Flowserve DRC-17 User Manual

FCD WCAIM2058-01

(Part 60130)

Worcester Actuation Systems
DataFlo Digital Electronic Remote Controller DRC-17

Installation, Operation and Maintenance Instructions

MODELS:

10 – For DataFlo Remote Controller and 10-23 75 Actuators

25 – For DataFlo Remote Controller and 25/30 75 Actuators

Setpoint Inputs:

DRC17-1K 1000 ohm Resistance Setpoint Input

DRC17-13 135 ohm Resistance Setpoint Input

DRC17-1 1 to 5 milliamp Setpoint Input

DRC17-4 4 to 20 milliamp Setpoint Input

DRC17-10 10 to 50 milliamp Setpoint Input

DRC17-5V 0 to 5 VDC Setpoint Input

DRC17-XV 0 to 10 VDC Setpoint Input

Voltages:

120A – 120 VAC Power Circuits

240A – 240 VAC Power Circuits

2 DataFlo Digital Electronic Remote Controller DRC17 WCAIM2058

Flow Control

Worcester Actuation Systems

TABLE OF CONTENTS

1.0 GENERAL 3

1.1 Important Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.2 Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.3 Operating Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.0 FIELD INSTALLATION OF MOTOR DRIVER BOARD INTO SERIES 75 ACTUATOR 4

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.2 Mounting Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.3 Mounting Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.0 WIRING OF THE DIGITAL CONTROLLER 7

3.1 Wiring the DRC Motor Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.2 Wiring From the DRC to the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.3 Wiring the DRC Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.3.1 Wiring for a Current Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.3.2 Wiring for a Potentiometer Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.3.3 Wiring for an Analog Current Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.3.4 Wiring for an RTD Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.3.5 Wiring for a Thermocouple Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.3.6 Serial Communications Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3.3.7 Alarm Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3.3.8 Position/Control Select Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3.3.9 Position Feedback Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

3.3.10 Utility Voltage Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

3.3.11 Spare Connection Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.0 OPERATION OF THE REMOTE CONTROLLER 14

4.1 General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.2 The DRC Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.3 Changing Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.4 Tuning the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.5 The Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.5.1 The DRC Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.5.2 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.6 Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.6.1 Entering the Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.6.2 Examining and Changing Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.6.3 Setting Default Factory Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.6.4 DRC Programmable Parameter Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4.7 Manual Setpoint Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.7.1 Entering the Manual Setpoint Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.7.2 Enabling, Disabling, and Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.8 Manual Position Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.8.1 Entering the Manual Position Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.8.2 Changing Valve Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.8.3 Auto-Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.8.3.1 Starting Auto-Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.8.3.2 The Automated Auto-Tune Procedure and Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.9 Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.9.1 Entering the Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.9.2 Calibration of Valve Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.9.3 Calibration of Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4.9.4 Calibration of 4-20 mA Setpoint Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4.9.5 Calibration of a Potentiometer Setpoint Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4.9.6 Calibration of an Analog (4-20 mA) Process Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4.9.7 Calibration of an RTD Process Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

4.9.8 Calibration of a Thermocouple Process Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

5.0 TECHNICAL DATA 25

6.0 TROUBLESHOOTING 26

1.0 General

The Worcester Actuation Systems Dataflo Remote Controller (DRC17)
was designed for use with the Worcester Series 75 electric actuators.
However, it may also be used with other actuators or electrically
operated rotary devices, provided the specified load parameters given
in Part 5.5 are not exceeded.

1.1 Important Items

PLEASE READ THIS SECTION

1.1.1 Sensitivity to Electrical Noise

The Dataflo Remote Controller (hereafter referred to as
the DRC) is sensitive to electrical noise on signal, process
and power supply lines. The DRC can also be affected by
radiated electrical noise. For maximum controller
sensitivity, the electrical noise level should be as low as
possible. Follow the installation and calibration guidelines
carefully and use shielded cable as noted in the paragraph
below.

Shielded wire should be used for all setpoint and process
signal input circuit wiring regardless of length. The
wiring from the feedback potentiometer and the control
signals between the actuator and the DRC enclosure
should be in a shielded cable as shown in section 3.0. If
multiple cables are used, their individual shields must be
attached together inside the actuator and connected as
shown for the one shield. A shield should never be used
as one of the signal wires. Shields for setpoint and
process signals should be grounded at their source and
not connected at the DRC.

NOTE: ALL WIRING TO TERMINAL STRIPS SHOULD BE
INSERTED ONLY TO MID-POINT OF TERMINAL STRIP.

For 240 VAC DRC 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.

1.1.2 Fuses and Input Currents

The Setpoint input circuit is protected with a fuse (F1)
located on the microcontroller board inside the DRC
enclosure. The fuse is used to protect the input circuit

from excessively high current. The fuse is a ¹⁄₁₆ Amp
(about 62 mA) fast-acting fuse (Littlefuse PICO II or
equivalent). Although this fuse limits excessively high
currents, care should be taken to prevent current values
that are less than 62 mA but above 20 mA. High current
that would not cause the fuse to open might cause
excessive heating of the sense resistor. This fuse is
mounted in a socket holder for easy replacement.

The power supply circuit is protected with a fuse (F1)

located on the DRC Power Supply Board. This fuse is ¹⁄₄
Amp slow-acting fuse used to protect the power supply
from excessive current. If this fuse opens, the DRC
should be returned to Flowserve for service.

If the Analog Process Module is used, it also contains a
fuse for protection. The fuse (F1) is the same as that
described for the Setpoint circuit and is located on the
Analog Process Module. Although this fuse limits
excessively high currents, care should be taken to prevent
current values that are less than 62 mA but above 20 mA.
High current that would not cause the fuse to open might
cause excessive heating of the sense resistor. This fuse is
mounted in a socket holder for easy replacement.

1.1.3 Valve Actuator Configurations

The DRC electronics are designed to control the valve
actuator in 90° quadrants only, however with alternate
feedback potentiometer gearing, 180° of rotation is also
available. The number of quadrants over which the board
will control is determined by the number of teeth on the
feedback potentiometer pinion gear.

Quadrants of Operation

1.1.4 Position Feedback Potentiometer Calibration

Quite often, units received for repair are totally functional
except the feedback potentiometer (pot) is out of
calibration. It is very important that the feedback pot be
properly calibrated for correct operation of the DRC. It is
also very important that the actuator shaft not be rotated
out of the quadrant for which the feedback pot has been
calibrated. Always check the feedback pot calibration first
if calibration problems are encountered. See paragraph

6.5.6 in the troubleshooting section.

WCAIM2058 DataFlo Digital Electronic Remote Controller DRC17 3

Flow Control

Worcester Actuation Systems

4 DataFlo Digital Electronic Remote Controller DRC17 WCAIM2058

1.1.5 Storage Conditions

Flowserve recommends that all products 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 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 Operating Temperature

Operating solid state electronic equipment near or beyond its
high-temperature rating is the primary cause for most failures. It
is very important to 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 actuator housing.

The DRC is rated for operation between –40°F (with heater and
thermostat) and 160°F. The Worcester Series 75 actuator and the
DRC enclosure both require a maximum ambient temperature of
115°F to insure the circuit boards 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.

1.3 Operating 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 assemblies 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 enclosures. The heater should not increase the enclosure
temperature to the point where a circuit board assembly’s
temperature exceeds 160°F.

In those instances where the internal heater would bring a circuit
board’s operating temperature near or above its maximum rating, the
user might consider purging the enclosures 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.

2.0 Field Installation of Motor Driver
Board into Series 75 Actuator

2.1 General

If the DRC was purchased with the Motor Driver Board factory
installed, proceed to section 3.0.

2.1.1 Parts Listing

Qty Name

1 Circuit Board Subassembly

1 Insulating Board

4 Washer (Nylon)

4 Grommets (Rubber)

4 Mounting Screws (Circuit Board)

1 Nameplate – Base

1 Wiring Label – Cover

5 Cable Ties

1 Closed End Splice

1 Wire – White

1 Potentiometer Kit Subassembly

1 Bracket – Right (Long) (10-23 sizes only)

1 Bracket – Left (Short) (10-23 sizes only)

2 Spacer (Bracket) (10-2 sizes only)

2 Mounting Screws (Bracket/Spacer)

(10-23 sizes only)

1 Mounting Bracket (25-30 sizes only)

2 Mounting Screw (Bracket) (25-30 sizes only)

2.1.2 Tools Needed

¹⁄₄" Nut Driver, ¹⁄₈" screwdriver, needle nose pliers, ¹⁄₁₆"
Allen wrench (cams and spur gear).

2.1.3 Operation Check of Basic Actuator

Set cams for about 1° to 3° of over travel in each
direction (full-open and full-closed). That is, for 0° to 90°
operation set at minus 3° and plus 93°. Power terminals
1 and 3 for CCW rotation, terminals 1 and 4 for CW
rotation (reference part 6.2).

Flow Control

Worcester Actuation Systems

WCAIM2058 DataFlo Digital Electronic Remote Controller DRC17 5

2.2 Mounting Potentiometer:

2.2.1 Mounting Single Potentiometer into Series 75 Actuator
(See Figure 1.)

A. With the potentiometer mounted to the potentiometer

bracket and the spur gear loosely fitted to the
potentiometer shaft, mount the potentiometer bracket
(if not already mounted) as follows:

10-23 75 Actuator: Remove the motor module
mounting screws on the side of the module furthest
away from the actuator shaft. Position potentiometer
assembly bracket holes over screw holes and line up
potentiometer shaft with center of actuator shaft,
replace and tighten screws.

25/30 75 Actuator: Attach potentiometer bracket to
motor support plate between the terminal strip and
actuator shaft with mounting screws as shown in
Figure 1.

2.2.2 Mounting Optional Dual Potentiometer Into Series 75
Electric Actuator

A dual potentiometer is also available when external
resistance indication is also desired. A dual pot consists
of an “A” & “B” pot. The “A” pot is at the front, closest to
the bracket. The “B” pot is at the rear, away from the
bracket. Each pot can serve only one function.

Note: Voltage limit of “B” pot is 30 volts maximum.

Mount potentiometer per paragraph A of 2.2.1.

2.2.3 Potentiometer Wiring
Connect the single or “A” potentiometer leads to the

terminal strip per wiring diagram. For dual pot, “B” pot
must be wired directly to external device.

2.2.4 Adjusting Potentiometer

A. Reference part 6.1 for moving the actuator shaft

electrically.

B. 10-30 75 Actuator

Place the large face gear (12) over the actuator shaft
with the gear teeth down and secure with snap ring
(16) provided.

NOTE: The face gear utilizes a friction fit to the shaft.
For best results, wipe off any lubricant that may be on
the shaft before sliding on the face gear.

CAUTION: Do not overstretch the snap ring; use the
minimum opening to allow it to slip over the gear.

C. Adjust the potentiometer spur gear until there is

approximately ¹⁄₁₆" engagement with the large face
gear. Ensure there is minimum backlash between the
gears. Tighten the spur gear set screw.

D. Rotate the face gear back and forth to ensure smooth

and easy operation of the potentiometer.

E. IMPORTANT: For 90° Valves:

See paragraph 4.9.2 for feedback potentiometer
calibration procedure.

F. The feedback potentiometer is now adjusted for use

in the 75 actuator. Add the potentiometer caution
label to the outside of the actuator cover.

CAUTION: If the actuator shaft is manually rotated a
multiple of 360° from its original position, the
feedback potentiometer will no longer be in
calibration. It must be recalibrated per paragraph

4.9.2, in order for the DRC to operate properly.

2.2.5 IMPORTANT
The feedback potentiometer is calibrated for only one 90

degree quadrant of valve operation.

If the valve and actuator output shaft is repositioned to
another 90 degree quadrant the feedback potentiometer
must be recalibrated as per paragraph 2.2.4.

The Series 75 actuators offer a manual override feature.
Whenever repositioning the valve using this manual
override capability on these actuators, move the valve
only within the 90 degrees for which the feedback
potentiometer has been calibrated.

2.3 Mounting Circuit Board

2.3.1 For 120/240 VAC 10-23 Size Electric Actuators
(See Figure 2.)

A. Mount the brackets to the actuator motors or spacers

as provided. The longer bracket is mounted to the
right side of the actuator (when facing the terminal
strip using the motor mounting screws).

B. Remove and replace motor screws carefully to avoid

stripping the threads of these self-tapping screws.

C. Once these motor screws and brackets are firmly

secured, firmly tap the motor stator to force
realignment of the top motor bearing.

D. Loosen all actuator terminal strip screws necessary to

connect the circuit board’s wiring to the terminal strip.
See manual section 3.0 for proper wiring of circuit
board to the actuator’s terminal strip. Wire routing is
important. Ensure that the wiring is not pinched and is
not near cams or mechanical brake (if installed).

E. Assemble circuit board into actuator. Slide rubber

grommets onto insulating board. Put nylon washer
under heads of self-tapping screws. (Four screws will
be used to install the circuit board onto the brackets).

F. Place circuit board over brackets. See Figure 2.

Loosely fasten board to brackets using mounting
screws.

G. The circuit board is wired to the terminal strip as

shown in section 3.0.

H. Snug down the circuit board and secure mounting

screws such that grommets are about half
compressed.

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Worcester Actuation Systems

6 DataFlo Digital Electronic Remote Controller DRC17 WCAIM2058

Flow Control

Worcester Actuation Systems

10-23 75

Plan View

25/30 75

Plan View

View A-A

View B-B

Figure 1

Item Description

1 LIMIT SWITCHES

2 MOTOR MODULE

3 MOTOR MODULE MOUNTING SCREWS (2)

4 TERMINAL STRIP

5 ACTUATOR SHAFT

6 POTENTIOMETER

7 POTENTIOMETER BRACKET

8 SPUR GEAR

9 SPUR GEAR SET SCREW

10 POTENTIOMETER LEADS

Item Description

11 POTENTIOMETER SHAFT

12 FACE GEAR

13 POTENTIOMETER BRACKET

14 MOUNTING SCREWS

15 MOTOR SUPPORT PLATE

16 SNAP RING

17 LOCKWASHERS (2)

18 NUT

NOTE: ILLUSTRATIONS SHOW SINGLE POTENTIOMETER ONLY.

WCAIM2058 DataFlo Digital Electronic Remote Controller DRC17 7

2.3.2 For 120/240 VAC 25 and 30 Size Electric Actuators:
(See Figure 3.)

A. Assemble circuit board to bracket as shown.

B. Place four rubber grommets onto the insulating

board. Put nylon washers on the self-tapping screws
and place screws through the circuit board and
insulating board. Start screws into the bracket.

C. If no insulating board is used, place a rubber

grommet between the board and the bracket. Tighten
all screws such that the grommets are about half
compressed.

D. Use two screws to fasten circuit board bracket to the

motor mounting plate (component side of the board
is facing out).

E. The circuit board is wired to the terminal strip as

shown in Section 3.0.

NOTE: Standard wiring for switches and capacitor as
shown in Figure 3 is the same for 10-23 75 actuators
and is for 120 VAC DRC only. For 240 VAC DRC, see
part 3.1.

2.3.3 Installation of Optional 4-20 Position Output Module
(if used and not factory installed)

A. The output of the position output option is suited for

a 4-20 mA DC meter with 0-100% scale (such as
General Electric type GE185) which is not part of the
package. If properly calibrated, it indicates actuator
shaft position from closed (0°, 0% to open (90°,
100%).

B. The module plugs into the upper left corner of the

Microcontroller Board located in the DRC enclosure.
Align pin 1 (soldered shut) on the module with the
lower right socket on the Microcontroller Board.

3.0 Wiring of the Digital Controller

The DRC consists of three circuit boards: 1) A motor driver board
inside the actuator housing; 2) A power supply board inside the DRC
enclosure; and 3) A microcontroller board inside the DRC enclosure.
The microcontroller board is prewired and installed to the cover of the
DRC enclosure. This wiring procedure discusses wiring for the motor
driver and power supply boards only.

Figure 4 shows the inside of the DRC enclosure. The following wiring
diagrams refer to connectors located inside the DRC enclosure and
the 75 actuator. The DRC enclosure connectors are located as
indicated in Figure 4.

For factory-installed motor driver board, wiring between board,
terminal strip and switches, and for feedback potentiometer has been
done.

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

Minimum Fuse Ratings

See table below for minimum fuse rating 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

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

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Worcester Actuation Systems

Figure 2

8 DataFlo Digital Electronic Remote Controller DRC17 WCAIM2058

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Worcester Actuation Systems

Limit Switch Locations

(SW-3 and SW-4 are optional.)

Figure 3

Figure 4

Location for

optional position

feedback module

Microcontroller

Board

Power Supply

Board

Process

Module

Alarm

LED

TB1

Top and bottom tiers are

connected together

P1

TB2

WCAIM2058 DataFlo Digital Electronic Remote Controller DRC17 9

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Worcester Actuation Systems

Power and Control Signal Wiring
120 VAC Models

Figure 5