Intrinsically Safe Modular Accessory System Series I90 · 2020. 1. 2. · I. INTRODUCTION The...

Worcester ControlsWCAIM2033

(Part 17188)

Intrinsically Safe Modular Accessory SystemSeries I90Installation, Operation and Maintenance InstructionsI. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

II. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

A. MOUNTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

B. AIR CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

III. OPERATING AND MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

A. HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1. COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2. BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

B. SOLENOID BLOCK OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4. REPAIR OF SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

5. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

C. SWITCH OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2. CAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

D. FEEDBACK POTENTIOMETER OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3. CALIBRATION FOR “P” (SINGLE POTENTIOMETER) OPTION . . . . . . . . . . . .12

4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

I. INTRODUCTIONThe Intrinsically Safe Modular Accesory System Series I90 (or I90M.A.S.) is designed to provide a wide choice of valve positionfeedback and pneumatic valve actuator control functions. Applicationsrange from simple end-of-travel limit switch indication to automatedcontrol using feedback from a system parameter sensor (temperature,flow rate, etc.). Maximum ambient temperature for models withsolenoid is 110°F.

The concept behind the unit is flexibility, allowing the user to customizean I90 M.A.S. for a particular application. For this reason, theseinstructions have been arranged as a series of individual chapters, eachdealing with separate options available in the I90 M.A.S. Regardless,this unit is a complex device and not all options can be accommodatedsimultaneously. A table summarizing the available options follows. Notethat POSITIONER or CONTROLLER options are not available. Certainoptions also require the addition of a second terminal block which willbe provided in the M.A.S. unit or kit when required.

a WARNING: The Series I90 M.A.S. is an electromechanical devicesubject to normal wear and tear. Its life is dependent uponapplication and environmental conditions. Breather/drain fittings arerecommended for humid environments when moisture may condenseinside the sealed M.A.S. housing.

CAUTION: Flowserve recommends that all product which must bestored prior to installation be stored indoors, in an environmentsuitable for human occupancy. Do not store product in areas whereexposure to: relative humidity above 85%, acid or alkali fumes,radiation above normal background, ultraviolet light, or temperatureabove 120°F or below 40°F may occur. Do not store within 50 feet ofany source of ozone.

The following options will be intrinsically safe when connectedthrough Zener barriers rated at 28 volts DC maximum, 300 ohmsminimum and 28 volt DC diode as shown in the wiring diagrams below.

IMPORTANT: Shielded cable must be used for each intrinsically safecircuit, and the shield must be connected to a Zener barrier ground.

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2 Intrinsically Safe Modular Accessory System (Series I90) WCAIM2033

AVAILABLE OPTIONS (Non-Positioner/Controller Units):Order Codes and Descriptions

B – Breather/Drain FittingP – Single Feedback PotentiometerS – Single-Acting Solenoid BlockD – Double-Acting Solenoid BlockM2 – 2 SPDT Mechanical Switches

PRODUCT CODE EXAMPLES:20 P I90 S M210 I90 D T3293

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.

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 Below.Product Series ________________________________ I90Action _______________________________________ Blank – If no Solenoid

S – Single-Acting Solenoid D – Double-Acting Solenoid

Direction _____________________________________ Blank – StandardSwitch options ________________________________ See Below.Circuit Board __________________________________ None – Will be Blank Custom Product No. (if special) ___________________ P#, T#, C#, or Similar #

II.INSTALLATIONA. MOUNTING INSTRUCTIONS

1. Refer to Figure 1. The Series I90 is designed to be mountedin-line with the major axis of the actuator. The air connectionsfor the Series I90 should be on the same end as the airconnections for the actuator. The standard 39 actuator has itsair connections on the right-hand end cap as you face theactuator nameplate. The Series I90 nameplate will be on thesame side as the actuator nameplate.

2. If the actuator is double-acting, rotate the actuator shaft to itsclockwise position. Spring-return actuators will be in thisposition already.

3. Place the mounting bracket on the actuator. Secure themounting bracket with the four (4) screws and lockwasherssupplied in the kit.

4. Place the coupling over the actuator shaft. (Note: For the 1039actuator only, shallow slot is placed over the actuator shaft).The coupling has four (4) threaded holes in it: two are Z\v"-20thread for set screws; the other two are #10-32 (located 45degrees off the center line of the coupling) and are not used.DO NOT tighten the set screws at this time.

5. Place the Series 90 unit on the bracket while inserting theshaft into the coupling slot. Be certain the holes in the bracketand 90 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 actuatorhas been cycled 90 degrees.

B. AIR CONNECTIONS

1. Series I90 mounting kits contain two (2) elbow “quick”fittings, two (2) straight “quick” fittings, and one (1) length ofZ\v" O.D. tubing. Single-acting, or “spring-return” assemblieswill use one elbow and one straight fitting. Double-actingassemblies will use two elbow and two straight fittings. Thelength of tubing will be cut to suit the assembly (one piece forspring-return, two pieces for double-acting).

Refer to Figure 2. Assemble the elbow fitting(s) to theactuator. Pipe thread sealant may be used on the threads (donot allow thread sealant to contaminate the internal airpassages of the M.A.S.). Fluoropolymer tape thread sealantshould not be used.

ACTUATOR SIZE PORT THREAD (NPT)

10 - 20 Z\,"25 - 40 Z\v"

3. Assemble the straight fitting(s) to the series 90 housing asshown in Figure 3. The thread sizes are labeled for referencein the figure. Pipe sealant may be used on the threads (do notallow thread sealant to contaminate internal air passages ofthe M.A.S.). Fluoropolymer tape thread sealant should not beused.


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WCAIM2033 Intrinsically Safe Modular Accessory System (Series I90) 3

ITEM NO. QTY. DESCRIPTION1 1 SERIES I90 - M.A.S.2 1 SERIES 39 ACTUATOR3 1 MOUNTING BRACKET4 2 COUPLING5 2 SET SCREW6 4 ACTUATOR MOUNTING SCREW7 4 ACTUATOR MOUNTING LOCKWASHER8 4 M.A.S. MOUNTING SCREW9 4 M.A.S. MOUNTING LOCKWASHER

10 1 Z\v" O.D. X 31" TUBING (CUT BY USER)11 2 STRAIGHT FITTING12 2 ELBOW FITTING

Figure 1

4. Cut the tubing provided to as short a length as possible thatwill still reach comfortably from the Series I90 unit to theactuator. On double-acting versions, the tubes run parallel toeach other and do not cross. The operation of the actuatorcan be reversed by reversing the location of the tubes at theactuator. Connect the tubes to their respective actuator andSeries I90 ports (refer to figures 2, 3, and 4).

5. Refer to Figure 4 for a diagram of the Series I90 airconnections in each of its two configurations.

a. Connect the supply air for the actuator (80 psinominal/100 psi maximum) to the location labeled“SUPPLY” in the appropriate sketch.

b. Locations labeled “VENT” may be fitted with a porousmuffler (or other fitting if desired) to reduce exhaustnoise. Air must be allowed to flow freely from these ports;“VENT” locations must not be plugged under anycircumstances.

c. Ports labeled “NOT USED” must remain plugged with thestainless steel pipe plugs provided.

III. OPERATION AND MAINTENANCE INSTRUCTIONS

A. HOUSING ASSEMBLY

The housing consists of the base, cover, shaft, baseplate, andassociated hardware. The housing is assembled as received fromFlowserve. For ease of maintenance, assembly instructions will beprovided here.

1. COVER

CAUTION: Use care to avoid damaging the machined flangesurface of the cover.

a. Apply a light coat of Cindol 2321 lubricant (or otherbearing grease) to the shaft hole.

b. Assemble the captive type cover screws through theflange holes. The screws must be turned throughapproximately Z\v" of thread until they reach the clearancediameter and remain loose in the cover. Use caution toavoid cross-threading these screws. Refer to Figure 5.


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FIGURE 2 – ACTUATOR FITTING LOCATIONS FIGURE 3 – M.A.S. FITTING LOCATIONS

FIGURE 4 – AIR CONNECTIONS FOR ALL I90 M.A.S. CONFIGURATIONS

#10–32 THREAD 4 PLACES REF. (NOT USED)

PORT "S"(CLOSEST TO EDGEOF ACTUATOR)

PORT "D"(CLOSEST TO CENTEROF ACTUATOR)

¹⁄₈" NPT¹⁄₄" NPT

SPRING-RETURN – USE ONE (1) STRAIGHT FITTINGIN PORT "D"

DOUBLE-ACTING – USE TWO (2) STRAIGHT FITTINGS:ONE (1) IN PORT "D" ANDONE (1) IN PORT "B"

DOUBLE-ACTING – USE TWO (2) ELBOW FITTINGS:ONE (1) IN PORT "S" ANDONE (1) IN PORT "D"

SPRING-RETURN – USE ONE (1) ELBOW FITTINGIN PORT "S"

DOUBLE-ACTINGSPRING-RETURN

c. Check to see that the shaft seal has been installed asshown in Figure 6.

CAUTIONS: When assembling cover to base be sure wiresare away from any rotating parts and are not pinchedbetween cover and base flanges.

Relubricate the shaft hole anytime cover is removed andreplaced.

To avoid damaging the cover hole finish and binding theshaft to cover, check the top of the shaft for burrs or impactdamage before installing or removing cover.

2. BASE

CAUTION: Use care to avoid damaging the machined flangesurface of the base.

a. Check to see that the shaft seal and bearing have beeninstalled as shown in Figure 6.

b. Apply a light coat of bearing lubricant to the shaft hole.

c. Insert the shaft through the shaft hole in the base fromthe inside. The shaft fits through this hole with minimalclearance — care must be taken to avoid damaging thebearing surfaces or causing the shaft to gall.

d. Place one of the nylon thrust washers onto the shaft endprotruding outside the base. Assemble one of the snaprings to the shaft in the groove below this thrust washer(rounded side towards thrust washer — see detail).

e. Place a second nylon thrust washer over the shaft andinto place against the shaft boss on the inside of the base.Secure the shaft in place with a second snap ring in thegroove adjacent to the second thrust washer (roundedside towards thrust washer — see detail).

f. Place the third snap ring into the upper groove as shownin Figure 6.

g. If the base is machined to accept a breather/drain fittingas shown in Figure 7, then the boss on the bottom of thebase near the electrical conduit connection bosses will be

tapped with C\," NPT threads. If this boss is tapped, thebreather/drain fitting must be installed. The use offluoropolymer tape or other thread sealant isrecommended prior to installing this fitting into the boss.

h. Plug the C\v" NPT conduit connection on the end of thebase temporarily with the threaded plastic plug provided.This plug will be removed and discarded when the unit isinstalled.

i. Plug the four Z\v" NPT and one Z\," NPT air connectionports with the stainless steel pipe plugs provided. Threadsealant is not recommended prior to installing theseplugs. The residue left by a thread-sealing compoundcould foul the solenoid valve air passages. If a solenoidvalve option is to be installed in the unit, some of theseplugs will not be used — refer to Section III.B todetermine which plugs can be left out.

IMPORTANT: If no solenoid is to be used, all of the portsmust be plugged. Refer to Figure 7.


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Figure 5

Figure 6

j. The M.A.S. uses a standard O-ring to achieve bothWatertight (TYPE 4) and Explosion-proof (TYPE 7)ratings. Refer to Figure 8.

k. Refer to figure 9. The baseplate contains one factory-assembled terminal strip located in the “primary” (side)location on the baseplate. A second terminal strip isrequired with some M.A.S. options, outlined below. Theextra terminal strip will be provided with the appropriateoptions. Attach it to the baseplate with four (4) #4 x C\,"self-tapping screws provided in the “secondary” (end)location.

l. Assemble the baseplate into the base using the four (4)#6-32 screws provided. Use care when tightening thesescrews as the baseplate is plastic and could be damagedif overtightened. If options such as Switches, Potentiometerkit, etc., are to be installed, they can be assembled to thebaseplate prior to installing baseplate into base.

CAUTION: Avoid contacting baseplate with solvents —damage may result.

OPTION REQUIRING SECOND TERMINAL STRIP*FEEDBACK POTENTIOMETER - P

* INCLUDED WITH OPTION OR KIT IF REQUIRED.

m. The base is provided with an alignment pin pressed intothe flange, which will allow the cover to be assembled inonly one orientation (See Figures 9 & 10). Be certain thecover is correctly positioned prior to tightening bolts, ordamage may result.

n. M.A.S. options are supplied with wiring diagrams whichshould be affixed to the inside of the cover as shown inFigure 10.

Note the orientation of the terminal strips on the wiringdiagrams, and their location in the cover.

Figure 10


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Figure 7

Figure 9

3. TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE(S) SOLUTIONShaft binds Cover not centered Loosen cover screws and

allow cover to center onshaft. Retighten coverscrews.

Inadequate lubrication Remove cover and lubricateshaft hole with bearinggrease, such as Cindol 2321.If excessive wear or galling ispresent, shaft and affectedpart of housing will have tobe replaced.

B. SOLENOID BLOCK OPTIONS

The Worcester/McCanna Series I90 Intrinsically Safe M.A.S. canprovide on/off control for both single– and double-actingpneumatic valve actuators.

Single– or Double-Acting on/off uses one three-way solenoidvalve and one four-way spool valve.

The Intrinsically Safe solenoid valves used in the M.A.S. aredesigned to operate on power levels compatible with IntrinsicSafety requirements. They are Factory Mutual (FM) approved forClass I, II and III Groups A, B, C, D, E, F and G applications. EntityApproval #OT4A6.AX (NFPA 493; July 19, 1990).

NOTE 1. For barrier interconnection, refer to maximum barrieroutput parameters as referenced on the specific barrierinstallation drawing. Connect as follows:

a. V max > Voc of single-channel or Vt of dual-channel barrier.

b. I max > Isc of single-channel or It of dual-channel barrier.

c. Ci + field wiring < Ca of single– or dual-channel barrier.

d. Li + field wiring < La of single– or dual-channel barrier.

For current and wattage values at various input voltages, see tablebelow.

INPUT VOLTAGE CURRENT WATTAGE15.5 VDC 43 mA 0.724 VDC 68 mA 1.6335 VDC 95 mA 3.3

NOTE 2. Installation of Intrinsically Safe systems is to be done inaccordance with ANSI/ISA R.P. 12.6.

DEFINITIONS

Ca – Maximum Allowed Capacitance

Isc – Maximum Output Current

Voc – Maximum Output Voltage

Ci – Maximum Internal Capacitance

La – Maximum Allowed Inductance

V max – Maximum Input Voltage

I max – Maximum Input Current

Li – Maximum Internal Inductance

Vt – Voltage Total

All lead wires are equipped with quick-connect plugs that areeasily connected/disconnected to the solenoid valve. See Figure11. The plugs will only fit one way — do not force the plugs;damage can result.

The solenoid block gasket has been designed to adapt thesolenoid blocks to the Series 90 M.A.S. housing air connections.The gasket is illustrated in Figure 12 for future reference in theseinstructions.

AIR SUPPLY: Lubricated or dry air (or other non-corrosive gas).

PRESSURE: 45 – 100 PSI.

FILTRATION: 5 micron strongly recommended.


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Li = 0Ci = 0

V max. = 35 V

CHANNEL BARRIERDUAL OR SINGLE

I max. = 300 mA

MAX. PARAMETERS FOR I.S. VALVE:

HAZARDOUS AREA

SWITCH

POWER SUPPLY24 VDC NOM.

V nom. = 15.5 VI nom. = 43 mAR nom. = 360 Ohm

COIL SPECIFICATIONS:

EXCESS OF 250 VOLTSOR GENERATE IN

EQUIPMENT CANNOT USE

NON-HAZARDOUS AREA

CIRCUIT (SEE NOTE 1)

TYPICAL INTRINSICALLY SAFE CIRCUIT

Figure 11

1. ASSEMBLY (Refer to Figure 13)

a. SINGLE-ACTING OR DOUBLE-ACTING INTRINSICALLYSAFE ON/OFF TYPE

NOTE: Where lubrication is required, Vaseline or othernon-corrosive grease is acceptable unless otherwisenoted. Use sparingly.

1. Attach the spool valve (item 2) to the solenoid block(item 1) in the location shown using the #4-40 screws(item 3) and gasket (item 4) provided.

CAUTION: Tighten screws to no more than 15 in-lbor breakage may occur. Be certain that the holes inthe gasket, solenoid valve, and solenoid block arealigned.

2. Attach the solenoid valve (item 5) to the solenoidblock in the orientation shown. The solenoid valve hasa #10-32 threaded stud that engages a tapped hole inthe block. The center retaining ring (item 6) may beloosened to position the electrical connector (item 7).

3. Lightly lubricate and install the four (4) straight andone (1) tee air fittings (items 8 and 9), and tighten.Assemble the Z\zn" I.D. x 3Z\v" (item 10), Z\zn" I.D. x 2"(item 11), and Z\zn" I.D. x 3Z\v" (item 12) lengths oftubing to these fittings as shown. The tubing isdifficult to remove and will not allow the fittings to betightened once installed.

4. Insert the three (3) #10-32 x 1Z\x" socket head screws(item 13) through the solenoid block from the sideshown (marked IS). Position the solenoid blockgasket (item 14) on these screws.

5. Attach the solenoid block and gasket to the angledinside wall of the M.A.S. base using the three (3)#10-32 x 1Z\x" screws.

6. Connect the lead wire plug (item 15) to the connectoron the solenoid valve. Refer to Section III.B and III.B.2for more information.

7. The air connection bosses on the outside wall of theM.A.S. base, function as indicated in Figure 14. Theporting varies depending on the actuator action(spring-return vs. double-acting).


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Figure 12

Single– or double-acting

For use with single-acting actuators

For use with single-acting actuators

For use with double-acting actuators

For use with double-acting actuators

Figure 13

Figure 14

2. WIRING

NOTE: All wiring is to be run smoothly and neatly and awayfrom any rotating parts and away from the base/cover flangejoint, using wire ties if necessary. Use caution to avoidpinching wires between the base and cover flanges.

Connect the solenoid lead wires to the side terminal strip asshown in the wiring diagram to the right. NOTE: All wiringshould be inserted only to mid-point of terminal strip. Refer tosection III.B for more details regarding wiring of intrinsicallysafe systems, barrier selection, etc.

3. OPERATION

a. Solenoid block is ported such that when not energized,the actuator will be in its closed (full-clockwise) position.

b. Energizing solenoid “A” will provide air to the actuator toopen (full-counterclockwise).

4. REPAIR OF SOLENOID VALVE (Refer to Figure 15)

The intrinsically safe solenoid valves used in the M.A.S. arevery reliable. Due to their construction, each is “hand-tuned”by the manufacturer to very close tolerances for optimumperformance. Occasionally, a valve may be operated in asystem with moist or lubricated air that causes the rubberseat in the valve to swell slightly. If this happens, the valvemay operate slowly, irregularly, or not at all. This situation canbe repaired in the following manner:

a. Obtain a new “spider” element (item 1). Contact ClippardInstrument Laboratory at (513) 521-4261 for informationon a local distributor.

b. Loosen the knurled retaining ring (item 2) and separatethe solenoid into its two sections (items 3 and 4).

c. Remove and replace the “spider” (item 1). Be certain thatthe protruding side of the rubber seat (item 5) facesdown, touching the lower section of the solenoid (item 3),and that the shim (item 6) is above the “spider” asshown.

d. Reassemble the two sections of the valve, orient theelectrical connector (item 7) to a convenient location, andtighten the retaining ring.

5. TROUBLESHOOTING

See table on following page.

C. SWITCH OPTIONS

A mechanical switch option is available in the Series I90 ModularAccessory System. The switches can be used to provide actuatorposition indication or to control other equipment.

The option always available (regardless of other options) is:

M2 – Two Single-Pole, Double-Throw mechanical switches

An “Adjustment Plate” is used to mount the single-polemechanical switches to the baseplate. Mechanical switches aremounted to the adjustment plate and set to a middle position —


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SINGLE– OR DOUBLE-ACTING ACTUATORS

INTERNAL

EXTERNALCustomer-Supplied

Wiring

SOLENOID "A"

SUPPLY VOLTAGE15.5 VDCNOMINAL

(CONNECT THROUGHAPPROPRIATE BARRIER)

Figure 15

not rotated towards or away from the shaft. There are two sets ofmounting holes in the adjustment plate; use the appropriate set asshown in Figure 16. Their use will be detailed later.

The cams used to actuate the switches offer unlimited positioningwithout the use of tools. These cams are essentially “wrap-springs” and grip the shaft tightly enough to prevent accidentalrotation. Squeezing together the two small protrusions from thecam, as shown in Figure 17, loosens the spring and allowsadjustment. Needlenose pliers may prove to be helpful wheninstalling the cams, but are not required.

NOTE: If potentiometer option is also going to be installed, thepotentiometer face gear should be installed before the switchesand cams.

1. ASSEMBLY

a. M2 – TWO SPDT MECHANICAL SWITCHES

1. Stack two (2) switches (item 1) and attach to theadjustment plate (item 2), as shown in Figure 18below, using two (2) #4-40 x 1" screws (item 3)provided.

Note: One of the screws will thread into a tapped holein the adjustment plate while the other engages aclearance hole without threads.

FOR MECHANICAL SWITCHESM2

Figure 16

SQUEEZE

SQUEEZE

Figure 17


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PROBLEM POSSIBLE CAUSE(S) SOLUTIONAir leak between Loose solenoid Tighten solenoid.solenoid/block or between block/housing Gasket out of position Remove solenoid block, realign gasket and

reattach solenoid block.

Defective gasket Contact Flowserve for replacement.

Rough surfaces on solenoid block Contact Flowserve for replacement.

Solenoid does not Power supply not connected/not working Check power supply.energize (go on)

Defective lead wires Check leads with ohmmeter or try new leadwires.

Defective solenoid valve Contact Flowserve.

Solenoid okay — actuator High valve torque Disconnect valve and check operation/torque.not working correctly

Air supply not connected/low pressure Check supply air piping and pressure.

Tubing connections to M.A.S.; or solenoid block tubing not correct Check M.A.S. air connections.

Debris in solenoid valve or block Remove and clean solenoid valve and block.Check filtering per Section III.B.

No obvious cause(s) Disconnect M.A.S. from actuator; test eachunit separately.

Figure 18

2. Assemble the switches and adjustment plate to thebaseplate (item 4), as shown below, using the “loose”#4-40 x 1" screw and the #4-40 x C\," screw (item 5)and #4 washer (item 6). Move the adjustment plate toa middle position and tighten the screws.

2. CAMS

Assemble the first spring cam, the spacer, and second springcam. To work the spring cam down the shaft, squeeze the twoprotrusions and turn. See Figure 19.

3. WIRING

NOTE: All wiring is to be run smoothly and neatly andaway from any rotating parts, using wire ties, if necessary.Use caution to avoid pinching wires and/or solenoid leads(if used) between the base and cover flanges.

a. The wire leads will be connected to the switches asprovided. Pay close attention to the switch labels,schematics, wire colors, etc., when wiring the switches.Switches are to be wired to the side terminal strip asshown in the wiring diagram below.

NOTE: Wiring should be inserted only to mid-point ofterminal strip.

b. Route the wires between the legs of the black terminalbrackets whenever possible. Be certain that the wires willnot get fouled on the shaft when it rotates.

4. OPERATION

a. Once the M.A.S. unit has been assembled and connectedto the actuator, the switch cams can be set per user’srequirements. Normally switch I indicates “closed” andswitch II indicates “open”.

b. The unit should be operated to ensure that switchactuation occurs at the end of rotation (or in whateverposition is desired by the customer) repeatedly.

NOTE: FOR INTRINSICALLY SAFE SYSTEMS ONLY.

All inputs/outputs (“external” wiring connections) must berun through approved intrinsic safety barriers.

IMPORTANT: Shielded cable must be used for eachintrinsically safe circuit and the shield must be connectedto Zener barrier ground.


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Figure 19

5. TROUBLESHOOTING

See table below.

D. FEEDBACK POTENTIOMETER OPTIONS

The M.A.S. can accept a potentiometer option designed to providefeedback representing the position of the M.A.S. shaft.

• Single 0-1000 ohm potentiometer - output

• Voltage limit of pot is 30 volts maximum.

1. ASSEMBLY (Refer to Figure 20 below)

P – SINGLE POTENTIOMETER

a. With the potentiometer (item 3) mounted to thepotentiometer bracket (item 4) and the pinion gear (item1) loosely fitted to the potentiometer shaft (item 2),mount the potentiometer bracket (item 4), if not alreadymounted, to the baseplate (item 5) using two #8-32 x B\zn"screws (item 10) provided.

b. Remove the upper snap ring (item 6) from the shaft (item7). Use care to avoid deforming it permanently.

c. Slide the face gear (item 8) onto the shaft, teeth facingdown, and secure with the snap ring (item 9) provided.

NOTE: The face gear utilizes a friction fit to the shaft. Forbest results, wipe off any lubricant that may be on theshaft before sliding on the face gear.

CAUTION: Do not overstretch the snap ring — use theminimum opening to allow it to slip over the gear.

d. Replace the upper snap ring (item 6).

2. WIRING

NOTE: All wiring is to be run smoothly and neatly and awayfrom any rotating parts, using wire ties if necessary. Usecaution to avoid pinching wires and/or solenoid rectifiersbetween the base and cover flanges.

a. Add the second terminal strip in the “secondary” locationusing the four (4) #4 x C\," self-tapping screws provided.Refer to figure 21.

b. Connect the wires to the end terminal strip as shown inthe wiring diagram on the next page.

NOTE: Wiring should be inserted only to mid-point ofterminal strip.

3. CALIBRATION FOR “P” (SINGLE POTENTIOMETER) OPTION

Prior to adjusting the potentiometer, the M.A.S. package mustbe mounted to the actuator, and the baseplate must beinstalled in the M.A.S. unit. Adjust the potentiometer piniongear so that there is approximately Z\zn" tooth engagementbetween the face gear and the pinion gear, and tighten the setscrew. The actuator must be in the full closed position prior to


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PROBLEM POSSIBLE CAUSE(S) SOLUTIONSwitches do not indicate Improper cam settings Reset cams.at proper positions

Switch does not actuate Switch too far from cam Loosen the adjustment plate screws and(never trips) rotate switches toward shaft until actuation

is correct; retighten screws.

Switch does not reset Switch too close to cam Loosen the adjustment plate screws and(always tripped) rotate switches away from shaft until

actuation is correct; retighten screws.No indication at Broken, defective, or misplaced wire Check wiring with appropriate wiringterminal strip diagram per Section III.C.3.

Cams not aligned with Cams/spacers in wrong order Check and reassemble cams per Sectionswitch arms III.C.2.

Cams not pushed into place Push cams into proper locations; align withswitch arms.

Figure 20

making the potentiometer adjustment. In the case of a double-acting actuator, either temporarily connect air to theappropriate actuator port or use a wrench to move theactuator to the closed position. Unless there is air supplied toa spring-return actuator, it should automatically be in theclosed position. Using an ohmmeter, measure the resistancebetween the purple and the white/black potentiometer leads atthe terminal strip. Rotate the face gear to obtain a resistanceon the ohmmeter of 80 to 90 ohms.

NOTE: It is not necessary to loosen or remove face gear snapring to rotate gear.

IMPORTANT: The feedback potentiometer is calibrated for onlyone 90 degree quadrant of valve operation. If the output shaftis repositioned to another 90 degree quadrant, or if the outputshaft is rotated a multiple of 360 degrees from its originalposition, or if the M.A.S. package is removed from theactuator, the feedback potentiometer will no longer be incalibration and must be recalibrated as directed.

4. TROUBLESHOOTING

See table below.


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PROBLEM POSSIBLE CAUSE(S) SOLUTIONIndicates backwards Green and Purple wires reversed Check wiring per Section III.D.2.

Reverse-acting actuator Reverse green and purple wires. Recalibratepotentiometer per Section III.D.3.

Indication not consistent Gears slipping Check gear tooth engagement (approximately Z\zn").

Pinion gear set screw loose Recalibrate and tighten set screw.

Indication not correct Potentiometer needs to be calibrated. Calibrate pot. per Section III.D.3.

M.A.S. shaft turned more than 90 degrees Re-calibrate for new quadrant.

Figure 21

“P” Single-feedback potentiometer

NOTE: FOR INTRINSICALLY SAFE SYSTEMS ONLY. All inputs/outputs(“external” wiring connections) must be run through approvedintrinsic safety barriers.

IMPORTANT: Shielded cable must be used for each intrinsically safecircuit and the shield must be connected to Zener barrier ground.

This page is intentionally left blank.


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Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended functionsafely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrialservice conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must thereforeassume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the InstallationOperation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.

While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee ofsatisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserveis continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerningthese provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices.

For more information about Flowserve Corporation, contact www.flowserve.com or call USA 1-800-225-6989.

FLOWSERVE CORPORATIONFLOW CONTROL DIVISION1978 Foreman DriveCookeville, Tennessee 38501 USAPhone: 931 432 4021Facsimile: 931 432 3105www.flowserve.com

© 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and Worcester Controls are registered trademarks of Flowserve Corporation. WCAIM2033 10/03 Printed in USA


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