Flowserve F75 User Manual

Worcester Actuation Systems

WCAIM2029

(Part 16022)

Series F75 Fail-Safe Module

Installation, Operation and Maintenance Instructions

CAUTION: 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.

1. DESCRIPTION

The Series F75 Fail-Safe Module is designed to be coupled with
Worcester/McCANNA’s Series 75 electric actuators:

• Series 20 F75 Module with Size 10 to 23 Series 75, 24 VDC Actuator.

Normal operation is accomplished utilizing a 120 or 240 VAC supply
voltage to power the Series F75 module. The module converts the AC
power to 24 VDC power, which is used to power the Series 75 actuator.

Upon loss of supply voltage, the Series F75 module latches out the
supply side circuitry and switches over to battery power to drive the
valve to the predetermined failure position. When the supply voltage
is returned, the Series F75 module can be returned to normal
operation by depressing the “RESET” switch on the face of the
module’s enclosure.

2. INSTALLATION AND WIRING

2.1 The Series F75 Module can be installed adjacent to or remote
from the actuator depending on requirements of the application. It
should be suitably mounted by the user in a well-ventilated area.
A small vent is located in the base of the enclosure to allow
venting of any battery gases should they occur. Batteries are of
the sealed type and, under normal charge/discharge usage, no
outgassing should occur. Replacement batteries should be of the
same or equivalent type.

IMPORTANT: If actuator is located in a hazardous location, the
F75 module must be remotely located away from this area.

Proper, standard industry practices should be used in wiring
Series F75 Module to actuator. Consult Figure 1 and Figure 3.

Wiring is shown for fail-safe close, fast mode. For other failure modes,
consult page 2.

Figure 1 – Worcester/McCANNA 10-23/75 24 VDC Actuator

2 Series F75 Fail-Safe Module WCAIM2029

2.2 Proper wire size should be selected from the table below for DC
power wiring between Series F75 Module and actuator to ensure
proper operation.

Cable Distance From Wire Size for

Module to Actuator 10-23 75 Actuator

Up to 50 Feet 14 AWG

100 Feet 12 AWG
200 Feet 10 AWG*

For longer distances consult factory.

* Because actuator strip wire size is limited to 12 AWG, 10 AWG wires will have to be

run to an appropriate NEMA rated box located close to actuator and 12 AWG wire run
from junction box to actuator.

2.3 Wire Series F75 Module to actuator as shown in Figure 1. AC
power input can be either 120 VAC or 240 VAC, single-phase
50/60 Hz (see Figure 2 for the 120/240 connections).

CAUTION: Internal batteries should not be connected until
actuator operation verification procedure 2.3.1 through 2.3.5 is
accomplished. Note that one lead is disconnected and insulated.

NOTE: All wiring to terminal strips should be inserted only to mid­point of terminal strips.

See 75 Actuator Installation, Operation and Maintenance
Instruction Manual for proper actuator grounding procedure.

Procedure to be followed:

2.3.1 Connect the proper single-phase AC power to the module

at terminals 9-10. Fuse protection on this line should be no
less than two amps. This AC power should be extended
from the F75 Module to the actuator terminals 11 and 12
to be used for heater if the actuator is so equipped.

2.3.2 Customer-provided external circuit for controlling the

open and closed function of the actuator/valve assembly
is to be wired between terminals 4 and 5.

2.3.3 Apply AC power to the module.

Press the “Reset” switch on the module’s front panel.

2.3.4 Close contacts between terminals 4 and 5 of the external

control circuit. The actuator will operate CCW. (For
standard fail-closed operation, the actuator/valve
assembly will be moving CCW to open.)

2.3.5 Open the contacts between terminals 4 and 5 of the

external control circuit. The actuator/valve assembly will
now move clockwise to the fail-safe position.

Leave the actuator/valve assembly in the fail-safe (closed)
position, and disconnect the module from AC power.

2.3.6 Having verified proper actuator operation under normal

line power conditions, the fail safe module’s batteries may
now be connected. AC power should be disconnected.

If two 12-volt batteries are shipped and not installed, they
have to be installed and wired as shown in Figure 3 and 4.
Before placing batteries into position inside the enclosure,
attach the black, red, and brown connector wires to the
battery terminals as shown in Figure 4.

2.3.7 Slide the batteries into position and secure with the
battery retention clamps 15 and 21 as shown in Figure 3
and 4.

2.3.8 After all battery wires are connected, verify that a minimum
of 24 VDC is available at terminals 6 and 7 and terminals 2
and 3 of the F75 Module. See note after paragraph 2.3.10.
If voltage is lower, allow at least 4 hours of operation on
the charger before operating the actuator.

2.3.9 Reapply AC power to the F75 Module.

2.3.10 Standard failure mode of operation is fail-close
(clockwise). For other failure modes see wiring per
paragraph 2.4 “Wiring for different failure modes”.

NOTE: Voltage for fully charged batteries with the F75 AC
input power off should be a minimum of 24 VDC ± .5 volts.
When power is applied, this voltage should increase by a
minimum of .5 volts within the first few hours of operation,
indicating proper charging action. When first installed, the
batteries should be allowed to reach the fully charged
condition before the F75 module is put into service. The
full-charge condition is indicated when the green panel
indicator is lighted and terminals 6 and 7 voltage is
between 27 and 28 volts with the F75 AC power input on.

2.4 Wiring for Different Failure Modes

Valve Wiring Between
Failure Actuator Actuator and Series
Mode Size Actuator Motor Wiring F75 Module

Actuator Module

Terminal # Terminal #

Close 10, 20 Red to Terminal #1. 1 2
(Clockwise) *(Fast) Black to Blue Wire Connecting 3 1
(Standard) Limit Switches. 4 3

Open 10, 20 Black to Terminal #1. 1 2
(Counter- *(Fast) Red to Blue Wire Connecting 3 3
Clockwise) Limit Switches. 4 1

Close 12, 22, 23 Black to Terminal #1. 1 2
(Clockwise) *(Slow) Red to Blue Wire Connecting 3 1

Limit Switches. 4 3

Open 12, 22, 23 Red to Terminal #1. 1 2
(Counter- *(Slow) Black to Blue Wire Connecting 3 3
Clockwise) Limit Switches. 4 1

* Marked indication “FAST” or “SLOW” on gear box of actuator will be located next to
the actuator’s shaft.

2.4.1 If heater option is used, an AC heater must be used. The
heater is wired to terminals 11 and 12 of 75 actuator
terminal strip that are then wired to terminals 9 and 10 of
the fail-safe module.

Flow Control Division

Worcester Actuation Systems

3. TESTING

The instructions below use directional conventions established for
standard wiring.

Once the Series F75 Module has been wired to the actuator, the power
source, and the external circuitry, the testing sequence has to be
completed as follows:

3.1 With AC power wired and ON, close external control circuit switch
between module terminals 4 and 5.

3.2 Press the “RESET” switch. The module will supply DC power to
the actuator from the AC power supply. The actuator will move to
the non-fail-safe, or CCW (counter-clockwise) position.

3.3 Open external control circuit switch between module terminals 4
and 5, and actuator will reverse its action — it will move to the
fail-safe, or CW (clockwise) position.

3.4 Close external control circuit switch between terminals 4 and 5 to
bring module/actuator to non-fail-safe position.

3.5 Press and hold “TEST” switch for period of at least three seconds
to simulate a power interruption of the AC power line. The
actuator should move to the fail-safe, or CW position.

3.6 Press and hold the “OPERATE” switch. Module should move
actuator to the non-fail-safe position, or CCW position. When the
“OPERATE” switch is released, the module should return actuator
to fail-safe, or CW position.

3.7 Press the “RESET” switch. The module will return to normal
operation on the AC power supply. This switch resets module to
AC power supply only if it is available.

IMPORTANT: Use paragraph 3.5 test procedure at least once a
month to verify continuous module operation and battery capability.

4. ILLUMINATED DISPLAY OF

BATTERY STATUS

4.1 The Series F75 Module is provided with an illuminated display
system to provide visual indication of battery voltage and charge
rate. The display system is comprised of three indicator lamps
(one each green, yellow and red) located on the face of the
module’s enclosure.

IMPORTANT: The indicator lamps are powered from the 120 or
240 VAC power supply and, therefore, will only be operational
when this power supply is available. The illuminated display
system is not functional during a power outage while the module
is operating the actuator on battery power.

4.2 Interpretation of the illuminated display is as follows:

4.2.1 Green – The green lamp will be illuminated when the

batteries are receiving a normal float charge from the
charging circuit. Battery voltage is between 27 and
28 VDC.

4.2.2 Yellow – The yellow lamp will be illuminated when the
batteries are being charged at a higher rate. Battery
voltage is between 20 and 27 VDC. The yellow lamp will
be illuminated as soon as the AC power supply returns
after an outage. Once the battery voltage has reached 27
VDC, the yellow lamp will go out and the green lamp will
be illuminated.

CAUTION: If the yellow lamp remains illuminated for
two days, the batteries are not being charged properly.
Verify charger operation as per paragraph 5, and if
correct, replace batteries as soon as possible.

4.2.3 Red – The red lamp will be illuminated when the battery
voltage drops below 20 VDC. This is a normal occurrence
following a power failure since the actuator has been
driven by the batteries. As soon as the battery voltage
becomes more than 20 VDC, the red lamp will go out and
the yellow lamp will be illuminated.

CAUTION: If the red lamp remains illuminated for
several hours after using battery power, the batteries
and their charging system should be checked. (See
paragraph 5, “Checking Battery Charger.”)

5. CHECKING BATTERY CHARGER

5.1 The following procedure may be used to verify proper operation
of Series F75 Module charging circuits:

5.1.1 Disconnect AC power. The actuator will move to the fail-

safe position after a delay of approximately two seconds.

5.1.2 Carefully disconnect battery leads at the terminals 6 and 7

being careful not to short battery. Cover the leads with
electrical tape after they are removed.

5.1.3 Connect a 15 watt, 50 ohm resistor across these terminals

6 and 7.

5.1.4 Apply AC power to fail-safe module. Depress “Reset”

switch. Verify that about 0.3 amps is flowing through
connected 50 ohm resistor with about 18V measured
across the resistor.

5.1.5 If voltage and current measurements are correct, charger

is working properly and batteries must be replaced. Install
new batteries using procedure described in paragraph

2.3.6, 7 and 8.

5.1.6 When new batteries are installed in the fail-safe module,

allow a minimum period of four hours of charging for the
red light to go out and the green or yellow light to go on.

5.2 New batteries should be permitted to come to the fully charged
condition (green light on) before considering the F75 Module to
be fully operational.

WCAIM2029 Series F75 Fail-Safe Module 3

Flow Control Division

Worcester Actuation Systems