Flowserve ESP-DC User Manual

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Cincinnati, Ohio 45242
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ESP-DC Electronic Servo Positioner

Installation & Operating Instructions

Automax electric actuators with servo control are
factory adjusted for 90 degree operation and
shipped in the full clockwise position as viewed
from the motor side.

ESP-DC Configuration

The ESP-DC board provides a variety of options for
the user. These options are made available with the
configuration of the jumpers JP1-JP6. See the table
at the bottom of this page for a summary of the
available configurations.

Servo Control Input Options

1 Connect input signal to terminals marked +IN

and -IN on the junction block J3.

A 4-20mA Current Input (100 Ohm sink) - JP1

set to "A" (left) position. This is supplied as
standard.

B 2-10 Vdc Input - JP1 set to "B" (right)

position.

Direct or Reverse Acting

1 Standard units are direct acting:

Low input (e.g. 4 mA) = CW*
High input (e.g. 20 mA) = CCW*.

2 To make reverse acting, move jumper JP2 to

the 'R' (right) position.

Fault Detection and Action

1 FAULT conditions occur when the torque of the

DC motor exceeds a preset maximum value.
This feature is used to protect the valve
hardware, the actuator hardware, and alert the
user that there may be an obstruction in the
valve. When a fault occurs, the LED labeled
'FLT' will be lit, and the actuator will stop. The
actuator must receive a signal to drive in the
opposite direction in order to reset the FAULT
condition.

*

2 By running a wire to the FLT terminal strip

location on junction block J3, a signal can be
returned to indicate if a FAULT occurs. Jumper
JP3 can be used to set the FLT terminal output
to the following:

A High - Jumper JP3 set to "P" (left) connects

the FLT terminal to the Power Supply "+"
when a FAULT condition occurs.

B Low - Jumper JP3 set to "N" (right) shorts

the FLT terminal to the Power Ground "-"
when a FAULT condition occurs.

Low Power Operation

1 The factory configures the ESP-DC for full

functionality. If low power consumption is
required, the FLT output and the LED's may be
disabled.

A FLT - to disable the FLT output, move JP4

to the "N" (right) position.

B LED's - to disable the LED's, move JP5 to

the "N" (right ) position.

Loss of Input Signal

1 If the input signal to the actuator is lost, the

ESP-DC is configured to turn full CW* as a
safety precaution.

2 The Loss of Input action above can be disabled

by setting JP6 to the "S" (lower) position. In
this case the actuator will simply stop if the
Input Signal is lost.

ESP-DC Jumper Configuration

JUMPER Factory Setting Option

JP1 - INPUT A : 4-20mA B : 2-10 Vdc
JP2 - ACTION D : Direct R : Reverse
JP3 - FLT output P : +Vcc N : GND
JP4 - FLT enable Y : Enable N : Disable
JP5 - LED enable Y : Enable N : Disable
JP6 - Loss of

Input

R : Full CW* S : Stop

* For Reverse Acting, the CW and CCW directions marked with a * are reversed.

B00156-0 Page: 1 of 4

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ESP-DC Electronic Servo Positioner

Valve Alignment and Servo Calibration

1 Connect DC power to terminals marked '+' and

'-' to junction block J3. The DC power supply
should be the same voltage as the actuating
motor (12 or 24 Vdc).

2 Safety overtravel switches disconnect the

motor if the actuator overtravels approximately
5 degrees past the full CW or CCW position.
On valves with mechanical stops, the safety
overtravel switches need to be set so that the
motor will disconnect prior to hitting a
mechanical valve stop. See note 3 under
"Trouble Shooting" on page 3 before
adjustment.

3 Minimum Position Adjustment:

Apply minimum input signal to ESP-DC terminals
+IN and -IN and adjust zero 'Z' potentiometer
until actuator stops at full CW* position and
CW** LED turns off. Turn the 'Z' adjustment CW
to move actuator CW* .

4 At the minimum signal position, the voltage from

test point TP1 to TP5 should be approximately

0.15 Vdc. If not, see note 4 under "Trouble
Shooting".

5 Maximum Position Adjustment:

Apply maximum input signal to ESP-DC and
adjust span 'S' potentiometer until actuator
stops at full CCW* position and CCW* LED
turns off. Turn the 'S' adjustment CCW to
move the actuator CCW.

6 Due to zero-span interaction, repeat steps 3

and 5 until actuator positions repeat at both
ends of travel (usually 2 to 3 times).

ESP-DC Transmitter (optional)

Note: If the ESP-DC Transmitter is used, the valve
alignment and servo calibration must be completed
with the 4-20mA transmitter installed. Servo
calibration should be performed before transmitter
calibration.
1 Connect 4-20mAdc output leads to transmitter

terminals marked '+' and '-'.

2 For 90` operation, the two jumpers on the

transmitter should be set to connect pins 1 and
3 , and pins 2 and 4. For 180` rotation, the
jumpers should connect pins 1 and 2, and pins
3 and 4.

3 Drive actuator to the full CCW position and

adjust 'S' span adjustment of the ESP-DC
Transmitter for 20mA output.

4 Drive actuator to the CW position and adjust 'Z'

zero adjustment of the ESP-DC Transmitter for
4mA output.

5 Repeat steps 3 and 4 until the desired output is

achieved at both positions. If there is difficulty
achieving the desired range, see note 4 under
Trouble Shooting on page 3.

6 Standard ESP-DC Transmitters are direct

acting.

Important Notes About Reverse Acting
ESP-DC with Transmitter

Note: Reverse acting transmitter means a 4mA

output for full CCW, and a 20mA output for full
CW position.

7 If you are using a positioner that is not factory

calibrated for reverse acting with a transmitter,
you will need to order an Adapter Kit #108921.

SPEED and TORQUE adjustments

1 The SPEED potentiometer can be adjusted to

increase (CW) or decrease (CCW) the Speed
of the actuator.

2 The TORQUE potentiometer can be adjusted to

Lower (CCW) or Raise (CW) the maximum
torque output of the actuator before a FAULT
condition occurs. The factory setting is full CW
(maximum Torque).

8 If you have specified a reverse acting ESP-DC

with a transmitter, JP2 is to be set on the 'D'
right position.

A The feedback potentiometer voltages as

measured from test points TP1 to TP5 on
the ESP-DC card are as follows:

FULL CCW ~ 0.15 Vdc

FULL CW ~ 1.42 Vdc
The drive LED's will now indicate the opposite of
the actual drive travel.

* For Reverse acting, the CW and CCW directions marked with a * are reversed.

B00156-0 Page: 2 of 4

11444 Deerfield Road
Cincinnati, Ohio 45242
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ESP-DC Electronic Servo Positioner

Trouble Shooting

Note: All of the Test Point voltage
measurements are taken in reference to test
point TP5 labeled "REF."

1 Actuator does not respond to the input signal.

A Verify proper input configuration and signal

polarity connections. Measure voltage at
TP4 and verify it's in the range .4 to 2.0 Vdc.

B Verify the proper power connections. Refer

to the schematic on page 4.

2 Actuator does not travel when CW or CCW

LED is lighted.

A Check the safety overtravel cams and

overtravel switches, and adjust as needed
(see note 3).

B If actuator exceeds full CW or CCW

positions, check the feedback potentiometer
voltage (see note 4).

3 Safety overtravel switches need adjustment.

Note: On valves with mechanical stops, the
safety overtravel switches must be set so that
the motor will disconnect prior to hitting the
mechanical valve stops.

A Disconnect the actuator power connector J1

from the ESP-DC.

B Drive the motor to 5 degrees past full CW by

placing DC power directly on the terminal of
the actuator electric motor. To drive the
motor CW, place +DC on the terminal with
the red wire. Be careful not to drive the

actuator into any mechanical stops. This
may damage the actuator and the valve.

Set the CW cam so the overtravel switch
trips.

C While setting CW safety overtravel switch,

ensure a voltage between 0.10Vdc and

0.20Vdc is measured at test point TP1
when switch is tripped. Otherwise see note
4 in this section.

from B. Adjust CCW cam (bottom) until
switch trips.

4 With the actuator in full CW position, the

feedback potentiometer voltage should read
approximately 0.15 Vdc at TP1. If the feedback

potentiometer is not set correctly, the "dead
spot" at the end of the pot's rotation may cause
over/under travel or a lack of transmitter range.

A Loosen potentiometer drive gear and rotate

potentiometer until approximately 0.15 Vdc
is measured at TP1, and then re-tighten
drive gear.

B Recalibrate ESP-DC Zero and Span

adjustments, starting with Step 3 on page 2.

5 Actuator is oscillating or is not responsive to

small input changes, the Dead Band 'DB'
potentiometer may need adjusting.

A Drive actuator to mid position and turn DB

CCW until both LED's energize, then
immediately turn CW until both LED's
de-energize. Turn adjustment CW an
additional 1/4 turn and operate actuator over
full range in small increments to check
operation. Voltage from test point TP2
should measure approximately 0.10 Vdc.

6 The FLT LED is lit and the actuator won't move:

The FLT LED indicates a FAULT condition,
where the actuator is drawing too much current.
Check the TORQUE potentiometer setting,
turning CW to increase the FAULT current limit,
Drive the actuator in the reverse direction to
reset . If this doesn't work, there may be an
obstruction in the valve.

7 Special precautions for operating the ESP-DC.

A It is always necessary to limit actuator from

repeated safety overtravel switch trippage.

B Always remove DC power to actuator, prior

to removing input signal, and apply signal
prior to applying DC power to actuator.

D Drive the actuator CCW until approximately

5 degrees past the standard full CCW
position by applying power to the motor
terminals, this time with the opposite polarity

B00156-0 Page: 3 of 4

Performance Data

LINEARITY 1%

RESOLUTION 1.0 `

DEADBAND 1%

HYSTERESIS 0.5 %

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Cincinnati, Ohio 45242
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ESP-DC Electronic Servo Positioner

INPUT 4-20 mA

+

­POWER SUPPLY

12/24 Vdc

TP1
FB

TP2
DB

TP3
OUT
TP4

IN

TP5
REF

DB
Z
S

JP1

Is
+IN

-IN
FLT
+

-

ESP-DC TRANSMITTER

+

-

JP4

Y N
P

JP3

J4

TORQUE

N

SPAREFUSE

JP2

R D

A

B

J5

JP6 R

S

Z S

JP5 Y

N

CW CCW FLT

SPEED

GREEN
YELLOW
BLUE

TO FEEDBACK POT.

TO MOTOR

Fig. 1 ESP-DC wiring diagram

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Cincinnati, Ohio 45242
[phone]
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B00156-0 Page: 4 of 4

Service Center

4214 Bluebonnet Drive
Stafford, Texas 77477
[phone]
Fax [phone]

Service Center

7445 Whitepine Road
Richmond Virginia 23237
[phone]
Fax [phone]

Automax Controls, Inc.

120 Vinyl Court
Woodbridge, Ontario L4L 4A3
[phone]
Fax [phone]

11444 Deerfield Road
Cincinnati, Ohio 45242
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Calibration Voltages

Actuator Angle TP1 Voltage

-10` Mechanical Stop

-5` Safety Overtravel Switch 0.10
0` CW Position

(4mA Direct)
(20mA Reverse)

90` CCW Position
(20mA Direct)
(4mA Reverse)

95` Safety Overtravel Switch 1.50
100` Mechanical Stop
180` Positioning Option 2.70

0.05

0.15

1.42

1.57

ESP-DC Electronic Servo Positioner

Technical Assistance

If technical assistance is required, please
have the following information ready
before calling:

A) Actuator model number.
B) Actuator serial number.
C) Actuator sales order number.
D) Input signal configuration used.

B00156-0 Page: 5 of 4