Flowserve DFP17 User Manual
Worcester Actuation Systems
MODELS:
10 - For DataFlo Boards Mounted Inside 10-23 75 Actuators.
25 - For DataFlo Boards Mounted Inside 25/30 75 Actuators.
Inputs:
DFP17 - 1K (120A, 240A, 24D) 1000 ohm Input
DFP17 - 13 (120A, 240A, 24D) 135 ohm Input
DFP17 - 1 (120A, 240A, 24D) 1 to 5 milliamp Input
DFP17 - 4 (120A, 240A, 24D) 4 to 20 milliamp Input
DFP17 - 10 (120A, 240A, 24D) 10 to 50 milliamp Input
DFP17 - 5V (120A, 240A, 24D) 0 to 5 VDC Input
DFP17 - XV (120A, 240A, 24D) 0 to 10 VDC Input
Voltages:
120A - 120 VAC Power Circuits
240A - 240 VAC Power Circuits
24D - 24 VDC Power Circuits
FCD WCAIM2037-00
(Part 17522)
DataFlo Digital Electronic Positioner DFP17
Installation, Operation and Maintenance Instructions
2 DataFlo Digital Electronic Positioner DFP17 Installation, Operation and Maintenance Instructions WCAIM2037
Flow Control
Worcester Actuation Systems
TABLE OF CONTENTS
Page
1.0 GENERAL 4
1.1 Basic Design 5
1.2 Environmental Considerations 5
1.2.1 Temperature 5
1.2.2 Humidity 5
1.2.3 Input Circuit Noise Protection 5
2.0 DataFlo ELECTRONIC POSITIONER CIRCUIT BOARD 8
2.1 General 8
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
4.0 CALIBRATION AND ADJUSTMENT 12
4.1 DataFlo Calibration Procedures, Initial Setup and Adjustment (Applies to all Models) 12
4.1.1 Calibration Procedures for Microchip U5 or U3 Rev. V2.12 and Newer 12
4.1.2 Calibration Procedures for Microchip U5 or U3 Rev. V2.11 and Older 12
4.1.3 Initial Setup and Adjustments 13
4.2 General Description of Digital Positioner 13
4.2.1 Valve Position Setpoint Input 13
4.2.2 Valve Position Feedback 13
4.2.3 Key Features of the Digital Positioner 13
4.2.4 Operating Modes 14
4.2.5 Data Readout 14
4.2.6 Local Data Entry 14
4.2.7 Display Modes 14
4.3 Program Mode 14
4.3.1 Security Code Screen 14
4.3.2 Unit Address Screen 15
4.3.3 Output Current Range 15
4.3.4 Analog Setpoint (Input) Range 15
4.3.5 Setpoint Direction - Direct-Acting (Rise), Reverse-Acting (Fall) 15
4.3.6 Setpoint Split Range START Selection 15
4.3.7 Setpoint Split Range END Selection 15
4.3.8 Setpoint Ramp - Time to Open 15
4.3.9 Setpoint Ramp - Time to Close 15
4.3.10 Setpoint Curve Function 16
4.3.11 Positioner Deadband 16
4.3.12 Loss of Signal Position and Delay Time 16
WCAIM2037 DataFlo Digital Electronic Positioner DFP17 Installation, Operation and Maintenance Instructions 3
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Worcester Actuation Systems
4.3.13 Power-On Position and Delay Time 16
4.3.14 Electronic Positioner Rotation Limits (Electronic Travel Stops) 17
4.3.15 Tight Valve Shutoff 17
4.3.16 Full Open Operation of Valve with Open Travel Limit Set 17
4.3.17 Brake On Time 17
4.3.18 Restore Factory Default Values 17
4.3.19 Run Time Cycles for Maintenance 17
4.3.20 Alarm Functions 17
4.4 Local Mode 18
4.5 Feedback Calibration Routine and Cycle Time Measurement 18
4.5.1 For Microchip U5 or U3 Rev. V2.12 and Newer 18
4.5.2 For Microchip U5 or U3 Rev. V2.11 and Older 19
4.6 Run Mode 20
4.6.1 Valve Position Screen 20
4.6.2 Input Setpoint 20
4.6.3 Cycle Count 20
4.6.4 Deadband Readout 20
4.6.5 CW and CCW Travel Time Readout 20
4.6.6 Alarm Status Readout 20
4.6.7 Changing Operating Modes 21
4.7 Default Values (Factory Installed) 21
4.8 Calibrating and Programming the Digital Positioner 22
4.8.1 Programming Switches 22
4.8.2 Programming the Positioner Board 22
4.8.3 Programming the FrE1, FrE2, FrE3, and FrE4 Curves 22
4.9 RS-485 Communications 22
4.9.1 Packet Communications Software 23
4.9.2 RS-485 Connection 23
4.9.3 Communications Software 23
4.9.4 Serial Port Setup 23
4.9.5 Monitor Display 23
5.0 TECHNICAL DATA 26
5.1 Allowable Supply Voltage Range 26
5.2 Input Circuit Specifications 26
5.3 Output Circuit Specifications 26
5.4 Input Circuit Load Resistances 26
6.0 APPLICATION NOTES 27
6.1 Bypass Switch for Manual Control (For 120 VAC Only) 27
7.0 TROUBLESHOOTING 28
7.1 General 28
7.1.1 Cam Adjustment 28
7.1.2 Check Fuse F1 28
7.1.3 Check Basic Actuator for Proper Operation 28
7.1.4 Check for Noise Problems 28
7.1.5 Replace Circuit Board 28
7.2 Symptom Table 29
7.3 Troubleshooting Guidelines 30
4 DataFlo Digital Electronic Positioner DFP17 Installation, Operation and Maintenance Instructions WCAIM2037
Flow Control
Worcester Actuation Systems
1.0 GENERAL
1.1 Basic Design
The Worcester/McCANNA DataFlo Digital Electronic Positioner
(DFP17) 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.
a CAUTION: This positioner is sensitive to electrical noise; please
see Section 1.2.
PLEASE READ THIS SECTION
A. The 4–20 mA signal input circuit of both the AC and DC Digital
Positioner 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 Positioner boards also use a standard 1
1
/4", 250 V,
3 A 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.
a CAUTION: It is important that the DC voltage power source
be properly connected 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 the
midpoint of terminal strip.
B. The Digital Positioner board is designed to receive a floating
current input signal. This allows several pieces of equipment to
be operated from the same current loop while at the same time
remaining electrically independent of each other. A floating input
signal means that the current input signal should not be
referenced to the circuit board ground. This is especially
important with DC powered circuit boards. The board power
source must have a ground independent from that of the signal
source.
C. The Digital Positioner 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.
The standard setup is 4 mA for full clockwise rotation - i.e., 0˚
and 20 mA for full counter-clockwise Rotation - i.e., 90˚ or 180˚.
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
positioner board. It is also very important that the actuator shaft
not be rotated out of the quadrant for which the feedback pot
has been calibrated. Whenever you have a problem with the
positioner calibration, always check the feedback pot calibration
first. This must be done with no power applied to the circuit
board. If the actuator is in the full clockwise position, check the
resistance between the purple and white/black potentiometer
leads. The reading should be 80-90 ohms. If it is not, rotate the
face gear until the proper reading is achieved. If the actuator
happens to be in the full counter-clockwise position then check
the resistance between the green and white/black potentiometer
leads. If necessary adjust the face gear for an 80-90 ohm
reading.
NOTE: It is not necessary to loosen or remove face gear snap
ring(s) (if present) to rotate gear, it is a friction fit. For gears that
do have snap rings, and if for any reason the snap ring(s) are to
be removed, do not over stretch them; use the minimum
opening to allow them to slip over the gear.
Figure 1 – Quadrants of Operation
WCAIM2037 DataFlo Digital Electronic Positioner DFP17 Installation, Operation and Maintenance Instructions 5
Flow Control
Worcester Actuation Systems
1.2 Environmental Considerations
a CAUTION: The DataFlo Digital Electronic Positioner is sensitive to
electrical noise on signal or supply lines and in the environment.
For maximum positioner sensitivity, the electrical noise level
should be as low as possible. Follow installation, calibration and
adjustment guidelines carefully and use shielded wire as stated
in section 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.
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
Positioner is rated for operation between -40˚F (with heater
and thermostat) and 160˚F. When using the Positioner
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.
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’s temperature rating of 160˚F is
exceeded.
In those instances where the internal heater would bring
the circuit board 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 signal input circuit
wiring regardless of length.
With separately housed positioners, the wiring from the
feedback potentiometer to remote positioner, 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 positioner from
different locations, ground the shields at the positioner.
6 DataFlo Digital Electronic Positioner DFP17 Installation, Operation and Maintenance Instructions WCAIM2037
Figure 2 – Digital Electronic Positioner Circuit Board
120/240 VAC
Flow Control
Worcester Actuation Systems
WCAIM2037 DataFlo Digital Electronic Positioner DFP17 Installation, Operation and Maintenance Instructions 7
Figure 2 – Digital Electronic Positioner Circuit Board (continued)
24 VDC
Flow Control
Worcester Actuation Systems
8 DataFlo Digital Electronic Positioner DFP17 Installation, Operation and Maintenance Instructions WCAIM2037
2.0 DataFlo ELECTRONIC POSITIONER
CIRCUIT BOARD
2.1 General
Figure 2 defines the location of major components and wires from the
Positioner Board to terminal strip connections. The Digital Positioner
Board is factory wired to the terminal strip either per Figure 4, Figure
5, Figure 6 or Figure 7, as found in Section 3.0, depending on power
circuit voltage and if 4–20mA position output option is installed.
The feedback potentiometer leads are factory connected to the
terminal block (TB1) on the Digital Positioner Board.
If a dual pot option 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 Positioner Board. Also, note
that the “B” pot has a voltage limit of 30 volts maximum.
2.2 Circuit Board Configurations
The positioner board is factory supplied for one of the seven input
signal options plus a two-wire RS-485 interface.
NOTE: Field changes to the positioner board are not advised. Consult
Flowserve before attempting any modification.
2.3 LED Indicators
Light emitting diodes (LEDs) 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 positioner 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 OPERA
TED
WITHIN THEIR RATINGS.
The ratings for the solid state switches used in the Worcester/
McCANNA DataFlo Digital Electronic Positioner are listed in
Section 5.3.
3.0 WIRING OF DIGITAL POSITIONER
AND SERIES 75 ELECTRIC
ACTUATOR
See wiring diagrams located under actuator cover and/or in Figures 4
through 7 for customer connections.
3.1 Actuator Power
a CAUTION: Wiring should be inserted only to midpoint of terminal
strip.
3.1.1 Wire Size
Power to the positioner and from the positioner 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/
McCANNA Series 75 actuators. When using the
Positioner 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
Positioner 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 the actuator base or to
any base plate mounting screw in the actuator.
3.1.3 Minimum Fuse Ratings
See table below for minimum fuse rating when over
current protection is used in motor power circuit.
Minimum Fuse Rating for Over Current 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.
Flow Control
Worcester Actuation Systems
WCAIM2037 DataFlo Digital Electronic Positioner DFP17 Installation, Operation and Maintenance Instructions 9
3.2 Input Signal Connections
NOTE: The Digital Positioner signal input circuit is protected by a 1/16
amp fuse, F1 (See Figure 2 and Section A of Section 1.1).
See Section 5.2 for input circuit 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
DFP17-1, DFP17-4, DFP17-10 (Milliamp Input Signal for
Digital Positioner)
For a milliamp 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 (+).)
This positioner is available for use with the standard
milliamp signals: 1 to 5, 4 to 20, and 10 to 50 milliamps.
The positioner board is factory calibrated for one of the
three milliamp signal ranges. A label on the circuit board
indicates the positioner’s signal range.
Section 5.4 gives the nominal resistance load, which the
positioner 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 attached to
it (See Figure 2), the board is set up for a Potentiometer
Input. See section 3.2.2 and Figure 3.
3.2.2 Resistive
DFP17-13, DFP17-1K (Potentiometer Input for Digital
Positioner)
NOTE: The Input Potentiometer is not the Feedback
Potentiometer, but is an additional potentiometer
provided by and externally located by the end user.
For a potentiometer input signal, the usual connections
will be similar to that shown in Figure 3 with a “Close”
command being generated when the potentiometer of
Figure 3 is rotated to its full CCW position and an “Open”
command when it is in the full CW position.
If the command signal is derived from other than a rotary
pot, it is only necessary to keep in mind that a “Closed”
(full CW) valve 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 full “Open” (full CCW) valve
would be the reverse condition; the least resistance
between terminals 11 and 12 and the most resistance
between terminals 10 and 11.
If the “Command” potentiometer is reasonably linear, the
actuator/valve will be approximately 50% open when the
potentiometer shaft is halfway through its travel and the
resistances between terminals 10 to 11 and 11 to 12 are
equal.
Potentiometer input circuit boards are made in two
versions, one for high resistance command circuits 1000 ohms nominal, and one for low resistance
command circuits - 135 ohms nominal.
3.2.3 DC Voltage
DFP17-5V, DFP17-XV (Direct Voltage Input Signal for
Digital Positioner).
For a voltage 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 (+)]
This positioner is available for use with the standard
direct voltage signals: 0 to 5 VDC and 0 to 10 VDC. The
positioner board is factory calibrated for one of these two
signal ranges and field changes are not advised.
Section 5.4 gives the nominal resistance load which the
positioner presents to the control circuit for the two
signal ranges.
Flow Control
Worcester Actuation Systems
Figure 3
10 DataFlo Digital Electronic Positioner DFP17 Installation, Operation and Maintenance Instructions WCAIM2037
NOTE: For all input signal circuit wiring, regardless of length, shielded wiring should be used. See Section 1.2.
Flow Control
Worcester Actuation Systems
Figure 4 Figure 5
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