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User Manual
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Flowserve I90 User Manual

Worcester Controls
WCAIM2053
(Part 19504)
Pulsair Loop-Powered Positioner Modular Accessory System (Series I90/L90)
Installation, Operation and Maintenance Instructions
I. Introduction...........................................................................................................................................2
II. Installation............................................................................................................................................4
III. Operating and Maintenance Instructions.............................................................................................6
1. Positioner Specifications and Technical Data ..............................................................................6
2. Environmental Considerations .....................................................................................................7
3. Electronic Circuit Board Basics....................................................................................................7
4. Calibration ...................................................................................................................................9
5. Recalibration..............................................................................................................................10
6. Operating Function Settings ......................................................................................................10
7. Wiring Diagrams and Fail Open Modifications Table .................................................................12
8. Troubleshooting.........................................................................................................................13
9. Circuit Board Replacement ........................................................................................................13
1. Cover .........................................................................................................................................14
2. Base...........................................................................................................................................14
3. Troubleshooting.........................................................................................................................15
1. Assembly...................................................................................................................................16
2. Wiring........................................................................................................................................17
3. Operation...................................................................................................................................18
4. Troubleshooting.........................................................................................................................18
1. Assembly...................................................................................................................................18
2. Cams .........................................................................................................................................19
3. Wiring........................................................................................................................................19
4. Operation...................................................................................................................................19
5. Troubleshooting.........................................................................................................................19
E. Feedback Potentiometer and Potentiometer Options .....................................................................20
1. Assembly...................................................................................................................................20
2. Wiring........................................................................................................................................20
3. Troubleshooting Potentiometer..................................................................................................21
1. Assembly...................................................................................................................................21
2. Wiring........................................................................................................................................21
3. Calibration .................................................................................................................................22
4. Troubleshooting.........................................................................................................................22
G. Radio Frequency Interference (RFI) Filter......................................................................................23
1. Installation and Wiring...............................................................................................................23
2 Pulsair Loop-Powered Positioner Modular Accessory System (Series I90/L90) WCAIM2053
I. INTRODUCTION
Pulsair Loop-Powered Positioner Modular Accessory System Series I90/L90
(or I90/L90 M.A.S.) is designed to provide accurate control over valve position, while providing feedback information from pneumatically actuated valves. This version of the M.A.S. uses “loop­powered” technology; the 4 to 20 milliamp signal loop provides all the power that is required to operate both the electronic positioner circuitry and solenoid valving.
The concept behind the unit is flexibility, allowing the user to customize an I90/L90 M.A.S. for a particular application. For this reason, these instructions have been arranged as a series of individual chapters, each dealing with separate options or components available in the I90/L90 M.A.S. Regardless, this unit is a complex device and not all options can be accommodated simultaneously. A table summarizing the available options follows on the bottom of page 3.
PLEASE READ (Regarding Stability of Position)
The following is to explain how the Pulsair operates from loop power, and why, with some current sources, the Pulsair may seem jittery at current input levels between 4 and 6 mA. One point that should be made clear before starting is the fact that the loop driving voltage is to be between 18 and 30 volts for the intrinsically safe board and between 18 and 35 volts for the non-intrinsically safe board.
The Pulsair is loop-powered. Loop-powered means that the 4-20 mA current signal provides both the signal to position the valve as well as providing all the power required by the circuit board electronics and the piezo valves. The piezo valve is a three-way pneumatic valve wherein the operator is a piezo crystal (a form of quartz crystal). This crystal has an unusual property. When an electrical field is placed across the crystal, the crystal distorts (bends). The crystal in the valve is shaped like a thin flat bar where the top and bottom surfaces are metallized (a metallic coating is applied to the crystal surface). The wires carrying the operating voltage are attached to these surfaces, one wire to each surface. Quartz is an insulator and, for all practical purposes, there is no current flow between the two surfaces. The crystal, therefore, electrically simulates a capacitor in operation. As with a capacitor, there is an inrush current associated with charging the piezo crystal. This can be as much as 2 mA. The valves and the circuit board must be capable of operating with a loop current as low as 4 mA and, in fact, they will operate with the loop current as low as 3.6 mA.
At this low current level it becomes very important that the current source be capable of not only maintaining the average set loop current, such as 5 mA, but also quickly responding to the power demands of the piezo valves as they operate. It is critical that the current source be capable of outputting an adjustable current that is independent of loop resistance (impedance). This means that for a set current, let’s say 5 mA, when the loop resistance changes from 50 ohms to 600 ohms (as an example) the loop current does not vary. This requires an active circuit that will quickly adjust its output voltage in order to maintain a constant set current in the loop as the loop resistance or impedance changes. The only way to increase the power available in the loop is to increase the loop driving voltage. In order for the loop driving voltage to increase and yet maintain a constant loop current, the input resistance of the circuit board must increase. This takes place within the electronics of the circuit board, which is
why it is impossible to give an input impedance for the board. The input impedance changes as the power requirements of the board and piezo valves change.
This capability of the current source to respond quickly to the changing power requirements of the loop is very important. This is why, with some current sources, the Pulsair acts jittery at the lower current end of signal range. These current sources are not capable of maintaining a constant output current while responding to the changing input impedance of the Pulsair circuit board. There are some calibrators on the market, for example, that will maintain a set output current only as long as the load impedance doesn’t change, or they are incapable of responding quickly enough or not at all at the lower end of the current range.
There are two other factors that can contribute to instability in the Pulsair positioner. The first of these is that it is recommended that the Pulsair not be set to an actuation time of less than the greater actuation time displayed during self-calibration. This is the value that “Auto” selects in the menu choices. A cycle time faster than this can potentially lead to overshooting and hunting. This parameter is called “tS” on the Pulsair setup menu. The other factor that can affect the stability of the positioner is the dead band setting. Setting the dead band too low can also lead to overshooting and hunting of the positioner. The recommended setting of the dead band is “AUto” in the “dEbA” parameter of the setup menu. This permits the microprocessor to determine the best dead band setting. This is a dynamic adjustment and will automatically change as loop conditions change if this parameter is kept set to “AUto”. If you should choose to set this parameter to a manual setting that is too low, be aware that this can lead to instability of the positioner.
WARNING: The PULSAIR Series I90/L90 M.A.S. is an electro­mechanical device subject to normal wear and tear. Its life is dependent upon application and environmental conditions. Breather/drain fittings are recommended for humid environments when moisture may condense inside the sealed M.A.S. Housing.
Supply Air Quality – See page 16; it is very important that clean, dry, oil-free air be supplied.
CAUTION: Flowserve recommends that all product 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 temperature above 120°F or below 40°F may occur. Do not store within 50 feet of any source of ozone.
The Intrinsically Safe (I90) version of the Pulsair will be intrinsically safe when connected through CSA certified zener barriers or CSA certified galvanic isolators rated 28 volts DC maximum, 300 ohms minimum (Potentiometer – rated 28 volts DC maximum, 300 ohms minimum and 28 Volts DC-diode return) as shown in the wiring diagrams.
IMPORTANT: Shielded cable must be used for each intrinsically safe circuit and, for zener barriers, the shield must be connected to a zener barrier ground.
Flow Control Division
Worcester Controls
M.A.S. Model: The M.A.S. product code is marked on the nameplate as the M.A.S. model number, with the exception of the voltage rating (if any) and Product Revision Level (R#). Voltage rating and R# are marked in separate locations on the nameplate.
Example: 20 P L90 S M2 P 4 T3293
The Product Code is Composed of:
Size . . . . . . . . . . . . . . . . . . . . . . . .Size of actuator (10, 15, 20, etc.)
to which the M.A.S. will be mounted. Will be blank if unknown.
Product Options . . . . . . . . . . . . . . .See Available Options.
Product Series . . . . . . . . . . . . . . .I90 – Loop-Powered
Intrinsically Safe L90 – Loop-Powered Non­Intrinsically Safe
Action . . . . . . . . . . . . . . . . . . . . . .S – Single-Acting Manifold Block
Switch Options . . . . . . . . . . . . . . .See Available Options.
Circuit Board . . . . . . . . . . . . . . . . .P – Positioner Circuitry
Input Signal . . . . . . . . . . . . . . . . .4 – 4 to 20 milliamp Input Signal
Custom Product No. (if special) . . .P#, T#, C# or similar #
Available Options:
Order Codes and Descriptions
B – Breather/Drain Fitting
P – 5000/1000 ohm Dual Potentiometer
5 – 5000/5000 ohm Dual Potentiometer
4 – 4-20 milliamp Output Transmitter (5000/1000 ohm
Dual Potentiometer Included)
M2 – 2 SPDT Mechanical Switches
Notes: All units are single-acting (spring-return) positioners with 4 to 20 milliamp input signal. Double-acting solenoids, "controller" function, and other input signals are not available.
P, 5 AND 4 OPTIONS CANNOT BE COMBINED IN ONE POSITIONER.
WCAIM2053 Pulsair Loop-Powered Positioner Modular Accessory System (Series I90/L90) 3
Flow Control Division
Worcester Controls
4 Pulsair Loop-Powered Positioner Modular Accessory System (Series I90/L90) WCAIM2053
II. INSTALLATION
A. MOUNTING INSTRUCTIONS
1. Refer to Figure 1. The Series I90/L90 is designed to be mounted in-line with the major axis of the actuator. The air connections for the Series I90/L90 should be on the same end as the air connections for the actuator. The standard 39 actuator has its air connections on the right-hand end cap as you face the actuator nameplate. The Series I90/L90 nameplate will be on the same side as the actuator nameplate.
2. Ensure that the actuator shaft is in its clockwise position. Spring-return actuators will be in this position already.
3. Place the mounting bracket on the actuator. Secure the mounting bracket with the four (4) screws and lockwashers supplied in the kit.
4. Place the coupling over the actuator shaft. (Note: For the 1039 actuator, shallow slot is placed over the actuator shaft). The coupling has four (4) threaded holes in it; two are
Z|v
-20 thread for set screws; the other two are #10-32 (located 45 degrees off the center line of the coupling) and are not used. DO NOT tighten the set screws at this time.
5. Place the Series I90/L90 unit on the bracket while inserting the shaft into the coupling slot. Be certain the holes in the bracket and I90/L90 housing are aligned and secure with the four (4) #10-32 socket head screws and lockwashers provided.
6. The coupling set screws can be tightened after the actuator has been cycled 90 degrees.
Flow Control Division
Worcester Controls
Item No. Qty. Description
1 1 Series I90/L90 M.A.S. 2 1 Series 39 Actuator 3 1 Mounting Bracket 4 1 Indicating Scale 5 2 Coupling 6 2 Set Screw 7 1 Indicating Arm 8 1 Locking Nut
9 4 Actuator Mounting Screw 10 4 Actuator Mounting Lockwasher 11 4 M.A.S. Mounting Screw 12 4 M.A.S. Mounting Lockwasher
13 1
Z|v
" O.D. X 31" Tubing
(Cut By User) 14 2 Straight Fitting 15 2 Elbow Fitting
Figure 1
WCAIM2053 Pulsair Loop-Powered Positioner Modular Accessory System (Series I90/L90) 5
B. AIR CONNECTIONS
IMPORTANT: Use industrial air (or other non-corrosive gas), which must be dry and oil-free. See section lll.C on page 15 for other air supply requirements and technical data.
1. Series I90/L90 mounting kits contain two (2) elbow “quick” fittings, two (2) straight “quick” fittings, and one (1) length of
Z|v
" O.D. tubing. Single-acting, or “spring-return,” assemblies will use one elbow and one straight fitting. The length of tubing will be cut to suit the assembly.
2. Refer to Figure 2. Assemble the elbow fitting(s) to the actuator. Pipe thread sealant may be used on the threads (do not allow thread sealant to contaminate the internal air passages of the M.A.S.). Fluoropolymer tape thread sealant should not be used.
Actuator Size Port Thread (NPT)
10 - 20
Z|,
"
25 - 40
Z|v
"
3. Refer to Figure 3. Assemble the straight fitting(s) to the Series I90/L90 housing as shown in Figure 3. The thread sizes are labeled for reference in the figure. Pipe sealant may be used on the threads (do not allow thread sealant to contaminate the internal air passages of the M.A.S.). Fluoropolymer tape thread sealant should not be used.
4. Cut the tubing provided to as short a length as possible that will still reach comfortably from the Series I90/L90 to the actuator. Connect the tubes to their respective actuator and Series I90/L90 ports (reference Figures 2, 3, and 4).
5. Refer to Figure 4 for a diagram of the Series I90/L90 air connections.
a. Connect the supply air for the actuator (pressure can
range from 30 psi minimum to 100 psi maximum with 80 psi as nominal) to the location labeled “SUPPLY” in the appropriate sketch.
b. Locations labeled “VENT” are fitted with an orifice plug. A
porous muffler or other fitting designed to reduce exhaust noise could be substituted if desired. Air must be allowed to flow freely from these ports. “VENT” locations must not be plugged under any circumstances.
NOTE: Orifice plug in port “C” can be removed to allow slightly faster actuation times on larger actuators (sizes 3039 and up).
c. Ports labeled “NOT USED” must remain plugged with the
stainless steel pipe plugs provided.
Flow Control Division
Worcester Controls
Figure 2 – Actuator Fitting Locations Figure 3 – M.A.S. Fitting Locations
Figure 4 – Air Connections For All I90/L90 M.A.S. Configurations
6 Pulsair Loop-Powered Positioner Modular Accessory System (Series I90/L90) WCAIM2053
C. WIRING CONNECTIONS
1. Connect 4-20 mA signal to terminals 1 and 2 as shown in wiring diagram to the right. If unit is intrinsically safe, connection must be made through a CSA certified zener barrier or a CSA certified galvanic isolator as shown below.
NOTE: Terminal numbers and polarity. Shielded cable should be used for all connections. For zener barriers, the shield must be connected to a zener barrier ground.
For switch, potentiometer and feedback option wiring, see Sections III.D.3, III.E.2 and III.F.2 respectively.
NOTE: All wiring to terminal strip should be inserted only to mid-point of terminal strip.
2. Please review cautions and background information below and on pages 7 and 8 before proceeding with calibration section III.A.4. on page 9.
III. OPERATING AND MAINTENANCE INSTRUCTIONS
A. POSITIONER
The Worcester/McCANNA Pulsair Loop-Powered Positioner circuit board is designed for use with the Worcester Series 90 Modular Accessory System. It is a microprocessor-controlled, loop-powered circuit capable of high-resolution control. The circuit is user­programmable, allowing a new level of flexibility and performance.
IMPORTANT: Instructions for powering up the Pulsair are located on page 9, Section 4 Calibration. It is highly recommended that the information be reviewed before turning on power supply.
1. POSITIONER SPECIFICATIONS AND TECHNICAL DATA
CAUTION: The voltage and current to the signal input circuit must never exceed 30 volts and/or 40 mA. Please observe proper signal polarity as marked in these instructions and on the wiring diagram located inside the M.A.S. cover.
Flow Control Division
Worcester Controls
WCAIM2053 Pulsair Loop-Powered Positioner Modular Accessory System (Series I90/L90) 7
The Pulsair Loop-Powered positioner board 4-20 mA signal input circuit is protected with a 63 mA fuse. The intrinsically safe version of the circuit board does not have a fuse, however, due to the requirements imposed by intrinsic safety practices.
Technical Data
Ambient Temperature: Circuit Board Temperature: Resistance to Vibration: 2 g’s – 0 to 100 Hertz Nominal Signal Range: 4 to 20 milliamp Minimum Current to
Maintain Power Supply: 3.6 milliamp
Load Voltage: 14[V] - ((i[mA] - 4)/2.67)[V]
+ .05[kohm] x i[mA] Static Destruction Limit: +/-40 mA Dynamic Destruction Limit
1.2/50 usec, 82 ohm: +/-500 V Internal Capacitance: Negligible Internal Inductance: Negligible
2. ENVIRONMENTAL CONSIDERATIONS
a. General
Caution: The Worcester/McCANNA Pulsair Loop­Powered Positioner M.A.S. circuit board is relatively insensitive to electrical noise on signal lines, and from noise in the environment. Follow installation, calibration, and adjustment guidelines carefully and use shielded wire as stated in paragraph III.A.2.d.
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 in areas where exposure to relative humidity levels above 85 percent, 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 span of electronic equipment.
b. Temperature
Operating solid-state electronic equipment near or beyond its high temperature rating 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 Pulsair-Loop Powered Positioner M.A.S. circuit board is rated for operation between 0°F and 176°F. Do not exceed an ambient temperature of 170°F. in order to ensure that the interior of the sealed M.A.S. housing does not exceed 176°F.
CAUTION: Exposure to direct sunlight can result in internal temperatures up to 40°F higher than ambient conditions.
c. Humidity
Most electronic equipment has a reasonable degree of inherent humidity protection and additional protection is supplied by Flowserve in the form of a moisture proofing and fungicidal coating.
Such protection will generally suffice for environments where the average relative humidity is in the area of 80 percent or less and ambient temperatures are in the order of 70°F average. Where relative humidity is consistently 80 to 90 percent and the ambient temperature is subject to large variations, a desiccant can be used to control humidity. The desiccant will need to be changed periodically to maintain its effectiveness.
In those instances where high ambient temperature would bring the internal operating temperature near or above its maximum rating, the user should 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, reduced maintenance needs and much less process downtime.
d. Shielding – Grounding of Shielding
Shielded wiring should be used for all signal input circuit wiring.
The shields should never be used in place of one of the input wires, and the shields normally 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 ground loops. If two or more shielded cables come to the positioner from different locations, they must be grounded at the positioner. For intrinsically safe Pulsair, using zener barriers, grounded shield must be connected to a zener barrier ground.
3. ELECTRONIC CIRCUIT BOARD BASICS
a. Circuit Board Configurations
There are two basic circuit board configurations. Both versions contain the same basic input, logic and solenoid control circuitry. The difference is in between the two is intrinsic safety. One version of the circuit is not intrinsically safe primarily due to the presence of a fuse on the circuit board, while the intrinsically safe version does not have the fuse.
Flow Control Division
Worcester Controls
8 Pulsair Loop-Powered Positioner Modular Accessory System (Series I90/L90) WCAIM2053
The Pulsair Loop-Powered Positioner M.A.S. as provided by Flowserve accepts a 4-20 mA position input control signal and uses a 5000 ohm feedback potentiometer (“A” pot, if dual pot is installed). The 4-20 milliamp signal also supplies all the power that the circuit and solenoid valves require to operate — no additional power is required. A minimum of 3.6 milliamps is needed to keep the circuitry operating.
b. Controls
Each version of the positioner board is calibrated and controlled by a set of three push buttons. These buttons, in conjunction with a system of programming menus, allow the user to calibrate, adjust and operate all features of the positioner. An LCD display provides feedback to the user about the menu selections and settings. The configuration table below lists the available functions and settings.
Flow Control Division
Worcester Controls
Display Configuring Settings/ Default Position Value Setting* Resolution Meaning
YFct Lin, nLin nLin
—
Position feedback function • Linear/non-linear
init no/oCay, Strt no — Self-Calibration
SCUr 0 MA, 4 MA 4 MA — Setpoint current range • 0 to 20 mA
• 4 to 20 mA
Sdir riSE, FALL riSE — Setpoint direction
SPrA 0.0 to 100.0 0.0 0.1 % Setpoint split range • Start
SPrE 0.0 to 100.0 100.0 0.1 % Setpoint split range • End
tS Auto, 0 to 40 0 1 s Setpoint ramp
SFct Lin Lin — Setpoint function • Linear
1 : 25 • equal percentage 1:25 1 : 50 • equal percentage 1:50 FrEE • freely adjustable
SL 0 0.0 0.1 % Setpoint vertices for freely 0 % SL 1 28.5 adjustable setpoint function 10 % SL 2 50.0 20 % SL 3 62.6 30 % SL 4 71.5 40 % Vertices Displayed only SL 5 0.0 to 100.0 78.5 50 % when SFct = FrEE SL 6 84.1 60 % SL 7 88.9 70 % SL 8 93.1 80 % SL 9 96.7 90 % SL 10 100.0 100 %
dEbA AUto, 0.1 to 10.0 AUto 0.1 % Positioner dead band
Ydir riSE, FALL riSE — Direction of action of manipulated variable
YnrM MPoS, FLoW MPoS — Manipulated variable standardization, mechanical travel, flow
YA 0.0 to 100.0 0.0 0.1 % Manipulated variable limit • Start YE 0.0 to 100.0 100.0 0.1 % • End
YCLS YES, no no 0.1 % Tight shutoff of valve
AFct oFF oFF — Alarms function • not present
Mi : MA — • A1 Min, A2 Max Mi : Mi — • A1 Min, A2 Min MA : MA — • A1 Max, A2 Max
A1 0.0 to 100.0 10.0 0.1 % Alarm 1 threshold
A2 0.0 to 100.0 90.0 0.1 % Alarm 2 threshold
Fct — Fault alarm output function •
.H.C. • + H + C
PrSt no/oCAY, Strt no — Preset (factory setting)
* Certain default settings must be changed to work with rotary actuators. Example: “YFct” must be set to “Lin.”
See section III.A.7 (OPERATION FUNCTION SETTINGS) for more information.
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