MegaMix TM Steam/Water Mixing Unit

Transcription

1 MegaMix TM Steam/Water Mixing Unit Model No: Valve Serial No: Actuator Serial No: Ship Date:

2 MegaMix TM Steam/Water Mixing Unit - Introduction Introduction Congratulations on selecting an Armstrong product. Armstrong devotes considerable care and attention to the design of its products. To obtain the best performance from them, the customer should read this manual from cover to cover. It contains important installation and operating instructions. The customer must strictly adhere to the safety tips, trouble shooting advice, cautions and warnings appearing throughout this manual. Along with the warnings, instructions and procedures in this manual, the customer should also observe such other procedures generally applicable to equipment of the same type. If the customer does not follow these and other such warnings, instructions and procedures, the product may not perform as expected. More seriously, it may cause property damage, personal injury, production down-time and other losses. The customer should train its employees and contractors in the safe use of Armstrong products in relation to the customer s specific application. If the customer does not understand a point in this manual, contact Armstrong or its authorized representative. Page ii

3 MegaMix TM Steam/Water Mixing Unit - Contents Section / Description Page Introduction... ii 1.0 MegaMix TM Steam/Water Mixing Unit - Datasheets... 5 Model E25S... 5 Model E40S... 6 Model E50S Valve - Parts and Materials Exploded Assembly Drawing List of Parts and Materials Spares Kits and Part Numbers Valve - Installation Valve Maintenance Disassembly Reassembly Actuator - Parts and Materials List of Parts and Construction Materials Actuator Accesories and Spare Parts Actuator - Mounting on to MegaMix TM Valves Actuator - Electrical Installation General information Wiring Instructions Power Supply Wiring Power Supply Wire Specification Wiring of Actuator ma Loop Receiver Wiring of Actuator ma Loop Transmitter Temperature Sensor Connector (Port-1) Auxiliary Input (Port-2) Serial Port Connector (Port-3) Page iii

4 MegaMix TM Steam/Water Mixing Unit - Contents Section / Description Page 8.0 Current Loop I/O Standard Configuration of Current Loop Input for Temperature Controller Mode Standard Configuration of Current Loop Input for Positioner Mode Standard MegaMix TM Current Loop Output Characteristic MegaMix TM Config Configuration Software Installation Operation Getting Started General Use Changing Values Property Categories Temperature Controller Values Motion Control Values Selecting Standard Configuration Sets Keypad Operating Instructions Dual Press Fail Safe Button Operation Controller Type Selection Controller Units Selection Remote & Local Control Toggle Changing Values (Set Point) Error Codes Troubleshooting Armstrong Hot Water, Inc. Limited Warranty and Remedy Important Notice Page iv

5 MegaMix Model E25S Steam/Water Mixing Unit General Features The shear action disc design of the E25S valve provides precise controlled mixing of steam and water. Fitted with the electronic actuator and an integrated temperature sensor, the system ensures fast, accurate and stable temperature control. The single compact assembly simplifies installation. The independence of this stand-alone unit provides a reliable solution for hot water supply for industrial applications. The calibrated temperature probe fits into a 1/8" NPSM port in the outlet, and connects via a cable to the actuator. With this temperature feedback signal, the actuator can provide temperature control accuracy of ±1 F (±0.5 C) and up to 200 F (95 C) heated water at the outlet. The E25S can handle a variety of input temperatures and pressures to give a temperature rise. The flow rate table below outlines only 4 typically requested output temperature rises. With sudden changes of inlet pressure and temperature to the valve, the controller aggressively minimizes outlet temperature variations. Valve Features ISO 5211, 5210 actuator flange mounting Nickel chrome and cobalt coated CF8M (316) stainless steel discs 1" valve flow coefficient C v (max): 8.0 End connection: 1" NPT inlets and 1-1/4" NPT outlet Top entry allows inline access to internal valve parts Maximum inlet steam temperature 482 F (250 C) Rated pressure: 145 psi (10 bar) Seat leakage is approximately 0.05% of the valves C v (max) Design verification to ASME B16.34 U.S. patent approved Electronic Actuator Features Analog (4-20mA) input and output control signals for interfacing with SCADA control Software configurable control settings Very high resolution capability (0.03 rotational) External RS232 connection (cable supplied) Stand-alone closed loop temperature control, or remote analog (4-20mA) control options Power: regulated 24Vdc 3-amp supply required Fail-safe position feedback (non-contact absolute encoder) Keypad: 4 membrane switches with dual touch safety features Display: 3.5 digit LCD display with back light Push-button power switch Extra analog input for interfacing ancillary devices (e.g., flow switch, level switch) 90 stroke time as low as 1.5 seconds for fast control action Gearbox: planetary, lifetime lubrication, low backlash 100% duty cycle rated actuator For a fully detailed certified drawing, refer to CDLW # " 6.3" 4.7" 17.9" Manual override handle (not shown) Epoxy powder coated aluminum enclosure designed to NEMA 4 Push-button power switch Graduated visual indicator on shaft coupling Constructed of CF8M (316) stainless steel MegaMix Model E25S Steam/Water Mixing Unit Shipping weight 46 lbs (incl packaging) Shipping box size 12.8" x 23.4" x 11.6" (W x L x H) The E25S can handle a variety of input temperatures and pressures to give a temperature rise. The flow table below outlines only four typical output rises. Contact Armstrong for application sizing assistance. A) 18 F (10 C) Temperature Rise Water Steam 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 124 (470) 124 (470) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 124 (470) 176 (665) 176 (665) 176 (665) U.S. gal/min (l/min) 60 psi (4.0 bar) 124 (470) 176 (665) 203 (768) 203 (768) U.S. gal/min (l/min) B) 55 F (31 C) Temperature Rise Water Steam 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 99 (373) 104 (393) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 99 (373) 104 (393) 173 (655) 176 (665) U.S. gal/min (l/min) 60 psi (4.0 bar) 99 (373) 104 (393) 173 (655) 203 (768) U.S. gal/min (l/min) C) 100 F (56 C) Temperature Rise Water Steam 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 55 (197) 124 (470) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 55 (197) 176 (665) 176 (665) 176 (665) U.S. gal/min (l/min) 60 psi (4.0 bar) 55 (197) 176 (665) 203 (768) 203 (768) U.S. gal/min (l/min) D) 135 F (75 C) Temperature Rise Local keypad and temperature display with hinged magnetic latching lockable cover Armstrong temperature control solution comprising the 3-port mixing valve and actuator with integrated temperature sensor NTC temperature sensor Water Steam. 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 38 (142) 75 (283) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 38 (142) 75 (283) 125 (472) 174 (660) U.S. gal/min (l/min) 60 psi (4.0 bar) 38 (142) 75 (283) 125 (472) 174 (660) U.S. gal/min (l/min) Safety Consideration should be given during the design phase to the following conditions of the proposed circuit/system: Sudden loss of water pressure Loss of power supply Over-temperature safety fail-safe system If cold water supply or temp. sensor fails, the valve will be closed within approximately 2 seconds. If there is a loss of power, the unit will remain in its last powered up position and can be manually actuated using the manual override handle. Hot Water Solutions Contact factory for other orientation options for the actuator on the valve Wiring Access 1/8" NPSM Sensor Port Port A 1" NPT Water Input Port C 1-1/4" NPT Outlet Port B 1" NPT Steam Input IMPORTANT NOTES: 1. A minimum flow rate must be established for effective mixing and temperature control. The approximate minimum flow for effective steam and water mixing for the E25S valve is 4 U.S. gpm. 2. Check (nonreturn) valves MUST be fitted to both inlets. Strainers are also recommended. 3. Sensible pipeline velocities must be considered in application design. 4. Further information on installation requirements and recommendations is available in the Installation, Operation and Maintenance Manual (IOM), a copy of which is provided with the product. 5. Armstrong s Engineering Team is available to assist you with application support, component selection and E25S valve sizing. All dimensions and weights are approximate. Use certified print for exact dimensions. Design and materials are subject to change without notice. Armstrong Hot Water Group, 221 Armstrong Blvd., Three Rivers, MI USA Phone: (269) Fax: (269) HWS-64

6 MegaMix Model E40S Steam/Water Mixing Unit Hot Water Solutions General Features The shear action disc design of the E40S valve provides precise controlled mixing of steam and water. Fitted with the electronic actuator and an integrated temperature sensor, the system ensures fast, accurate and stable temperature control. The single compact assembly simplifies installation. The independence of this stand-alone unit provides a reliable solution for hot water supply for industrial applications. The calibrated temperature probe fits into a 1/8" NPSM port in the outlet, and connects via a cable to the actuator. With this temperature feedback signal, the actuator can provide temperature control accuracy of ±1 F (±0.5 C) and up to 200 F (95 C) heated water at the outlet. The E40S can handle a variety of input temperatures and pressures to give a temperature rise. The flow rate table below outlines only 4 typically requested output temperature rises. With sudden changes of inlet pressure and temperature to the valve, the controller aggressively minimizes outlet temperature variations. Valve Features ISO 5211, 5210 actuator flange mounting Nickel chrome and cobalt coated CF8M (316) stainless steel discs 1-1/2" valve flow coefficient C v(max): 13.3 End connection: 1-1/2" NPT inlets and 1-1/2" NPT outlet Top entry allows inline access to internal valve parts Maximum inlet steam temperature 482 F (250 C) Rated pressure: 145 psi (10 bar) Seat leakage is approximately 0.05% of the valves C v(max) Design verification to ASME B16.34 U.S. patent approved Electronic Actuator Features Analog (4-20mA) input and output control signals for interfacing with SCADA control Software configurable control settings Very high resolution capability (0.03 rotational) External RS232 connection (cable supplied) Stand-alone closed loop temperature control, or remote analog (4-20mA) control options Power: regulated 24Vdc 3-amp supply required Fail-safe position feedback (non-contact absolute encoder) Keypad: 4 membrane switches with dual touch safety features Display: 3.5 digit LCD display with back light Push-button power switch Extra analog input for interfacing ancillary devices (e.g., flow switch, level switch) 90 stroke time as low as 1.5 seconds for fast control action Gearbox: planetary, lifetime lubrication, low backlash 100% duty cycle rated actuator For a fully detailed certified drawing, refer to CDLW # " 6.3" 6.8" 19.1" Manual override handle (not shown) Epoxy powder coated aluminum enclosure designed to NEMA 4 Push-button power switch Graduated visual indicator on shaft coupling Constructed of CF8M (316) stainless steel MegaMix Model E40S Steam/Water Mixing Unit Shipping weight Shipping box size The E40S can handle a variety of input temperatures and pressures to give a temperature rise. The flow table below outlines only four typical output rises. Contact Armstrong for application sizing assistance. A) 18 F (10 C) Temperature Rise Local keypad and temperature display with hinged magnetic latching lockable cover Armstrong temperature control solution comprising the 3-port mixing valve and actuator with integrated temperature sensor NTC temperature sensor Water Steam 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 124 (470) 124 (470) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 124 (470) 176 (665) 176 (665) 176 (665) U.S. gal/min (l/min) 60 psi (4.0 bar) 124 (470) 176 (665) 203 (768) 203 (768) U.S. gal/min (l/min) B) 55 F (31 C) Temperature Rise Water Steam 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 99 (373) 104 (393) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 99 (373) 104 (393) 173 (655) 176 (665) U.S. gal/min (l/min) 60 psi (4.0 bar) 99 (373) 104 (393) 173 (655) 203 (768) U.S. gal/min (l/min) C) 100 F (56 C) Temperature Rise Water Steam 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 55 (197) 124 (470) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 55 (197) 176 (665) 176 (665) 176 (665) U.S. gal/min (l/min) 60 psi (4.0 bar) 55 (197) 176 (665) 203 (768) 203 (768) U.S. gal/min (l/min) D) 135 F (75 C) Temperature Rise 53 lbs (incl packaging) 12.8" x 23.4" x 11.6" (WxLxH) Water Steam. 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 38 (142) 75 (283) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 38 (142) 75 (283) 125 (472) 174 (660) U.S. gal/min (l/min) 60 psi (4.0 bar) 38 (142) 75 (283) 125 (472) 174 (660) U.S. gal/min (l/min) Safety Consideration should be given during the design phase to the following conditions of the proposed circuit/system: Sudden loss of water pressure Loss of power supply Over-temperature safety fail-safe system If cold water supply or temp. sensor fails, the valve will be closed within approximately 2 seconds. If there is a loss of power, the unit will remain in its last powered up position and can be manually actuated using the manual override handle. 348 HWS-65 Contact factory for other orientation options for the actuator on the valve Wiring Access 1/8" NPSM Sensor Port Port A 1-1/2" NPT Water Input Port C 1-1/2" NPT Outlet Port B 3/4" NPT Steam Input IMPORTANT NOTES: 1. A minimum flow rate must be established for effective mixing and temperature control. The approximate minimum flow for effective steam and water mixing for the E40S valve is 6 U.S. gpm. 2. Check (nonreturn) valves MUST be fitted to both inlets. Strainers are also recommended. 3. Sensible pipeline velocities must be considered in application design. 4. Further information on installation requirements and recommendations is available in the Installation, Operation and Maintenance Manual (IOM), a copy of which is provided with the product. 5. Armstrong s Engineering Team is available to assist you with application support, component selection and E40S valve sizing. All dimensions and weights are approximate. Use certified print for exact dimensions. Design and materials are subject to change without notice. Armstrong Hot Water Group, 221 Armstrong Blvd., Three Rivers, MI USA Phone: (269) Fax: (269)

7 MegaMix Model E50S Steam/Water Mixing Unit General Features The shear action disc design of the E50S valve provides precise controlled mixing of steam and water. Fitted with the electronic actuator and an integrated temperature sensor, the system ensures fast, accurate and stable temperature control. The single compact assembly simplifies installation. The independence of this standalone unit provides a reliable solution for hot water supply for industrial applications. The calibrated temperature probe fits into a 1/8" NPSM port in the outlet, and connects via a cable to the actuator. With this temperature feedback signal, the actuator can provide temperature control accuracy of ±1 F (±0.5 C) and up to 200 F (95 C) heated water at the outlet. The E50S can handle a variety of input temperatures and pressures to give a temperature rise. The flow rate table below outlines only 4 typically requested output temperature rises. With sudden changes of inlet pressure and temperature to the valve, the controller aggressively minimizes outlet temperature variations. Valve Features ISO 5211, 5210 actuator flange mounting Nickel chrome and cobalt coated CF8M (316) stainless steel discs 2" valve flow coefficient C v(max): 26.6 End connection: 2" NPT inlets and 2-1/2" NPT outlet Top entry allows inline access to internal valve parts Maximum inlet steam temperature 482 F (250 C) Rated pressure: 145 psi (10 bar) Seat leakage is approximately 0.05% of the valves C v(max) Design verification to ASME B16.34 U.S. patent approved Electronic Actuator Features Analog (4-20mA) input and output control signals for interfacing with SCADA control Software configurable control settings Very high resolution capability (0.03 rotational) External RS232 connection (cable supplied) Stand-alone closed loop temperature control, or remote analog (4-20mA) control options Power: regulated 24Vdc 5-amp supply required Fail-safe position feedback (non-contact absolute encoder) Keypad: 4 membrane switches with dual touch safety features Display: 3.5 digit LCD display with back light Push-button power switch Extra analog input for interfacing ancillary devices (e.g., flow switch, level switch) 90 stroke time as low as 1.5 seconds for fast control action Gearbox: planetary, lifetime lubrication, low backlash 100% duty cycle rated actuator For a fully detailed certified drawing, refer to CDLW # " 6.3" 8.7" Manual override handle (not shown) Epoxy powder coated aluminum enclosure designed to NEMA 4 Push-button power switch Graduated visual indicator on shaft coupling Constructed of CF8M (316) stainless steel MegaMix Model E50S Steam/Water Mixing Unit Shipping weight 75 lbs (incl packaging) Shipping box size 13.6" x 27.0" x 14.0" (W x L x H) The E50S can handle a variety of input temperatures and pressures to give a temperature rise. The flow table below outlines only four typical output rises. Contact Armstrong for application sizing assistance. A) 18 F (10 C) Temperature Rise Water Steam 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 124 (470) 124 (470) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 124 (470) 176 (665) 176 (665) 176 (665) U.S. gal/min (l/min) 60 psi (4.0 bar) 124 (470) 176 (665) 203 (768) 203 (768) U.S. gal/min (l/min) B) 55 F (31 C) Temperature Rise Water Steam 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 99 (373) 104 (393) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 99 (373) 104 (393) 173 (655) 176 (665) U.S. gal/min (l/min) 60 psi (4.0 bar) 99 (373) 104 (393) 173 (655) 203 (768) U.S. gal/min (l/min) C) 100 F (56 C) Temperature Rise Water Steam 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 55 (197) 124 (470) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 55 (197) 176 (665) 176 (665) 176 (665) U.S. gal/min (l/min) 60 psi (4.0 bar) 55 (197) 176 (665) 203 (768) 203 (768) U.S. gal/min (l/min) D) 135 F (75 C) Temperature Rise Local keypad and temperature display with hinged magnetic latching lockable cover Armstrong temperature control solution comprising the 3-port mixing valve and actuator with integrated temperature sensor NTC temperature sensor Water Steam. 20 (1.5) 45 (3.0) 75 (5.0) 100 (7.0) psi (bar) 22 psi (1.5 bar) 38 (142) 75 (283) 124 (470) 124 (470) U.S. gal/min (l/min) 45 psi (3.0 bar) 38 (142) 75 (283) 125 (472) 174 (660) U.S. gal/min (l/min) 60 psi (4.0 bar) 38 (142) 75 (283) 125 (472) 174 (660) U.S. gal/min (l/min) Hot Water Solutions Contact factory for other orientation options for the actuator on the valve Wiring Access 1/8" NPSM Sensor Port Port A 2" NPT Water Input Port C 2-1/2" NPT Outlet 22.2" Port B 2" NPT Steam Input Safety Consideration should be given during the design phase to the following conditions of the proposed circuit/system: Sudden loss of water pressure Loss of power supply Over-temperature safety fail-safe system If cold water supply or temp. sensor fails, the valve will be closed within approximately 2 seconds. If there is a loss of power, the unit will remain in its last powered up position and can be manually actuated using the manual override handle. IMPORTANT NOTES: 1. A minimum flow rate must be established for effective mixing and temperature control. The approximate minimum flow for effective steam and water mixing for the E50S valve is 20 U.S. gpm. 2. Check (nonreturn) valves MUST be fitted to both inlets. Strainers are also recommended. 3. Sensible pipeline velocities must be considered in application design. 4. Further information on installation requirements and recommendations is available in the Installation, Operation and Maintenance Manual (IOM), a copy of which is provided with the product. 5. Armstrong s Engineering Team is available to assist you with application support, component selection and E50S valve sizing. All dimensions and weights are approximate. Use certified print for exact dimensions. Design and materials are subject to change without notice. Armstrong Hot Water Group, 221 Armstrong Blvd., Three Rivers, MI USA Phone: (269) Fax: (269) HWS-66

8 2.0 Valve - Parts and Materials 2.1 Exploded Assembly Drawing Figure 2.1 below shows an exploded view of the Armstrong MegaMix TM Steam/Water Mixing Valve. Refer to section 2.2 for parts and material descriptions. For spares kits and order part numbers see section 2.3. Figure 2.1 Exploded assembly drawing of the Armstrong MegaMix TM Steam/Water Mixing Valve. Page 8

9 2.0 Valve - Parts and Materials 2.2 List of Parts and Materials Part Description Quantity Material Included in Seal and Bearing Kit 1 Locking screw Stainless Steel 2 O-Ring Gland Internal 1 EPDM X 3 Gland Nut Stainless Steel 4 O-Ring Gland External 1 EPDM X 5 Screw Body/Bonnet (1) Stainless Steel 6 Spring washers (2) Stainless Steel 7 Bonnet Stainless Steel 8 Thrust washer 2 C-Cr Steel X 9 Needle Roller Bearing 1 C-Cr Steel X 10 Support Washer Stainless Steel X 11 Cup Seals 2 Carbon PTFE X 12 Split Ring Stainless Steel 13 Wear Ring (thick) 1 Carbon PTFE X 14 Wear Ring (thin) 1 Carbon PTFE X 15 Spindle Stainless Steel 16 Moving Disc Stainless Steel O 17 Fixed Disc Stainless Steel O 18 Spring * Stainless Spring Steel X 19 Pins Stainless Steel 20 Face Seals 2 Carbon PTFE X 21 O-Ring Bonnet to Body 1 Silicone X 22 U Hammer Drive Screw Stainless Steel 23 Name Plate Stainless Steel 24 Body Stainless Steel * 25S: 3, 40S: 4, 50S: 5 X Included in Seal and Bearing Spares Kits (see section 2.3) O Included in Disc Set Spares Kits (see section 2.3) Notes: (1) A2-80 grade high tensile strength stainless steel fasteners used on the 50S valve size. (2) Not used on 50S valve size. 2.3 Spares Kit Part Numbers For ordering spares kits and valves use table to find the coresponding part number. Table 2.3.1: Spares Kits and Valve Part Numbers. Valve model: 25S 40S 50S Seal and Bearing Spares Kit Part Number: MM-CPSK0071 MM-CPSK0072 MM-CPSK0073 Disc Set Spares Kit Part Number: MM-CPSK0074 MM-CPSK0075 MM-CPSK0076 Valve Part Number: 25S 40S 50S Page 9

10 3.0 Valve - Installation 1 When installing the valve in line, be sure to follow good practice using either sealing tape or thread adhesive in the joints. 2 The valve may be attached straight to the pipe work. Note: Be sure to consider the ease of removing the valve should this become necessary in the future. See images 3 and 4 for typical installation methods. 3 Note: For valve maintenance, the bonnet screws can be removed and full access to the internal components is possible. 4 The valve may be connected to the pipe work with a union style of fitting (image 3). The valve may be connected to the pipe work with a thread adapter and a clamp style fitting. e.g. Tri-Clover (TM) (image 4). CAUTION: Prior to installation ensure that the pipes leading to the valve are clear from debris which may block or damage the valve on commissioning. WARNING: Only trained personnel familiar with pipe work and pressure systems should install and maintain Armstrong equipment. Failure to do so may result in serious personal injury! WARNING: Depressurize pipe work to atmospheric pressure and drain all fluids from the pipe work before working on the valve. Failure to do so may result in serious personal injury! WARNING: Ensure that the intended maximum operating pressure of the line does not exceed the pressure rating of the valve. Failure to do so may result in serious personal injury! WARNING: Check valves are strongly recommended upstream of the valve inlets. Failure to install them may cause undesirable back-flow and may result in serious personal injury and or equipment damage! WARNING: The valve must be supported adequately so as not to over stress the pipe work and/or the valve body. See image 5 and Table 3.1 below for the maximum nozzle loads on the valves. Application of loads above these values may result in serious personal injury and or equipment damage! M y F y 5 Table 3.1: Maximum Nozzle Forces and Moments F x M x Valve Size Force - F x F y F z Moment - M x M y M z 25S 90 lbf lbf.in 40S 180 lbf lbf.in M z F z Nozzle load orientations 50S 450 lbf lbf.in Page 10

11 4.0 Valve Maintenance - Disassembly 1 2 CAUTION! Before dismantling the MegaMix TM valve, ensure all upstream and downstream pressurized pipe work is isolated appropriately. Ensure the pressure and fl uids are drained from the valve and pipework. Remove the gland nut locking screw. Fit the gland nut wrench into the two holes provided in the top of the gland nut and unwind counterclockwise to remove the gland nut from the bonnet. 3 Use an allen wrench to remove the bonnet bolts and spring washers that fasten the bonnet to the body. Spring washers are not used on the size 50S. 4 Carefully remove the bonnet from the body particularly if the valve is mounted in a vertical position. Note that the moving disc is not fastened to the spindle. Take care that the moving disc is not dropped as the bonnet assembly is removed. Fixed Disc Rotating Disc 5 Set the rotating disc aside. Remove the fi xed disc being careful not to lose any of the springs from the back face. Underside of fi xed disc showing springs 6 Remove the bonnet/body seal. Remove the spindle from the bonnet by pushing down on the spindle end. Bonnet/Body seal Check that the secondary cup seal and thrust bearing assembly is on the spindle. You may have to remove these from the bonnet bore. Primary cup seal 7 Split Ring Secondary cup seal Remove the thrust bearing assembly, wear rings, cup seals and split ring from the spindle. Wear Rings Cup Seals 8 Wear Rings Thin Thrust Washers Bearing Support Washer Caged Needle Roller Thrust Bearing Clean all grease and dirt from parts not being replaced. Ensure that the spindle seal surfaces are protected from damage while the valve is disassembled. Split Washer Spindle Seal and Wear Ring Assembly Page 11

12 4.0 Valve Maintenance - Reassembly 1 PREPARATION: Ensure the assembly area is completely dirt free. Ensure also that the valve parts are clean and ready to be re assembled. Check all valve parts for damage or wear. 2 ASSEMBLY: Lay out the seals from the seal kit on a clean surface. Note: Inox mx6 grease is supplied to lubricate the surfaces of all the soft seals and the disc surfaces during assembly. 3 In the valve body fi t the 2 face seals and the bonnet/body seal. Check the disc locating pins are in and secure (image 2). 4 Take the fi xed disc and check the seal surface is clean and that all springs are in place. Add grease to the springs to retain them in the disc (image 3) and assemble onto the valve body and locating pins (image 4). Fixed Disc Rotating Disc 5 Bonnet/Body seal Take the rotating disc, check the seal surface is clean, smooth and undamaged. Apply a light layer of Inox mx6 grease supplied in the Seal Kit. Place the moving disc onto the fi xed disc as shown (image 5), then rotate several times to bed discs together. Push on the primary cup seal to the spindle. Ensure the orientation is correct! (See image 7). Fit the split washer and thick wear ring before fi tting the secondary cup seal. 6 Wear Rings Cup Seals (thin) (thick) Split Washer Spindle Seal and Wear Ring Assembly Wear Ring (thin) Primary cup seal 7 Split Ring Secondary cup seal Smear on a liberal quantity of the Inox mx6 grease to the bearing support washer and needle roller bearing making sure all surfaces are coated and approximately 60% of the bearing void is fi lled. 8 Wear Ring Thin Thrust Washers (thick) Bearing Support Washer Caged Needle Roller Thrust Bearing Fit the bearing support washer, thin washer and then the needle roller bearing onto the spindle. Slide on the thin top washer. Smear a liberal amount of grease onto the spindle seal and wear ring surfaces. Locate the spindle assembly onto the top disc (image 8). Page 12

13 4.0 Valve Maintenance - Reassembly 9 Fit the internal and external o-rings into the gland nut (image 9). Apply a coating of grease to the oring surfaces and thread. Wind the gland nut into the body 2 or 3 revolutions by hand (image 10). 10 Check the lightly greased bonnet/body seal is in it s groove, and place the bonnet over the spindle. Push down gently so that the spindle seals slide into the bore. 11 The bonnet should be able to be pushed all the way so that the fl ange contacts the body. Use 4 fasteners (2 front and 2 rear) to hold the bonnet in place against the spring and o-ring pressure. Insert the remaining fasteners and tighten evenly (image 11). Rotate the gland nut all the way down so that the spindle and disc assembly are clamped (image 12) Back off the gland nut 1-2 notches and rotate the spindle one turn clockwise and counterclockwise several times to evenly spread the applied lubricants. Tighten the gland nut all of the way down so that the spindle and disc assembly are clamped. The spindle should be diffi cult to rotate or even locked. Back off the gland nut 1 notch. Insert the locking screw after applying a thread locking adhesive. (e.g. Locktite 262) (see image 13). Note: Rotate the spindle 1-2 times to ensure the operating torque is constant, and the rotating action is smooth. Reassemble the actuator. Again cycle the valve several times to ensure the assembly is correct. Table 2: Nominal Tightening Torques for Lubricated Stainless Steel Socket Head Cap Screws Metric Cap Screw UNC Cap Screw Size Torque (Nm) Torque (inlb) Size Torque (Nm) Torque (inlb) M M # M # M / M / M / M / Table 3: Recommended Lubricants and Thread Adhesives Description Manufacturer/Model Code Used for: Food Safe Tefl on Lubricant* Inox mx6 Discs Seats; o-rings; wear rings; bonnet bore lubrication; roller thrust bearing lubricant Thread Locking Adhesive Loctite 262 All Stainless Steel Fasteners *Sachets of this lubricant are included in Armstrong Seal Kits. Page 13

14 5.0 Actuator - Parts and Materials 5.1 Actuator Parts and Construction Materials Stated below are the parts and material descriptions for the MegaMix TM actuator and standard mounting bracket. Refer to section 5.2 for actuator accessories and spare parts. Standard mounting bracket Item E1.2 and E1.3 details Construction materials Valve Mounting Kit 1 Manual override lever 316 SS / acetal 2 Padlock holes for manual override N/A 3 Keypad lid (in closed position) Powder coated aluminum 4 Padlock holes for keypad lid N/A 5 Cable entry plug (o-ring sealed 1/2 NPT plug, LHS) Glass filled nylon 6 Push button power switch Plastic with silicone cover 7 Warning label 316 Stainless steel 8 Terminal cover, sealed, wiring access Powder coated aluminum 9 Sealed plug Acetal 10 Sealed plug (for factory encoder adjustment) Nickel plated brass 11 Cable entry plug (o-ring sealed 1/2 NPT plug, RHS) Glass filled nylon 12 Name plate with model code and serial # 316 Stainless steel 13 Pressure relief vent Polyamide 6 14 Port-1, Temperature sensor input * Nickel plated brass 15 Output shaft (not shown) 17-4 PH Stainless steel 16 Fasteners and spring washers Stainless steel 17 Port-2, Auxiliary port * Nickel plated brass 18 Port-3, Serial port * Nickel plated brass 19 Coupling 2 piece slotted 316 Stainless steel 20 Mounting bracket (Fits ISO5211 F05 & F07 size) 316 Stainless steel 21 Drive enclosure (extrusion) Powder coated aluminum 22 Electronics enclosure (extrusion) Powder coated aluminum 23 Keypad cover window Polycarbonate 24 Body base (casting) Powder coated aluminum 25 Body top (casting) Powder coated aluminum 26 Coupling fitting 316 Stainless steel * See Section 7 page 19 for more detail Page 14

15 5.0 Actuator - Parts and Materials 5.2 Actuator Accesories and Spare Parts For ordering MegaMix TM actuator accessories use table to find the corresponding part number. For ordering actuator spare parts use table Table 5.2.1: MegaMix TM Actuator Accessories. MegaMix TM Actuator Accessery Remote Set Point Selector Switch - 7 Position Serial Cable Support CD-Rom (contains actuator configuration software) Water Mixing Unit IOM (Installation, Operation and Maintenance) manual. (For models E20W, E25W, E40W and E50W) Water Mixing Unit IOM (Installation, Operation and Maintenance) manual. Model E80W. Steam/Water Mixing Unit IOM (Installation, Operation and Maintenance) manual. (For models E25S, E40S and E50S) Remote Set Point Selector Switch IOM (Installation, Operation and Maintenance) manual. Part Number RSPSS-07 MM-CPEL0091 MM-CPAC0001 MM-CPAC0036 MM-CPAC0037 MM-CPAC0038 MM-CPAC0005 Table 5.2.2: MegaMix TM Actuator Spare Parts. MegaMix TM Actuator Spare Parts Part Number Temperature Sensor Assembly NTC 10K3 350mm NPS MM-CPAC0021 Temperature Sensor Assembly NTC 10K3 930mm NPS (Model E80W) MM-CPAC0116 Kit Sensor Adapter 1/2 NPT - 1/8 NPS (supplied with 80W valves) MM-CPAC0008 1/2 NPT Plug Assembly (see item 5 & 11 page 10) MM-CPAA0041 Valve Mounting Kit. Models 20 and 25 (see items 19 & 16 page 10). MM-CPMA0070 Valve Mounting Kit. Models 40, 50 and 80 (see items 19 & 16 page 10). MM-CPMA Amp Miniblade Fuse. MM-MEFU0006 Page 15

16 6.0 Actuator - Mounting on to MegaMixTM Valves Note: The actuator may be mounted in any one of four positions. 1 The instructions below explain how to mount the actuator facing the outlet port as per image 7 page To ensure the actuator is in the zero position, power on the actuator (a 24V DC regulated power supply is required). Ensure the actuator is in Temperature Controller mode (see section 10.3). Disconnect the temperature probe from the actuator. The actuator will move automatically to the zero position and the keypad display will show E2. Set the valve position to closed. Ensure the notch on spindle (image 1) points towards the cold port (image 2). 4 Place the graduated coupling (image 3) on the spindle & ensure that zero points to the outlet port (image 4). 3 4 If the actuator is to be mounted in one of the other three positions, rotate the zero graduation to the desired position BEFORE placing on spindle. 5 Place the center coupling (image 5) on the graduated coupling (image 6). 6 Continued... Page 16 Product sizing, selection, compatibility, installation and operation are the customer s responsibility. The illustrations, designs and specifications are not guaranteed accurate in every detail

17 6.0 Actuator - Mounting on to MegaMix TM Valves 7 Place the actuator on the valve in the desired position (image 7). The zero mark on the coupling (image 4) should align with the notch on the bracket (image 8). Insert one M8 X 20 socket cap screw into one of the mounting holes with M8 Spring Washer and Nut. Insert the remaining three cap screws and fasten. 8 bracket notch 9 Ensure the bonded washer (image 9) is on the sensor (image 10) Screw the sensor into the outlet port of the valve (image 11) and tighten. 12 Plug the sensor connector into the actuator input port labelled 1 and tighten. The actuator is now assembled correctly. For checking the actuator software confi guration see section 9.0 THE ACTUATOR MUST NOT BE INSTALLED USPSIDE DOWN Page 17

18 7.0 Actuator - Electrical Installation 7.0 Electrical Installation Do not attempt electrical installation unless you are qualifi ed to do so under the laws of your jurisdiction. It is essential that you understand the information in this section to achieve a successful electrical installation. If in doubt, contact Armstrong or its authorized representative. The wiring of the actuator must be carried out by a qualifi ed technician and according to the instructions described below. The wire sizes as recommended in the instructions must be adhered to. Always consider environmental and mechanical conditions of the installation, such as ambient temperatures, chemicals, moisture and exposure to mechanical impacts, shock and vibration. For mechanical protection of the wiring as well as to comply with EMC (Electro Magnetic Compatibility) standards it is recommended to place the wiring in screened conduit or to use screened cables. 7.1 General information The enclosure of the actuator has two 1/2 NPT cable (or conduit) entry points. Use an appropriate metal conduit adapter (such as Kopex) for these cable entries and use screened (PVC coated metal) Conduit (connected to ground), both with appropriate ingress ratings. In case only one entry is being used, leave the pre-installed blanking plug (watertight) for the unused grommet hole. Install the conduit as required for the installation and place the wire or cables in the conduit as described in the wiring instructions. Remove the terminal enclosure cover from the actuator. A terminal with the following wiring layout (Fig.7.1 pictured below) will be accessible. Note that the terminal block has a Warning Label attached covering all terminal connections except the power supply terminals (not shown). This is to avoid accidental connection of the power supply wires to the loop input terminals, which will permanently damage the unit. SPARE FUSE FUSE GROUND POINT SUPPLY FEEDBACK SET POINT Figure 7.1: Terminal enclosure cover removed to expose the wiring terminal GROUND LINK TO TERMINAL ENCLOSURE COVER Page 18

19 7.0 Actuator - Electrical Installation 7.2 Wiring Instructions SWITCH THE SUPPLY OFF BEFORE CONNECTING! WIRE THE SUPPLY FIRST (before making any other connections). Insure that the actuator supply consists of a 24V DC supply (not AC) and that the voltage tolerances are within the permissible voltage limits of the actuator Power Supply Wiring Wire the supply connections as indicated below using the correct diameter shielded cable. When placing the wiring in metal conduit, which is grounded, shielded cable is not required. POWER SUPPLY 24V DC Connect screen to secure ground! Shielded cable Wire gauge 18 AWG Screen connection Figure 7.2: Supply Conection Page 19

20 7.0 Actuator - Electrical Installation Power Supply Wire Specification Consider the minimum cross sectional area and length of the supply cable such that the voltage drop across the total cable length remains within the permissible voltage tolerance of the actuator. For example when using a 18 AWG cable, the voltage drop will be 1.2V at 3A and 30ft length, which is 5% of the 24V supply. Use table 7.1 below as a guide to determine cable size and maximum length. Table 7.1: Cable length (depending on cable area and actuator model) E inch lbs American wire gauge (AWG) Diameter (inch) Resistance (Ohm/1000ft) Voltage Drop (Volt/ft) Recommended maximum (ft) E inch lbs American wire gauge (AWG) Absolute maximum (ft) Diameter (inch) Resistance (Ohm/1000ft) Voltage Drop (Volt/ft) Recommended maximum (ft) Wiring of Actuator ma Loop Receiver Absolute maximum (ft) To comply with EMC (Electro Magnetic Compatibility) standards, the wiring must be placed in the conduit (must be connected to ground) and shielded twisted pair cable (24 AWG) should be used. Depending on the type of output available on the controller (PLC), i.e.; isolated ma Loop Output (isolated from ground potential) or non isolated output (referenced to ground), different wiring schemes are feasible, see below (Fig.7.3 and 7.4). Figure 7.3: Controller with isolated output. Figure 7.4: Controller with non-isolated output. Page 20

21 7.0 Actuator - Electrical Installation Wiring of Actuator ma Loop Transmitter. To comply with EMC (Electro Magnetic Compatibility) standards, the wiring must be placed in the conduit (must be connected to ground) and shielded twisted pair cable (24 AWG) should be used. Depending on the type of input available on the controller (PLC), i.e.; isolated ma Loop input (isolated from ground potential Fig. 7.5) or non isolated input (referenced to ground) and if a Loop Supply is available, different wiring schemes are feasible, see below; Figure 7.5 Controller with isolated 4-20mA loop input (recommended) using the 24V DC supply from the actuator by means of a wire link. Due to this arrangement the loop output is no longer isolated which requires the input on the controller to be isolated! Page 21

22 7.0 Actuator - Electrical Installation Figure 7.6 Controller with non-isolated 4-20mA loop input using the 24V DC supply from the controller or PLC itself. (Recommended) Figure 7.7 Controller with non-isolated 4-20mA loop input using the 24V DC supply from an external isolated supply. This could possibly increase noise in the system and is therefore not recommended. Page 22

23 7.0 Actuator - Electrical Installation Temperature Sensor Connector (Port-1) The Sensor Input and internal electronics are specifically designed to take the Armstrong Temperature Probe. NTC CONECTIONS ON M8 FEMALE CONNECTOR (PORT-1) Do not attempt to use any other type of sensor as this may damage the actuator. 4 SCREEN IN 3 1 IN Auxiliary Input (Port-2) This input is set to receive a signal from a binary switch, usually a flow switch, or a flow sensor such as a paddle wheel flow meter output. The Auxiliary input is a 4 pole M8 male connector that accepts a 5-24V configurable active low or high signal to indicate when there is flow. AUXILLARY INPUT ON M8 MALE CONNECTOR (PORT-2) The 24V output can be used to power the auxiliary port if required. The current draw MUST NOT EXCEED 100mA. This input can be used in conjunction with the MegaMix TM actuator s automatic gain switching feature to allow the actuator to respond appropriately in applications where flow is variable or intermittent. FLOW 4 +24V 3 SCREEN 2 0V Serial Port Connector (Port-3) The actuator can be connected to a standard RS232 serial port for modifying control options using the Armstrong Configuration Software, MegaMix TM Config, supplied on the MegaMix TM Support CD (part number: MM-CPAC0001) and provided Armstrong Actuator Serial Cable (part number: MM-CPEL0091). Caution: The Serial Port is intended for diagnostics and configuration only and the length of cable for this connection should not exceed a distance of 35 feet. RS232 CONNECTIONS ON M8 FEMALE CONNECTOR (PORT-3) SCREEN 4 GND 3 2 RX TX 1 The serial port is provided by means of a 4-pole M8 (female) connector located at the bottom of the actuator housing. Page 23

24 8.0 Actuator - Current Loop I/O 8.0 Current Loop I/O The MegaMix TM current loop hardware is capable of operating across the standard 4-20mA range. By default the linear control range, for both input and output, has been limited to the range 5-19mA. Values outside this range on the loop input represent non-linear behaviors such as closed, cold only or hot only. Values outside the 5-19 ma range on the loop output are used to signal error conditions. Contact Armstrong for customized configuration settings. 8.1 Standard Configuration of Current Loop Input for Temperature Controller Mode The unit will respond to the current loop input when in REMOTE mode only (Refer to Keypad Operating Instructions Section 10.4). The full control range in Temperature Controller mode is C or F. This corresponds to a Loop Input range of 5 to 19mA. Calibrate the current loop transmitter (usually an external PLC or Controller) according to the following equations. Temperature Linear Range Calculation Celsius Current input (ma) = (0.14 x Temperature required ( C)) + 5 Temperature Linear Range Calculation Fahrenheit Current input (ma) = ( x (Temperature required ( F)) If given a signal outside the 5-19 ma range, the actuator will not control temperature, but will move to a fixed angle depending on the actuator configuration. Refer to Figure 8.1 for a graphical description of Loop Input behavior in Temperature Controller mode for several standard configuration types. Page 24

25 8.0 Actuator - Current Loop I/O Standard Loop Input For Temperature Controller Mode With MegaMix Valve Models: 20W, 25W, 40W, 50W, 25S, 40S and 50S Hot Port B: 100% Cold Port A: 0% 230 W Valves Only Stroke Position Temperature Control Region Hot Port B: 100% Cold Port A: 50% 180 S Valves Only Stroke limiting. Stroke Angle Hot Port B: 0% Cold Port A: 100% 90 All Ports Closed Loop Input (ma) C 32 F Temperature Set Point 100 C 212 F Figure 8.1: Standard Loop Input for Temperature Controller Mode (see section on page 28). Page 25

26 8.0 Actuator - Current Loop I/O 8.2 Standard Configuration of Current Loop Input for Positioner Mode The unit will respond to the current loop input when in REMOTE mode only (Refer to Keypad Operating Instructions Section 10.4). The full control range in Positioner mode is 0-100%, corresponding to a Loop Input range of 5 to 19mA. Calibrate the current loop transmitter (usually an external PLC or Controller) according to the equations below. If given a signal outside the 5-19 ma range, the actuator will behave according to the response curves given in Figure 8.2. Note that the actual operating stroke is dependent on configuration. Figure 8.2 shows several common configurations. Position Calculation: % of Max Open Position For the input current range of 5 to 19 ma and position of 0 to 100% of the maximum open position. Current input (ma) = (0.14 x Position required (%) ) + 5 Position Calculation: 1/4 turn application in Degrees Current input (ma) = ( x Position required ( CCW) ) + 5 Position Calculation: Armstrong Water MegaMix TM Unit application in Degrees Current input (ma) = ( x Position required ( CCW) ) + 5 Page 26

27 8.0 Actuator - Current Loop I/O Figure 8.2: Standard Loop Input for Positioner Mode (See section on page 28). Page 27

28 8.0 Actuator - Current Loop I/O 8.3 Standard MegaMix TM Current Loop Output Characteristic The unit will deliver a current loop output (feedback signal) according to the graphs below. If feedback is required (such as external monitoring), calibrate the current loop receiver (external PLC or Controller) according to Fig: 8.3 and Fig: 8.4. In Temperature Controller Mode, the actuator will output the current temperature according the scale shown in Fig: 8.3. Figure 8.3: Temperature Control Measured Temperature ( C ) Measured Temperature ( F ) Current Loop Output (ma) Figure 8.4: Position Control 100% 80% Actuator Position ( % ) 60% 40% 20% 0% Current Loop Output (ma) In Positioner Mode, the actuator will output the position set point according to Figure 8.4. As can be obtained from the above graphs, the full control range in either Temperature control ( C) or Position control (0..100%) corresponds to a Loop Output range of 5 to 19mA (linear response). This has been implemented to obtain the same output loop signal as the input loop-controlling signal when the actuator is in control. A loop signal output of 20mA indicates an error condition. Check the actuator display for the error number, and see section 10.6 for error code definitions. Page 28

29 8.0 Actuator - Current Loop I/O Temperature Output Calculation Celsius Temperature Output ( C) = (7.143 x Current Output (ma) ) Temperature Output Calculation Fahrenheit Temperature Output ( F) = ( x Current Output (ma) ) Position Output Calculation % of max open position Position Output (%) = (7.143 x Current Output (ma) ) Position Output Calculation 1/4 Turn application in Degrees Position Output (Deg.) = (6.429 x Current Output (ma) ) Position Output Calculation MegaMix TM Water Mixing Unit application in Degrees Position Output (Deg.) = ( x Current Output (ma) ) Page 29

30 9.0 MegaMix TM Config Configuration Software 9.0 MegaMix TM Config Configuration Software The MegaMix TM Configuration software provides access to configuration of many parameters within the MegaMix TM actuator. The software is supplied on the Armstrong MegaMix TM Support CD (part # MM-CPAC0001). For updated versions of MegaMix TM Config check the Armstrong web site at The software is designed to run on any Win32 system (Windows 95/98/ME/NT/2000/2003/XP). It connects to the MegaMix TM actuator through a standard RS232 serial port using the DB9 to DIN cable supplied by Armstrong (part # MM-CPEL0091). 9.1 Installation Run the file setup.exe from the installation CD. Follow the on screen instructions, selecting an install path for the software. The installation will require around 3.7 MB of local hard disk space. 9.2 Operation Getting Started Connect the serial cable between the MegaMix TM actuator and the PC. Make sure that the MegaMix TM actuator is powered and the push button is pressed for 2 seconds to turn the unit ON. Load the MegaMix TM Config Software onto the PC (CD-ROM is supplied, Armstrong part number MM-CPAC0001 or download it from To start MegaMix TM Config, select it from the Start menu, or from the desktop shortcut. To establish a connection with the actuator, it is necessary to tell MegaMix TM Config which COM Port to use. This is selected from the Coms menu (shown in Figure 9.1). NOTE: If you are unsure of the COM Port being used you can try the Detect Actuator function from the Tools menu. This will try each available COM port and test for the presence of a MegaMix Actuator. If the COM port is successfully opened the message Opening COM x will appear in the COMS log window to the right of the screen. If the COM port is unavailable, the message Can t Open COMx will be displayed. This could be due to another application using the COM port, or that the selected port is not recognized by Windows. In this case, try another COM port or close the application currently using it. Select the Utility Tab and check the box titled Show Broadcast Packets. A stream of data will appear in the right window of the screen when communication is established. Once the connection is active, a stream of data should begin to appear in the COMS log at the right of the screen. If no activity is observed, check the cable connection and make sure that the correct COM port is selected. Figure 9.1: Selecting COM Port. Page 30

31 9.0 MegaMix TM Config Configuration Software General Use The MegaMix TM Config interface consists of several tabs containing a variety of controls. The most important for configuration of the actuator is the Device Manager tab. This section provides access to information about the actuator, and allows the user to modify some of the permanent settings. The available parameters, called Properties, are displayed in a tree format in the MegaMix TM Devices window. This display is operated much like a Windows explorer display and each item display with a + can be expanded to show its child Properties. Each top-level item in the list represents a category of configuration. Expanding these will display a list of available properties. Clicking on a Property will cause MegaMix TM Config to attempt to read the value of the Property from the actuator s memory. If the read is successful, the value will be displayed in the Value box. If the read fails, then??? will be displayed indicating that the value is not known. To retry, just click on the Property name again, or click on the Refresh button. Figure 9.2: Refreshing a Property Value Changing Values To alter a Property value, enter a new value in the New Value text box and click the Set button. If successful, the number in the Value box will change to reflect that the update has occurred. Some Properties are not user configurable. When these Properties are displayed, the Set button will be dimmed out. Page 31

32 9.0 MegaMix TM Config Configuration Software 9.3 Property Categories Temperature Controller Values This section contains properties related to closed loop temperature controller mode. The properties in this section that will most often require alteration by the user are the controller gain settings Proportional Gain and Differential Gain. The MegaMix TM actuator is designed to provide accurate and stable temperature control over a wide range of conditions without altering the default factory setup. However, in some applications it may be necessary to make adjustments to maintain stability of control. Proportional Gain (P Gain) This value defines how quickly the actuator will rotate to compensate for a deviation from the set point. It is the Property that controls the overall speed of the controller. A P gain that is too low will result in a slow response to system disturbances, while a value that is too high may result in instability (oscillation). Differential Gain (D Gain) D Gain is best thought of as a compensation factor for lag in the temperature measurement system. It helps to prevent overshoot in response, and to assist in giving quick response to disturbance. In general this is a negative value. A Differential gain that is too small may cause an overshoot. A value that is too large (or a positive value) will cause serious instability. Controller Gain Setting Application Description P Gain D Gain Standard ( >90% of applications) Moderate flow without major pressure imbalance Fast High flow with well balanced water supply pressures Slow Low flow and/ or imbalanced supply pressures Motion Control Values The MegaMix TM actuator can have the gains automatically set to 3 standard values: Standard, Fast or Slow. To select a particular temperature controller speed, follow the menu as per Figure 9.3. Figure 9.3: Selecting Control Gains Page 32

33 9.0 MegaMix TM Config Configuration Software Selecting Standard Configuration Sets MegaMix TM Config comes preloaded with several sets of standard (default) configuration, which can be downloaded to a MegaMix TM actuator with a single click. To access these standard configurations, choose Standard Config from the Tools menu. This will show a list of available configurations. Each item represents the combination of a model of MegaMix TM actuator with a particular valve type. Selecting the appropriate item will initiate the download of the standard settings. The process should take about 10 seconds, and a message will appear confirming that the operation is complete. Figure 9.4: Selecting Default Configuration Settings. Table 9.3: Standard Configuration Sets. Name Description E1.2 20W Armstrong Megamix TM E1.2 Actuator with 20W MegaMix TM Valve E1.2 25W Armstrong Megamix TM E1.2 Actuator with 25W MegaMix TM Valve E1.2 40W Armstrong Megamix TM E1.2 Actuator with 40W MegaMix TM Valve E1.3 50W Armstrong Megamix TM E1.3 Actuator with 50W MegaMix TM Valve E1.3 80W Armstrong Megamix TM E1.3 Actuator with 80W MegaMix TM Valve E1.2 25S Armstrong Megamix TM E1.2 Actuator with 25S MegaMix TM Valve E1.2 40S Armstrong Megamix TM E1.2 Actuator with 40S MegaMix TM Valve E1.3 50S Armstrong Megamix TM E1.3 Actuator with 50S MegaMix TM Valve Page 33