voltage Setpoint Input Signal for Digital Controller)

For a voltage setpoint input signal, the more positive or “High” signal lead should connect to terminal 11. The less positive or “Common” lead should connect to terminal

10. (Terminal 10 is (), Terminal 11 is (+).)

The Controller is available for use with the following direct voltage setpoint input signals: 0 to 5 VDC and 0 to 10 VDC. The Controller board is factory calibrated for one of these two signal ranges and field changes are not advised.

Part 5.4 gives the nominal resistance load which the Controller presents to the control circuit for the two signal ranges.

3.3 4–20 mA (4-75) Position Indicator Option Connections

For units with a 4–20 mA (4–75) position indicator option installed (indicator board installed over limit switches) the red and black wires from the position indicator board will have to be spliced directly to the external positive and negative output (meter) wires respectively.

Note: Before wiring, calibrate indicator board per the following paragraph. All other wiring of option, including the dual potentiometer, has been done at the factory.

To obtain proper 4–20 mA output, the indicator board output has to be calibrated prior to wiring red and black wires. Using an ammeter connected to the red and black wires of the indicator board, adjust the two potentiometers R4 and R5 on the board. With the actuator in the closed position (0%), adjust R5 potentiometer (adjacent to the number “4” etched on the circuit board and closest to terminal block) to obtain 4 mA on the ammeter. Move the actuator to the open position (100%) and adjust R4 potentiometer (adjacent to the number “20” etched on the circuit board) to obtain 20 mA. Because adjustment of one potentiometer affects the other, repeat the procedure several times to obtain proper values.

NOTE: If a dual pot option only is installed, the “B” pot leads will have to be wired directly to external device. The “A” pot leads are factory connected to the terminal Block (TB1) on the Digital Controller Board. Also, note that the “B” potentiometer has a voltage limit of 30 volts maximum.

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