Flowserve Worcester Controls Electri-SAFE DataFlo User Manual

FCD WCAIM2048-01

(Part 18736)

Worcester Controls Electri-SAFE DataFlo
Digital Electronic Positioner

Technical Reference Manual

Contents

1.0 Description of Positioner . . . . . . . . . . . . . . . . . . . . . . .3

2.0 Features of the Electri-SAFE

Electronic Positioner Circuit Board . . . . . . . . . . . . . . . .3

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.2 Circuit Board Configurations . . . . . . . . . . . . . . . . . . . .3

2.3 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.4 Controls (Override) . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.5 AC Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3.0 Wiring of Electri-SAFE Digital

Positioner and Actuator . . . . . . . . . . . . . . . . . . . . . . . .4

3.1 Actuator Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3.1.1 Minimum Fuse Ratings . . . . . . . . . . . . . . . . .4

3.1.2 Wiring and Installation of Accessories . . . . . .4

4.0 Positioner – General Description and Modes of Operation 4

4.1 Programming Switches (Key Functions) . . . . . . . . . . .4

4.2 Limit Switch Adjustment

and Calibration Procedures . . . . . . . . . . . . . . . . . . . . .4

4.2.1 Adjustment of Over-Travel Limit Switch . . . . .4

4.2.2 Calibration Procedures for Positioner . . . . . .5

4.3 General Description of Digital Positioner . . . . . . . . . .6

4.3.1 Valve Position Setpoint Input . . . . . . . . . . . . .6

4.3.2 Valve Position Feedback . . . . . . . . . . . . . . . . .6

4.3.3 Key Features of The Digital Positioner . . . . . .6

4.3.4 Operating Modes . . . . . . . . . . . . . . . . . . . . . .6

4.3.5 Data Readout . . . . . . . . . . . . . . . . . . . . . . . . .6

4.3.6 Local Data Entry . . . . . . . . . . . . . . . . . . . . . .6

4.3.7 Display Modes . . . . . . . . . . . . . . . . . . . . . . . .6

4.4 Program Mode (Data Entry Parameters) . . . . . . . . . . .7

4.4.1 Security Code Screens . . . . . . . . . . . . . . . . . .8

4.4.2 Unit Address Screen . . . . . . . . . . . . . . . . . . . .8

4.4.3 Output Current Range . . . . . . . . . . . . . . . . . .8

4.4.4 Analog Setpoint (Input) Range . . . . . . . . . . . .8

4.4.5 Setpoint Direction (Rise/Fall) . . . . . . . . . . . . .9

continued

Models

15 DP 72 – DataFlo Positioner
Mounted On 15-72 Electri-SAFE Actuator

20 DP 72 – DataFlo Positioner
Mounted On 20-72 Electri-SAFE Actuator

Inputs

DP – 1K (120A) 1000 ohm Resistance Input

DP – 10 (120A) 10 to 50 milliamp Input

DP – 13 (120A) 135 ohm Resistance Input

DP – 5V (120A) 0 to 5 VDC Input

DP – 1 (120A) 1 to 5 milliamp Input

DP – XV (120A) 0 to 10 VDC Input

DP – 4 (120A) 4 to 20 milliamp Input

Voltages

120 A – 120 VAC Power Circuits

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4.4.6 Setpoint Split Range START Selection . . . . . .9

4.4.7 Setpoint Split Range END Selection . . . . . . . .9

4.4.8 Setpoint Ramp-Time to Open . . . . . . . . . . . . .9

4.4.9 Setpoint Ramp-Time to Close . . . . . . . . . . . . .9

4.4.10 Setpoint Curve Function . . . . . . . . . . . . . . . . .9

4.4.11 Positioner Dead Band . . . . . . . . . . . . . . . . . .10

4.4.12 Loss-of-Signal Position and Delay Time . . . .10

4.4.13 Power-On Position and Delay Time . . . . . . .10

4.4.14 Electronic Positioner Rotation Limits

(Electronic travel stops) . . . . . . . . . . . . . . . .11

4.4.15 Tight Valve Shutoff . . . . . . . . . . . . . . . . . . . .11

4.4.16 Full-Open Operation of Valve

with Open Travel Limit Set . . . . . . . . . . . . . .11

4.4.17 Restore Factory Default Values . . . . . . . . . .11

4.4.18 Run Time Cycles for Maintenance . . . . . . . .11

4.4.19 Alarm Functions . . . . . . . . . . . . . . . . . . . . . .11

4.5 Local Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.6 Feedback Calibration Routine

and Cycle Time Measurement . . . . . . . . . . . . . . . . . .12

4.7 Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.7.1 Valve Position Screen . . . . . . . . . . . . . . . . . .13

4.7.2 Input Setpoint . . . . . . . . . . . . . . . . . . . . . . . .13

4.7.3 Cycle Count . . . . . . . . . . . . . . . . . . . . . . . . .13

4.7.4 Dead Band Readout . . . . . . . . . . . . . . . . . . .13

4.7.5 CW and CCW Travel Time Readout . . . . . . .13

4.7.6 Alarm Status Readout . . . . . . . . . . . . . . . . .13

4.7.7 Changing Operating Modes . . . . . . . . . . . . .13

4.8 Default Values (factory installed) . . . . . . . . . . . . . . .14

4.9 RS-485 Communications . . . . . . . . . . . . . . . . . . . . .14

4.9.1 Packet Communications Software . . . . . . . .14

4.9.2 RS-485 Connection. . . . . . . . . . . . . . . . . . . .14

4.9.3 Communication Software . . . . . . . . . . . . . .14

4.9.4 Setting Up the Communication

Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.9.5 Monitor Display . . . . . . . . . . . . . . . . . . . . . .15

5.0 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

5.1 Allowable Supply Voltage Range . . . . . . . . . . . . . . . .17

5.2 Input Circuit Specifications . . . . . . . . . . . . . . . . . . . .17

5.3 Output Circuits Specifications . . . . . . . . . . . . . . . . . .17

5.3.1 Motor Driver Circuitry Specifications . . . . . . . .17

5.3.2 Position Feedback – Current Output . . . . . . . .17

5.3.3 Alarm Output . . . . . . . . . . . . . . . . . . . . . . . . . .17

5.4 Input Circuit Load Resistances . . . . . . . . . . . . . . . . .17

6.0 Switch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

6.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

6.2 Cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

6.3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

6.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

6.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

7.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

7.1.1 Signal Input Fuse F1 . . . . . . . . . . . . . . . . . . .19

7.1.2 Signal Noise . . . . . . . . . . . . . . . . . . . . . . . . .19

7.1.3 Signal Generator . . . . . . . . . . . . . . . . . . . . . .19

7.2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

7.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

7.2.2 Power Supply Output Voltage (5 VDC) . . . . .21

7.2.3 Power Supply Replacement . . . . . . . . . . . . .21

7.3 Positioner Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

7.3.1 Positioner Board Replacement . . . . . . . . . . .21

7.4 Actuator Troubleshooting . . . . . . . . . . . . . . . . . . . . .21

7.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

7.4.2 Command Functions (CW & CCW)

Voltage Check . . . . . . . . . . . . . . . . . . . . . . . .21

7.4.3 Pump/Motor and Positioner

Solenoid Valve Functions . . . . . . . . . . . . . . .21

7.4.4 Positioner/Control Solenoid Valve

Coil Continuity Test . . . . . . . . . . . . . . . . . . . .22

7.4.5 Positioner/Control Solenoid Valve

Coil Replacement . . . . . . . . . . . . . . . . . . . . .22

7.4.6 Fail-safe Solenoid Valve

Function and Continuity Test . . . . . . . . . . . .22

7.4.7 Fail-safe Solenoid Valve

Coil Replacement . . . . . . . . . . . . . . . . . . . . .22

8.0 APPENDIX: Illustrations and Wiring Diagrams . . . . . . .23

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1.0 Description of Positioner

The Worcester/McCANNA Electri-SAFE DataFlo Digital Electronic
Positioner was designed for use with the Worcester/McCANNA Series
72 Electri-SAFE Hydraulic Actuators only.

This Electri-SAFE DataFlo Digital Electronic Positioner provides
positioning of the Series 72 electro-hydraulic actuator for partial
opening of the valve. The positioner operates by receiving a signal
from a remote source to open the actuator to a particular position. A
feedback loop is designed into the electronic board to keep the
actuator at the required position. A resistance potentiometer and gear
are attached to the output shaft to provide accurate position feedback.
A change in the remote input signal will cause the actuator to open or
close to meet the new desired position.

Three switches (keys) are located on the positioner circuit board to
allow for manual operation of the positioner, calibration, function
programming of the microchip, and troubleshooting.

CAUTION: The Electri-SAFE DataFlo Digital Electronic Positioner is
sensitive to electrical noise on signal or supply lines and in the
environment. For maximum positioner sensitivity, the electrical
noise level should be as low as possible. Follow installation,
calibration and adjustment guidelines carefully and use shielded
wire for all low-voltage signals.

The Digital Positioner board is designed to receive a floating current
input signal. This allows several pieces of equipment to be operated
from the same current loop while at the same time remaining
electrically independent of each other. A floating input signal means
that the current input signal should not be referenced to the circuit
board ground. The board power source must have a ground
independent from that of the signal source.

The Digital Positioner board standard setup is 4 mA for full clockwise
rotation (0°) and 20 mA for full counterclockwise rotation (90°).

The 4-20 mA signal input circuit for the Digital Positioner boards is
protected with a 62 mA fuse (F1). The fuse is used to protect the input
circuit from an excessively high voltage. The fuse used in the input
circuit is a Littlefuse PICO II very fast-acting fuse rated at 62 mA.

Quite often when we receive an actuator for repair at Flowserve, we
find that the only thing wrong with the unit is that the feedback
potentiometer is out of calibration. It is very important that the
feedback potentiometer be properly calibrated for correct operation of
the positioner board. Whenever you have a problem with the
positioner calibration, always check the feedback potentiometer
calibration first. This must be done with no power applied to the
circuit board. If the actuator is in the full clockwise position, check the
resistance between the purple and white/black potentiometer leads.
The reading should be 80-90 ohms. If it is not, rotate the face gear
until the proper reading is achieved. If the actuator happens to be in
the full counterclockwise position then check the resistance between
the green and white/black potentiometer leads. If necessary adjust the
face gear for an 80-90 ohm reading.

NOTE: It is not necessary to loosen or remove face gear snap ring to
rotate gear—it is a friction fit. If for any reason the snap ring is to be
removed, do not over-stretch it; use the minimum opening to allow it
to slip over the gear.

2.0 Features of the Electri-SAFE
Electronic Positioner
Circuit Board

2.1 General

Figure 7 in the appendix defines the location of major electrical
components in the positioner housing. The Digital Positioner
Board is factory wired to the terminal strips per Figure 4 and
Figure 5 in the appendix.

The feedback potentiometer leads are factory connected to the
terminal block (TB2) on the Digital Positioner Board.

If a dual potentiometer option is installed, the “B” potentiometer
leads will have to be wired directly to external device. The “A”
potentiometer leads are factory connected to the terminal block
(TB2) on the Digital Positioner Board. Also, note that the “B”
potentiometer has a voltage limit of 30 volts maximum.

2.2 Circuit Board Configurations

The positioner board is factory supplied for one of the seven input
signal options plus a two-wire RS-485 interface.

NOTE: Field changes to the positioner board are not advised.
Consult Flowserve before attempting any modification.

2.3 LED Indicators

Light emitting diodes (LED) marked LD1 (CW) (see Figure 2 in
the appendix) and LD2 (CCW) mounted on the power supply (are
in the output circuits) and when lit indicate which direction the
actuator is trying to drive to. A third LED, LD3 (see Figure 1 in the
appendix), is used to indicate when an alarm condition exists. If
LD3 is lit, the alarm that caused it to light must be determined by
looking at the LCD on the circuit board and finding the alarm
parameter with the UP or DN switch.

2.4 Controls (Override)

There are no adjustable controls provided on the circuit board,
because none are necessary. All parameters are set through the
programming switches (keys) or the RS485 interface. Local push­button control is provided at the controller by simultaneously
pressing the SEL and UP switches (keys) for three seconds. At
this point the UP and the DN switches (keys) can be used to
manually rotate the actuator shaft. Pressing the SEL switch for
three seconds will return the positioner to the run mode.

2.5 AC Power Control

The AC output circuits are controlled by solid state switches
(triacs Q3, Q4), which will provide trouble-free operation for the
life of the equipment they are used with, AS LONG AS THEY ARE
OPERATED WITHIN THEIR RATINGS.

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3.0 Wiring of Electri-SAFE Digital
Positioner and Actuator

See wiring diagrams located under positioner and actuator covers and
in figures 4, 5 and 6 in the appendix for customer connections.

CAUTION: Wiring should be inserted only to midpoint of terminal
strip.

3.1 Actuator Wiring

An Actuator Electrical System is made up of two major
components involved in user connections:

1) Actuator housing

2) Positioner housing

Incoming power is brought to the Electri-SAFE unit via the
Actuator Housing.

Signal wiring is brought to the Electri-SAFE unit via the Positioner
Housing.

The positioner input power, pump motor and solenoid control
signals (and wires for optional indicating switches) are factory­wired to the actuator housing terminals (figure 6 in the appendix)
and wired to meet Class-1, Div-1 requirements.

1) The actuator housing contains the CCW over-travel limit
switch, and wiring for the motor, control and fail-safe
solenoid valves. All of the high-voltage input wiring is
connected here.

2) The positioner housing contains the Digital Positioner Board,
power supply, position potentiometer, terminal strips, and
optional indicating switches. Figure 7 in the appendix defines
the location of major electronic components in the positioner
housing. The power supply is factory wired to terminal strip
1-10 (see Figure 4 in the appendix). Wiring from the
positioner terminal strip 1-10 to the actuator terminal strip
1-8 is factory-wired. Signal wiring is brought from the
positioner board to terminal strip A-H in the positioner
housing (see Figure 5 in the appendix).

All field signal connections are at terminal strip A-H in the
positioner housing (see Figure 5 in the appendix).

NOTE: IT SHOULD BE NOTED THAT INSTALLING THIS
ACTUATOR IN A HAZARDOUS AREA REQUIRES THE USE OF
CONDUIT AND SEALS AND OTHER REQUIREMENTS AS
SPECIFIED IN THE NATIONAL ELECTRICAL CODE,
CHAPTER 5.

3.1.1 Minimum Fuse Ratings

See table on this page for minimum fuse rating when over­current protection is used in motor power circuit.

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

Actuator Size Voltage Fuse Rating

15-72 120 VAC 10 A

20-72 120 VAC 10 A

3.1.2 Wiring and Installation of Accessories

Refer to installation and wiring instructions, contained in Part

6.0 of this manual and/or respective accessory kit.

4.0 Positioner – General Description
and Modes of Operation

When properly adjusted, the actuator will stop at the full CCW and full
CW positions as a result of having reached one of the respective
limits of the input signal span. The full CCW over-travel limit switch
will be used only as a backup to stop the actuator pump motor should
a failure of an electronic component occur.

4.1 Programming Switches (Key Functions)

There are three switches (keys) on the positioner circuit board
which are labeled SEL (black) for select, DN (white) for down, and
UP (white) for up. These are the keys that are used to calibrate,
program and position the Digital Positioner Board locally.

The UP and the DN switches can be used to advance through the
menu until the desired parameter is reached. At this time, the
display will be flashing between the parameter name and its
current setting. Momentarily pressing the SEL switch will lock in
that parameter’s current setting and allow the user to change it. If
the display is alphabetic such as riSE or FALL for setpoint
direction, momentarily pressing the UP switch will cycle through
the setting options for that parameter. When the desired setting
option is reached, momentarily pressing the SEL switch will set
the parameter to that option and store it in nonvolatile memory. If
the display is numeric, momentarily pressing the SEL switch will
lock in the value with the left most digit flashing. Pressing the UP
switch will increment this digit. Pressing the DN switch will
advance the flashing digit to the next digit to the right. Therefore,
the UP switch is used to set the flashing digit to the desired value
while the DN switch is used to select the flashing digit. Once the
overall value is entered, momentarily press the SEL switch to
store the value in nonvolatile memory.

4.2 Limit Switch Adjustment and Calibration Procedures

4.2.1 Adjustment of Over-Travel Limit Switch

The Positioner has been shipped with a limit switch factory­calibrated to stop the actuator in the full CCW position
(approximately 92°). It is located in the actuator housing,
behind the flat cover. If it has been determined that the limit
switch requires adjustment, perform the adjustment as
follows:

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NOTE: Be very careful when adjusting the switch. It can be
damaged by the actuator switch probe if the switch is
adjusted (tightened) too far in toward the probe. If in doubt of
switch position, loosen (back out) the switch adjustment
screw to its loose limit before performing the following steps.

If not already done, remove the actuator and positioner
housing covers.

When power is first applied, the unit will be in the Run Mode.
The positioner display should be flashing between POS and a
number between 0 and 100.

On the positioner board, simultaneously press the SEL and
UP keys for three seconds to enter the Manual Mode. The
display should alternate between POS and 0.0.

Press and hold the UP key until the actuator goes full CCW
and stops moving. The actuator should be full CCW, and there
should be no motor noise.

If the motor continues to run, turn the limit switch adjustment
screw clockwise until the motor stops running. Turn the
adjustment screw clockwise an additional

1

/

4 turn to set the

switch. Verify the switch setting as follows:

Press the DN key to rotate the actuator shaft about 20
degrees CW.

Turn the limit switch adjusting screw counterclockwise

1

/

2

turn.

Press and hold the UP key until the actuator shaft rotates
to full CCW and stops moving.

If the actuator is not at full-open:

Press the DN key to rotate the actuator shaft about 20
degrees CW.

Turn the limit switch adjusting screw counterclockwise

1

/

2

turn.

Press and hold the UP key until the actuator shaft rotates
to full CCW and stops moving.

Repeat until the actuator is full-open and there is no
motor noise.

The actuator shaft must travel a couple of degrees beyond the
90 degree full CCW position for the positioner to control the
full range of operation. Place a straight edge along the flats
on the positioner shaft to verify that the actuator has gone
past the 90 degree position when stopped by the limit switch.

To return to the RUN mode, press and hold the SEL key for
three to five seconds.

4.2.2 Calibration Procedures for Positioner

NOTE: Also refer to section 4.6 for step-by-step procedures.

When power is first applied, the unit will be in the Run Mode.
The display should be flashing between POS and a number
between 0 and 100.

Simultaneously press and hold the SEL and DN switches
(keys) for three seconds to enter the calibration mode. When
first entering the Calibration Mode, CAL will be displayed for
two seconds and the security code will be checked. If the
required security code is not zero (“0000”), the display will
begin alternating between codE and 0000. Enter the security
code as described in paragraph 4.4.1 and per paragraph

4.3.6. If the required security code is zero, it will not need to
be entered by the user, i.e., it will be bypassed and the display
will automatically flash SEtL, and you can skip to paragraph b.
Note: If the security code is forgotten, the special number
4800 can be used to gain entry. However, this number will
now be the new security code and if another code number is
still desired, it will have to be reprogrammed.

If and after a security code has been entered, press and
release SEL to accept code. The display will now flash SEtL
and a value.

Simultaneously press and release the SEL and UP keys, then
adjust input signal to lower input value, e.g., 4 mA. Press and
release SEL to lock in value.

Press and release the DN key, the display will now flash SEtU
and a value. Simultaneously press and release SEL and UP,
then adjust input signal to higher input value, e.g., 20 mA .
Press and release SEL to lock in value.

Press and release DN, the display will now flash PoC and a
number between 0.0 and 5.0. Simultaneously press and
release SEL and UP. Rotate the actuator to the full CW
position by pressing and holding the DN key. Release the DN
key when full rotation has been achieved.

Important: Be careful not to go past the CW “0” degree
position. (Position a straight edge along the flats on the
positioner shaft to verify the shaft position). The display
should read between .200 and .400. If not: rotate the face gear
located on the positioner shaft (that drives the potentiometer)
until you read between .200 and .400. The gear is held in place
by means of a friction lock and a snap ring. No tools are
needed nor is it necessary to loosen or remove the snap rin

g
to move the gear. Steady gentle finger pressure will move the
gear to allow you to adjust the feedback potentiometer. Press
and release SEL to lock in the value.

Press and release the DN key, the display will now flash PoCC
and the feedback voltage value. Simultaneously press and
release SEL and UP. Adjust so shaft is full CCW using the UP
key (do not go past 90 degrees). Press and release SEL to
lock in value.

Press and release the DN key, the display will now flash Cyt
and a cycle time reading. Simultaneously press and release
the SEL and UP keys. At this time the actuator will perform
one cycle to measure its cycle time displaying PoC as the
actuator travels to the full CW position and PoCC for the
CCW position.

To return to the RUN mode, press and hold the SEL key for
three to five seconds.

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4.3 General Description of Digital Positioner

The Digital Positioner is used for intelligent control and operation
of the Electri-SAFE Electro-Hydraulic Actuator.

4.3.1 Valve Position Setpoint Input

The valve position setpoint input signal is derived from either
an analog input signal or from a digital RS485 serial input.

4.3.2 Valve Position Feedback

Valve position feedback to the digital positioner board is from
the 1,000 ohm potentiometer geared to the actuator shaft.

4.3.3 Key Features of The Digital Positioner

Easy push-button calibration of the positioner

Programmable set point direction

Microprocessor-based positioner

Programmable split range

High resolution

Programmable deadband as well as auto adjust

Cycle count

Programmable operating parameters

Hi, Low, and Deviation alarms

Four programmable position response curves

Loss of signal position and time delay

Local and remote positioner operation

Loss-of-power position and time delay

Electronic travel limits

ASCII text area in EEPROM (420 + bytes)

4.3.4 Operating Modes

The four modes of operation are:

CALIBRATION (see part 4.2 and part 4.6)

PROGRAM (see part 4.4)

LOCAL (see part 4.5)

RUN (This is also the default mode, see part 4.7.)

4.3.5 Data Readout

A four-digit LCD mounted on the positioner board provides
local data readout. Each LCD segment is controllable, which
allows display of some letters in addition to all digits.
Parameters will be identified by names, not numbers.
Provisions for numerical values with decimal points will
be made.

4.3.6 Local Data Entry

Three push-button switches (as shown below) on the
positioner board are used for local data entry:

SEL Selects a parameter for editing or changes modes of
operation.

UP Increases selected value or selects next parameter.
Hereafter this switch will be called UP.

DN Decreases selected value or selects previous parameter.
Hereafter this switch will be called DOWN.

In the Program Mode of operation, data is edited by pressing
the SEL switch while the parameter name is alternating with
its value. The display will then be in the Fixed Mode where
one or more digits will flash.

With a single digit flashing, pressing the UP switch will
increase the digit value by 1, wrapping from 9 to 0. Pressing
the DOWN switch will cause the next digit to blink and allow it
to be edited. Pressing the SEL switch will store the value in
non-volatile memory, discontinue editing, and return the
display to the Toggle Mode.

Note: Displayed data cannot be edited in the Run Mode.
Pressing the SEL switch in that mode causes the display to
stop alternating and only the parameter value is displayed.

4.3.7 Display Modes

The display has two modes of operation: Toggle Mode and
Fixed Mode.

In Toggle Mode (default), the display will alternate between a
parameter name and its value. In Fixed Mode (press SEL
switch), only the value appears on the display. If a parameter
is being edited, one or more digits are blinking as the value of
the parameter is being displayed.

Key combination New mode
while in run mode New mode entry display

SEL Program Mode Prog

SEL + UP Manual Setpoint Mode Loc

SEL + DN Calibration Mode CAL

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4.4 Program Mode (Data Entry Parameters)

The table below shows all programmable parameters, their display name and data range.

Parameter Minimum Maximum

Name Display Numeric Value Numeric Value Pick List Values Description Notes

CodE 0000 9999 Security code

Addr 1 255 Communications address

Ocur 4-20, 0-20 Optional current output module range

Sdir riSE, FALL Setpoint direction

SPrS 0.0 % 99.9 % Split range start point.

SPrE 0.1 % 100.0 % Split range end point.

OPEn 0 sec 200 sec Ramp open (CCW) time. 1

CLOS 0 sec 200 sec Ramp close (CW) time. 1

SFc Lin, FrE1, FrE2, Setpoint function (linear or curve select)

FrE3, FrE4

dEbA 0.3 % 10.0 % Auto Positioning deadband 2

SPOS 0.0 % 100.0 % HOLd Loss of setpoint signal position

SPt 0 sec 9999 sec Loss of setpoint dwell time

PPOS 0.0 % 100.0 % HOLd Power-on position

PPt 0 sec 9999 sec Power-on position dwell time

yA 0.0 % 100.0 % Positioner lower (CW) rotational limit 3

yE 0.0 % 100.0 % Positioner upper (CCW) rotational limit 3

yCLS yES, no Tight valve shutoff operation. 4

yOPn yES, no Full open valve operation. 5

bAUd 1200, 2400, 4800, Communications rate.

9600, 19200, 38400

CyS Valve total travel time

(from full CW to full CCW and back). 6

CyCn Total number of valve cycles.

AdE Deviation alarm time. 6

AHi 0.0 % 100.0 % Valve high (CCW) position alarm.

ALo 0.0 % 100.0 % Valve low (CW) position alarm.

SLxx 0.0 % 100.0 % Free curve vertices (see section 4.4.10)

PrSt yES, no Option to set all parameters to their

default values (see section 4.4.17).

8 Electri-SAFE DataFlo Digital Electronic Positioner FCD WCAIM2048-01

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The Program Mode is entered from the Run Mode by
pressing the on-board SEL switch for three seconds.

When first entering the Program Mode, Prog will be displayed
for two seconds and the security code will be checked. If the
required security code is not zero, the display will begin
alternating between CodE and 0000. Enter the security code
as described in paragraph 4.4.1. If the required security code
is zero (“0000”) it will not need to be entered by the user, i.e.,
it will be bypassed.

After any required security code is correctly entered, a menu
allows the user to select individual parameters they wish to
program.

For all parameters in the table on previous page, the display
will be in Toggle Mode alternating between showing the
parameter name for one second then its value for one second.
Pressing the UP or DOWN switches in the Toggle Mode will
display the next or previous parameter (respectively).
Pressing the SEL switch while in the Toggle Mode will enter
the Fixed Mode of display where the value can be altered.

As explained in paragraph 4.3.6, values are edited by pressing
the UP or DOWN switches (UP to increment digit and DOWN
to advance to the next digit) until the desired value is
obtained. Pressing the SEL switch while editing will record
the new value and return the display to the Toggle Mode.

If an invalid value is entered for a parameter, the display will
flash an error message until acknowledged by the user. The
user can acknowledge an error by pressing the SEL switch.

4.4.1 Security Code Screens

The display will alternately display CodE and 0000

The correct security code number must be entered to gain
access to Program and Calibration Modes. Once in the
Program Mode, the security code can be reprogrammed.

Legal security code values are 0000 to 9999. Note that when
the security code of 0000 is used, the security option will be
bypassed. With a code of 0000 the user is not required to enter
the code to gain access to modes that use the security code.

If the security code is forgotten, the special number 4800 can
be used to gain entry to modes that require a security code.
However, this number will now be the new security code and
if another code number is still desired, it will have to be
reprogrammed.

4.4.2 Unit Address Screen

The display will alternately display Addr and the com­munications address, which is factory set at 1 on new units.

CAUTION: Do not install two units with the same address on
the same RS485 bus.

To edit the value, use the UP or DOWN switches to select a
value from 1 through 255.

4.4.3 Output Current Range

The display will alternately display Ocur and either 4-20
or 0-20.

Edit the value and use the UP or DOWN switches to select
0-20 or 4-20.

4-20 selects a 4-20 mA output current range.

0-20 selects a 0-20 mA output current range.

A voltage output can be achieved by connecting a resistor
across the current output.

The output current feedback is linear.

4.4.4 Analog Setpoint (Input) Range

The analog setpoint (input) signal range is fixed.

Notes Description

1 If a time of “0” is used or a time is entered that is less than the travel time, the rate of response to a step change in the

input signal we be as fast as the actuator can operate.

2 The deadband is used to prevent oscillations about a setpoint because of small fluctuations in either the setpoint signal or

the position feedback signal. The deadband represents a plus and minus percentage of the full range of either the input
signal or the feedback signal. Deadband can be set to a fixed value or it can be set to Auto. See paragraph 4.4.11 for a
discussion of deadband.

3 In normal operation, the valve will operate in the yA to yE limits. yA must be less than yE. The yA value is the most CW

position and the yE value is the most CCW position the valve will be able to travel.

4 Tight valve shutoff specifies if the valve should be closed completely when the signal is between 4.1 and 4.2 mA, regardless

of the yA setting. So if yCLS is yES and yA is at 20.0 % the valve will close completely (full CW) when the setpoint is between

4.1 mA and 4.2 mA even though 20% was the lower limit.

5 Full-open valve operation specifies if the valve should be opened completely when the signal is between 19.8 and 19.9 mA,

regardless of the yE setting. So if yOPn is yES and yE is at 70.0% the valve will open completely (full CCW) when the
setpoint is between 19.8 mA and 19.9 mA even though 70% was the upper limit.

6 This parameter is read-only and cannot be modified by editing.

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4.4.5 Setpoint Direction (Rise/Fall)

The display will alternately display Sdir and either riSE or
FALL.

Use the UP or DOWN switches to select riSE or FALL.

riSE selects direct acting positioner control where the actuator
rotates in the CCW direction as the setpoint signal increases.
The valve is full CW at the minimum setpoint signal value.

FALL selects reverse acting positioner control where the
actuator rotates in the CCW direction as the setpoint signal
decreases. The valve is full CCW at the minimum setpoint
signal value and full CW at the maximum setpoint signal value.

4.4.6 Setpoint Split Range START Selection

The display will alternately display SPrS and its value.

For a direct-acting positioner, SPrS specifies the START of the
split range input signal for the full CW actuator position, and
must be less than SPrE. For a reverse-acting positioner, SPrS
specifies the START of the split range input signal for the full
CCW actuator position, and must be less than SPrE.

The setting can be anywhere from 0.0 to 99.9% of the input
signal range in 0.1% increments.

Split ranging is useful when more than one valve is used in a
control system. As an example, one actuator can be calibrated
to open for an input signal between 4-12 mA and another to
open for an input signal between 12 and 20 mA.

4.4.7 Setpoint Split Range END Selection

The display will alternately display SPrE and its value.

For a direct-acting positioner, SPrE specifies the END of the
split range input signal for the full CCW actuator position, and
must be greater than SPrS. For a reverse-acting positioner,
SPrE specifies the END of the split range input signal for the
full CW actuator position, and must be less than SPrS.

The setting can be anywhere from 0.1 to 100.0% of the input
signal range in 0.1% increments.

4.4.8 Setpoint Ramp-Time to Open

The display alternately displays OPEn and the selected time to
open.

Times from 0 to 200 seconds can be selected as the time for
the actuator to travel from the full-closed (CW) to the full­open (CCW) position.

If “0” (or a time less than the CCW travel time) is selected,
the rate of response to a step change in the input signal will
be as fast as the valve actuator can operate. The slowest time
to open is 200 seconds.

4.4.9 Setpoint Ramp-Time to Close

The display alternately displays CLOS and the selected time to
close.

Times from 0 to 200 seconds can be selected as the time for
the actuator to travel from the full-open (CCW) to the full­closed (CW) position.

If “0” (or a time less than the CW travel time) is selected, the
rate of response to a step change in the input signal will be as
fast as the valve actuator can operate. The slowest time to
close that can be selected is 200 seconds.

4.4.10 Setpoint Curve Function

The positioner translates the setpoint input using a table of
values. The positioner contains a linear table and four 21­point curves called free curves. By default, the linear
translation table is used (SFn is set to Lin). The four free
curve tables can be edited to allow different translation curves
to be used. By default, free curve #1 (FrE1) is preset to a 1:25
equal percentage response curve, free curve #2 (FrE2) is
preset to 1:50 equal percentage response curve, and free
curves #3 and #4 (FrE3 and FrE4) are each preset to a linear
response curve. All four free curves can be modified. The
table on the next page shows all the tables and the default
free curve values. These values are loaded any time the
parameters are defaulted with the PrSt parameter.

NOTE: Definition of equal percentage: for equal increments of
valve rotation, the C

v

increases by a given percentage over

what it was at the previous setpoint.

The display will alternately display SFc and either Lin or FrE1,
FrE2, FrE3, or FrE4.

This function tells the positioner the desired shaft positioning
characteristic with respect to input signal.

Lin causes the shaft position to vary in a linear fashion as
the input signal changes (i.e., if the signal is at 50 percent,
the shaft position will be at 50 percent of the selected
operating range).

The FrE1-FrE4 curves allow 21 setpoint vertices to be set. In
this way, a custom shaft positioning characteristic can be
entered. There is a vertices set (data point) at 4 mA and then
every 0.8 mA up to and including 20 mA. The vertices are
displayed as SL 0 to SL 20 and will only be displayed when
one of the FrE1-FrE4 curves is chosen as the setting. The SL
parameters can be found in the menu between the PrSt
parameter and the CodE parameter. Use the UP and DOWN
switches to select and change the vertices settings.