Flowserve Pulsair III Digital User Manual

USER INSTRUCTIONS

Worcester Controls

Pulsair III Digital Electronic Positioner

FCD WCAIM2056-00 – 08/04 (Replaces IOM-19990)

Installation

Operation

Maintenance

Experience In Motion

Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

Contents

Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

1 Introduction 4

Safety Instruction 4

2 Storage 5

General 5 Storage Indoors 5 Storage Outdoors or for a Longer Period 6

Storage in a Warm Place 6 3 Design 7 4 Variants 8

Pulsair III 270° (W) 8

Pulsair III Explosion-Proof (Z) 8

Pulsair III Intrinsically Safe 8

Pulsair III Remote Mounted 8 5 Function 9

Double-Action Function 9

Single-Action Function 9 6 Installation 10

Tubing 10

Air Supply Requirements 10

Mounting 11

Connections 12

Air 12 Electrical Connection 12

Dimensions 12 Single-Action Positioner (Direct Function) 13 Double-Action Positioner (Direct Function) 14 Electrical Connections 14

7 Control 16

Menu and Pushbuttons 16

Other Functions 16 Menu Indicator 17 Menus 17 Changing Parameter Values 18 Basic Menu: Calibrate 19

First Start 19

Calibration Error Messages 19 Basic Menu: Read 22 Basic Menu: Man/Aut 23 Basic Menu: Shift Menu 23 Full Menu: Protection 24 Full Menu: Status 25 Full Menu: Setup 26 Full Menu: Tuning 32 Full Menu: Alarms 34 Full Menu: Fact Set 38

8 Maintenance/Service 40

Disassembling Pulsair III W 40 Silencer 44 Spindle Adapter 44 Potentiometer 45 Transmitter Boards 46 Disassembling the Worcester Pulsair III Z 51 Filter Change, Pulsair III W and Z 52 Converting for Remote Control 52

9 Troubleshooting 54 10 Technical Data 55 11 Spare Parts 58

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Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

1 Introduction

The PULSAIR III is a digital positioner designed primarily for controlling modulation valves.

Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

Warning:

• The valve package moves when in operation and can cause personal injury or damage if handled incorrectly.

The positioner can be used with single- or double-action actuators with either rotary or linear movement.

The PULSAIR III can be equipped with modules for feedback, limit switches, and a pressure gauge block.

The modules can be factory-assembled before delivery or ﬁ tted later.

The modules for feedback and limit switches can contain 4-20 mA feedback and one of the following functions:

• Two mechanical switches

• Two reed switches

• Two inductive sensors

Safety notices are presented in this manual in three forms:

Warning: Refers to personal safety. Alerts the user to potential danger. Failure to

follow warning notices could result in personal injury or death.

Caution: Directs the user’s attention to general precautions that, if not followed,

could result in personal injury and/or equipment damage.

NOTE: Highlights information critical to the user’s understanding of the actuator’s installation and operation.

• If the input signal fails or is turned off, the valve moves quickly to its end position.

• If the compressed air supply fails or is turned off, fast movements can occur.

• The valve is not controlled by the input signals when in the “Out of service” mode. It will open/close in the event of a leak.

• If a high value is set for Cut off, fast movements can occur.

• If the valve is controlled in the Manual mode, the valve can move quickly.

• Incorrect settings can cause self-oscillation, which can lead to damage.

Important:

• Always turn off the compressed air supply before removing or disconnecting the air supply or the integral ﬁ lter. Remove or disconnect with care because C- is still under pressure even after the air supply is turned off.

• Always work in an ESD protected area when servicing the PCBs. Make sure the input signal is switched off.

• The air supply must be free from moisture, water, oil and particles.

2 Storage

Safety Instruction

Read the safety instructions in this manual carefully before using the product. The installation, operation, and maintenance of the product must be done by staff with the necessary training and experience. If any questions arise during installation, contact the supplier/sales ofﬁ ce before continuing work.

General

The PULSAIR III positioner is a precision instrument. Therefore, it is essential that it is handled and stored in the correct way. Always follow the instructions below!

NOTE: As soon as the positioner is connected and started, an internal air leakage will provide protection against corrosion and prevent the ingress of moisture. For this reason, the air supply pressure should always be kept on.

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Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

Storage Indoors

Store the positioner in its original packaging. The storage environment must be clean, dry, and cool 60-80°F (15-26°C).

Storage Outdoors or for a Longer Period

If the positioner must be stored outdoors, it is important that all cover screws are tightened and that all connections are properly sealed. The unit should be packed with a desiccant (silica gel) in a plastic bag or similar, covered with plastic, and not exposed to sunlight, rain, or snow.

This is also applicable for long-term storage (more than 1 month) and for long transport by sea.

Storage in a Warm Place

When the positioner is stored in a warm place with a high relative humidity and is subjected to daily temperature variations, the air inside the unit will expand and contract.

This means that air from outside the unit may be drawn into the positioner. Depending on the temperature variations, relative humidity, and other factors, condensation and corrosion can occur inside the unit, which in turn can give rise to functional disorders or a failure.

3 Design

The PULSAIR III positioner contains:

• electronic board with microprocessor, HART modem, display etc.

• pneumatic valve block

• positional feedback with potentiometer

• sealed compartment for electrical connections.

The pushbuttons and display are accessible underneath the aluminum cover, which is sealed with an O-ring.

The ﬁ gure shows the PULSAIR III with the cover removed.

Display, control

Filter

Adjusting screws,

damping

pushbuttons

Terminal block

Valve block

Potentiometer

Processor and

motherboard

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Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

4 Variants

Pulsair III 270° (W)

A Pulsair III for up to 270° extended travel range is available. It features all beneﬁ ts and options similar to the standard Pulsair III. Communication with HART is possible.

Pulsair III Intrinsically Safe

The Pulsair III is available in an intrinsically safe version for installation in hazardous areas. It features the same easy-to-use user interface for local conﬁ guration as the Pulsair III. Communication with HART is possible. It features all beneﬁ ts and options similar to the Standard Pulsair III positioner: gauge block, local graphic LCD display, feedback option, etc.

Pulsair III Explosion-Proof (Z)

The Pulsair III digital positioner is available in an explosion-proof enclosure. It features the same easy-to-use user interface for local conﬁ guration as the Pulsiar III. Communication with HART is possible.

Further features are gauge ports and local graphic LCD display.

Pulsair III Remote Mounted

The Pulsair III with remote mount is now available. This version is suitable for installations in severe applications, e.g. vibration, high or low temperature, corrosive environment, difﬁ cult to access installations, etc. A ﬂ at or dome-style indicator can be ﬁ tted on the feedback box installed on the actuator.

The maximum recommended distance between the Pulsair III and remote unit is 16 ft. (5m).

Standard Housing Weatherproof (W) and Intrinsically Safe

“Z” Housing

Remote Mount

Control signal 4-20 mA

Potentiometer

Piezo–valve 2

Actuator

➾

Venting

C– C+

V enting

Signal converter and microprocessor

Piezo–valve 1

Diaphragm

17.4 psig (1.2 bar)

Pressure regulator

Replaceable Filter

Air supply 30-105 psig (2-7 bar)

5 Function

Double-Action Function

The control signal and the feedback potentiometer position are converted to digital signals that are processed with a PID algorithm in the microprocessor. This provides control signals to the two piezo-valves.

The two piezo-valves are closed in the schematic diagram above and have no effect on the valves A and D. Air from the pressure regulator is lead through the open valve A to the valve B, which opens. The supply pressure can now pass through valve B to the actuator via H. The actuator then moves in the direction of the arrow. At the same time, air from valve A keeps valve C open and allows venting of the actuator.

When both the piezo-valves open, valve A closes but valve D opens and controls valves E and F to that the actuator moves in a direction opposite to the arrow. When only piezovalve 1 is open, the actuator is stationary.

Single-Action Function

Valve B is used for the supply air and valve F for venting.

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Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

6 Installation

Tubing

Use tubes with an inner diameter of ¼ " (6 mm) minimum.

Air Supply Requirements

For the maximum air supply pressure, see section 10, Technical Data.

The air supply must be free from moisture, water, oil, and particles.

The air must come from a refrigeration-dried supply or be treated in such a way that its dew point is at least 18°F (10°C) below the lowest expected ambient temperature. If air is now used, the supply medium must be a noncorrosive and non-ﬂ ammable gas.

To ensure a stable and problem-free air supply, we recommend the installation of a ﬁ lter/pressure regulator <30 microns as close to the positioner as possible.

Before the air supply is connected to the positioner, open the hose freely for 2 to 3 minutes to allow any contamination to be blown out.

Direct the air jet into a large paper bag to trap any water, oil, or other foreign materials. If contamination is detected, the air supply should be thoroughly cleaned before connecting to the positioner.

Warning: Do not direct the open air jet towards people or objects because it

may cause personal injury or damage.

Poor air supplies are the main source of problems in pneumatic and electro-pneumatic systems.

Mounting

NOTE: If the positioner is installed in a hazardous environment, it must be of a type approved for this purpose.

The PULSAIR III W positioner has an ISO F05 footprint, A. The holes are used to attach it to the mounting bracket B, which is suitable for most types of linear actuator.

The spindle adapter C can be changed to suit the actuator in question.

Remove the existing adapter using two screwdrivers. Check that the spring ring on the new spindle is undamaged and ﬁ ts the new adapter before installing.

It is important that the positioner’s spindle and the arms that transfer the actuator movements are correctly mounted. Any tension between these parts can cause incorrect operation and abnormal wear.

Assembly Examples

Linear Movement

Rotary Movement

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Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

The PULSAIR III Z positioner has an ISO F05 footprint, A. The holes are used to attach it to the mounting bracket B, which is suitable for most types of linear actuators.

The spindle adapter C can be changed to suit the actuator in question, as previously explained in this section.

For data for air and electrical connections, see Technical Data section.

Connections

Air

Port S Supply air

Port C+ Connection to actuator

Port C- Connection to actuator (only for

double-action)

Must be plugged when converting to single-action function.

Electrical Connection

See Electrical Connections section.

Dimensions

Air connections: ¼ " NPT or G ¼ "

Electrical connection: ½ " NPT or M20 x 1.5

Loctite 577 or equivalent is recommended as a sealant.

Single-Action Positioner (Direct Function)

Actuator with Fail/Close Spring

When the control signal increases, the pressure C+ to the actuator is increased. The valve stem moves upward and rotates the positioner spindle counterclockwise. When the control signal drops to zero, C+ is vented and the valve closes.

–

S C+

–

S C+

Actuator with Fail/Open Spring

When the control signal increases, the pressure C+ to the actuator is decreased. The springs press the valve stem upward and the positioner spindle rotates counterclockwise. When the control signal drops to zero, C+ is vented and the valve opens.

For data for air and electrical connections,

C– S C+

see Technical Data section.

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Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

Double-Action Positioner (Direct Function)

Double-Action Actuator

When the control signal increases, the pressure C+ to the actuator is increased. The valve stem is pressed upward and rotates the positioner spindle counterclockwise. When the control signal is reduced, the pressure C- to the actuator increases and the valve stem is pressed downward. If the control signal disappears, the pressure goes to C-, C+ vents, and the valve closes.

–

S C+

Electrical Connections

The diagrams on the next page show the terminal blocks in the Pulsair III W and Z.

Remote Unit

The remote unit shall be connected between terminals 3, 4 and 5 in the Pulsair III and 3, 4 and 5 in the remote unit. Use a shielded cable and ground it in the Pulsair III only. The maximum recommended distance between the Pulsair III and the remote unit is 16 ft., 5 in. (5 m).

Pulsair III W

1 4-20 mA + input signal 2 4-20 mA – input signal

3 Switch 1 NO 4 Switch 1 NC 5 Switch 1 COM 6 Switch 2 NO 7 Switch 2 NC 8 Switch 2 COM 9 AUX input 4-20 mA + 10 AUX input 4-20 mA – 11 4-20 mA + Feedback 12 4-20 mA – Feedback 13 Alarm output + 14 Alarm output –

Pulsair III Z

HART – connection

1 2 3 4 5 6 7 8 9 10 11 12 13 14

+ – + – + – + –

Option

Shielded cables, grounded in the Pulsair III unit

HART Connection

Connecting a remote unit

123456

+ –

345

Remote unit

Shielded cables, grounded on the Pulsair III unit

Remote Unit

Note: When converting a Pulsair III W or Z for use with a remote unit, some changes have to be done inside the positioner, see section 8.

Warning: In a hazardous environment where there is a risk of explosion,

electrical connections must comply with the relevant regulations.

Terminal Blocks

The terminal blocks in the illustrations at right are accessible when the terminal cover is removed, see Section 8 for disassembly instructions.

Warning: In a hazardous environment where there is a risk of explosion,

electrical connections must comply with the relevant regulations.

1 4-20 mA + input signal 2 4-20 mA – input signal

3 Switch 1 NO (Remote unit) 4 Switch 1 NC (Remote unit) 5 Switch 1 COM (Remote unit) 9 AUX input 4-20 mA + 10 AUX input 4-20 mA – 11 4-20 mA + 12 4-20 mA – 13 Alarm output + 14 Alarm output –

Optional

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Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

7 Control

Menu and Pushbuttons

The positioner is controlled using the ﬁ ve pushbuttons and the display, which are accessible when the aluminium cover is removed.

For normal functioning, the display shows the current value. Press the ESC button for two seconds to display the main menu.

Use the up and down pushbuttons to browse through the main menu and the submenus.

The main menu is divided up into a basic menu and a full menu, see the ﬂ owchart in the section, “The Menu System.”

OUT OF SERVICE MANUAL

BASIC MENU MAN/AUTO

UNPROTECTED

ESC FUNC

MANUAL: The positioner can be adjusted manually using the pushbuttons. See Man/ Auto section.

UNPROTECTED: Most of the parameters can be changed when the positioner is in the “Unprotected” position. However, critical parameters are locked when the positioner is in the “In service” position.

Menu Indicator

There are indicators at both sides of the display window and they indicate as follows:

• Flashing in position Out of service

• Flashing in position Manual

• Displayed in position Unprotected

The indicators on the right-hand side show the position in the current menu.

Flashing in position Out of Service

FULL MENU MAN/AUTO

Flashing in position Manual

FULL MENU CALIBRATE

Other Functions

ESC: Exit the menu without making any changes (as long as any changes have not been conﬁ rmed with OK).

FUNC: To select functions and change parameters.

OK: To conﬁ rm selection or change of parameters.

MENU INDICATOR: Displays the position of the current menu row in the menu.

IN SERVICE: The positioner is following the input signal. This is the normal status when

the positioner is working.

OUT OF SERVICE: The positioner is not following the input signal. Critical parameters can be changed.

Displayed in position Unprotected

FULL MENU SHIFT MENU

Menus

To display the menu you can select:

• Basic menu, which means you can browse through four different steps

• Full menu, which comprises ten steps. Use the Shift Menu to browse through the steps.

Full Menu can be locked out using a passcode.

The main menus and submenus are shown on the subsequent pages.

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Worcester Controls Pulsair III Digital Electronic Positioner FCD WCAIM2056-00 - 08/04

Changing Parameter Values

Change by pressing the left and right arrows until the desired ﬁ gure is ﬂ ashing.

Press the up and down arrows to step to the desired ﬁ gure. Conﬁ rm by pressing OK.

A change can be undone by pressing the ESC button, which returns you to the previous menu.

BASIC MENU READ

BASIC MENU MAN/AUTO

BASIC MENU CALIBRATE

BASIC MENU SHIFT MENU

FULL MENU READ

FULL MENU MAN/AUTO

FULL MENU CALIBRATE

FULL MENU SHIFT MENU

FULL MENU PROTECTION

FULL MENU STATUS

FULL MENU SETUP

FULL MENU TUNING

Basic Menu: Calibrate

BASIC MENU CALIBRATE

First Start

Calibrate in the basic menu is displayed automatically the ﬁ rst time the positioner is connected, and can be selected from the basic/main menu at any later time.

A complete calibration takes about three minutes and includes end limit calibration, auto-tuning, leak test, and a check on the speed of movement. Start the automatic calibration by selecting Auto-Cal and then answer the questions on the display by pressing OK or the respective arrow. The menu is described later in this section.

Calibration Error Messages

If a fault occurs during the calibration, one of the following error messages will be displayed:

Invalid movement/press ESC to abort

No movement because the air is incorrectly connected, for example. After the fault is corrected, the calibration sequence must be restarted.

Pot unaligned/press ESC to abort

The potentiometer has been set to an illegal value. The potentiometer is aligned using the Calibrate - Expert cal - pot Menu. The calibration sequence must be restarted after the fault is corrected.

FULL MENU ALARMS

FULL MENU FACT SET

An air leak has been detected. The calibration sequence should be restarted after the fault is corrected.

Increase C- damper/ESC = abort OK to retry

Increase C+ damper/ESC = abort OK to retry

Clockwise Increased damping/Less ﬂow CCW Decreased damping/More ﬂow 3 revs CCW Maximum ﬂow

C+

(C–)

NOTE: Too much increased damping (low ﬂow) might cause irregular actuator function.

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Air leak detected/ESC = abort OK = go on

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