WCAIM2043 (Part 18460) Solenoid Block Kit for Series 90 Modular Accessory System Installation, Operation and Maintenance Instructions INTRODUCTION Note: For M.A.S. housing assembly, installation, and maintenance instructions, refer to Installation, Operation, and Maintenance Manual WCAIM2005. The Worcester/McCanna Series 90 M.A.S. Solenoid Block Kit can provide on/off or modulating control for both single- and doubleacting pneumatic valve actuators. The type and number of solenoid valves varies for the differing applications: Single-acting on/off (spring-return) uses one three-way solenoid valve. The various solenoid options are designed to operate either singleacting or double-acting actuators. Each of these applications requires its own air porting to operate properly. The solenoid block gasket has been designed to adapt the solenoid block to the Series 90 M.A.S. housing air connections for each type of operation. The gasket is illustrated here for future reference in this section of the instructions. NOTE: The double-acting block will operate and increase the speed of a single-acting actuator. To accomplish this, plug the B Port on the M.A.S. base. This is recommended for size 25 and larger 39 actuators. AIR SUPPLY: Lubricated or dry air (or other non-corrosive gas) Double-acting on/off uses one four-way solenoid valve. Single- or double-acting modulating applications use two threeway solenoid valves. The solenoid valves used in the M.A.S. are marked with a voltage rating. Although the 120 volt solenoids are intended for use with AC power, they actually operate on DC. Valves marked 120 or 120 VAC therefore require the use of special lead wires incorporating a builtin rectifier. It is this rectifier that converts the incoming AC power to DC power. All lead wires are equipped with quick-connect plugs that are easily connected/disconnected to the solenoid valve. The plugs will only fit one way do not force the plugs together; damage can result. Figure 1 Figure 2 VOLTAGE REQUIRES RECTIFIER REF. FIGURE 120 VAC YES 1 12 VDC NO 2 24 VDC NO 2 PRESSURE: 45 100 PSI. FILTRATION: Strongly recommended refer to table below. SERVICE SPRING-RETURN DOUBLE-ACTING ON/OFF 20 MICRON 5 MICRON MODULATING 20 MICRON 20 MICRON 1. ASSEMBLY (See figures below and on following pages.) a. SINGLE-ACTING ON/OFF TYPE, DOUBLE-ACTING ON/OFF TYPE NOTE: Where lubrication is required, Vaseline or other noncorrosive grease is acceptable unless otherwise noted. Use sparingly. 1. Attach the solenoid valve (item 2) to the solenoid block (item 1) in the orientation shown using the #4-40 screws (item 5) and gasket (item 3) provided.
CAUTION: Tighten screws to no more than 15 in-lb or breakage may occur. Be certain that the holes in the gasket, solenoid valve, and solenoid block are aligned. 2. Lightly lubricate and install the two #10-32 air fittings (item 6) for D/A or (items 6 and 11) for S/R as shown, and tighten. Assemble the length of tubing ( 1 /8" I.D. for S/R, 1 /16" I.D. for D/A) (item 8) to these two fittings after they are in place. The tubing is difficult to remove and will not allow the fittings to be tightened once installed. 3. Insert the three #10-32 x 1 1 /2" socket head screws (item 9) through the solenoid block from the side shown (marked SR or DA). Position the solenoid block gasket (item 4) on these screws. 4. Attach the solenoid block and gasket to the angled inside wall of the M.A.S. base using the three #10-32 x 1 1 /2" screws. 5. Connect the lead wire plug (item 10) to the connector on the solenoid valve. Refer to Introduction and Section 2 Wiring, for more information. 6. The air connection bosses on the outside wall of the M.A.S. base function as indicated in the figures below. b. SINGLE-ACTING MODULATING TYPE (POSITIONER/CONTROLLER) NOTE: Where lubrication is required, Vaseline or other noncorrosive grease is acceptable unless otherwise noted. Use sparingly. 1. Attach the two solenoid valves (item 2) to the solenoid block (item 1) in the orientations shown on the top of the next page, using the four #4-40 screws (item 5) and two gaskets (item 3) provided. CAUTION: Tighten screws to no more than 15 in-lb or breakage may occur. Be certain that the holes in the gaskets, solenoid valves, and solenoid black are aligned. 2. Thread needle (item 17) fully into solenoid block. Do not tighten. Install O-ring seal (item 18) and thread gland (item 19) into block. Tighten gland to 15-20 in-lb maximum. (Needle valve is shipped from factory fully open). Spring-Return Double-Acting 2 Solenoid Block Kit for Series 90 Modular Accessory System WCAIM2043
3. Lightly lubricate and install three #10-32 air fittings (item 6) as shown, and tighten. Assemble the shorter length of 1 /16" I.D. tubing (item 8) between the solenoid valve and solenoid block, as shown, after the air fittings are in place. The tubing is difficult to remove and will not allow the fittings to be tightened once installed. Lubricate and assemble the #10-32 air plug (item 7) into the end of the solenoid valve as shown. 7. After the baseplate has been installed into the base, the 1 /16" I.D. x 6" length of tubing (item 16) can be connected between solenoid block and pressure switch. 4. Insert the three #10-32 x 1 1 /2" socket head screws (item 9) through the solenoid block from the side marked SR-PC (as illustrated). Position the solenoid gasket (item 4) on these screws. NOTE: See solenoid valve identification table on page 4. 8. Install the Exhaust Throttle Fitting (item 20) into Port C. Thread the Exhaust Throttle Nut (item 21) onto the fitting. (Throttle valve is shipped from the factory fully open.) Pipe thread sealant can be applied sparingly if desired. fluoropolymer tape thread sealant is not to be used. 5. Attach the solenoid block and gasket to the angled inside wall of the M.A.S. base using three #10-32 x 1 1 /2" screws. 9. The air connection bosses on the outside wall of the M.A.S. base function as indicated in the figure below. 6. Attach the pressure switch (item 15) to the baseplate (item 12) in the orientation shown below using the #4 x 7 /8" selftapping screw (item 13) and #4 washer (item 14) provided. NOTE: It will be necessary to remove side terminal strip and bracket, if installed, in order to attach pressure switch. c. DOUBLE-ACTING MODULATING TYPE (POSITIONER/CONTROLLER) NOTE: Where lubrication is required, Vaseline or other noncorrosive grease is acceptable unless otherwise noted. Use sparingly. 1. Attach the two solenoid valves (item 2) to the solenoid block (item 1) in the orientation shown below using the four #4-40 screws (item 5) and two gaskets (item 3) provided. CAUTION: Tighten screws to no more than 15 in-lb or breakage may occur. Be certain that the holes in the gaskets, solenoids valves, and solenoid block are aligned. WCAIM2043 Solenoid Block Kit for Series 90 Modular Accessory System 3
2. Lightly lubricate and install the four #10-32 air fittings (item 6) as shown, and tighten. Assemble the two lengths of 1 /16" I.D. tubing (item 8a 3" and item 8b 6") between the solenoid valve and solenoid block after the air fittings are in place. The tubing is difficult to remove and will not allow the fittings to be tightened once installed. 6. The air connection bosses on the outside wall of the M.A.S. base function as indicated in the figure below. 3. Insert the three #10-32 x 1 1 /2" socket head screws (item 9) through the solenoid block from the side marked DA-PC. Position the solenoid gasket (item 4) on these screws. Solenoid Valve Identification Table: Spring-Return Solenoid A Solenoid B Identification No. Identification No. Voltage (Normally Open) (Normally Closed) 120 VAC D1X268P D1X268 12 VDC D1X270P D1X270 24 VDC D1X271P D1X271 Solenoid Valve Identification Table: Double-Acting SOL. B SOL. A Solenoid A Solenoid B Identification No. Identification No. Voltage (Normally Open) (Normally Closed) 120 VAC D1X268 D1X268P 12 VDC D1X270 D1X270P 24 VDC D1X271 D1X271P NOTE: See solenoid valve identification table. 4. Attach the solenoid block and gasket to the angled inside wall of the M.A.S. base using the three #10-32 x 1 1 /2" screws. 5. Install the Exhaust Throttle Valve (item 20) into port C as shown in the figure below. Thread Exhaust Nut (item 21) onto the fitting. (Throttle valve is shipped from the factory fully open.) Pipe thread sealant can be applied sparingly if desired. Fluoropolymer tape thread sealant is not to be used. 2. WIRING NOTE: All wiring is to be run smoothly and neatly and away from any rotating parts and away from the base/cover flange joint, using wire tires, if necessary. Use caution to avoid pinching wires and/or solenoid rectifiers between the base and cover flanges. All wiring to terminal strip shall be inserted only to mid-point of terminal strip. Grounding wires should be connected to green-colored grounding screw on M.A.S. base. a. SINGLE-ACTING AND DOUBLE-ACTING ON/OFF TYPE 1. 120 VAC OPERATION Connect one of the black wires from the lead wire/connector to the internal side of terminal A (neutral AC power) on the side terminal strip. Connect the other black wire to the internal side of terminal B (hot AC power). To assure proper operation of the low-current AC solenoid valves used in the M.A.S. with DCS and PLC controllers, a 1 mfd capacitor is placed across the incoming 120 VAC power supply. 4 Solenoid Block Kit for Series 90 Modular Accessory System WCAIM2043
Cut one capacitor lead to 1 1 /4" long; leave the other lead at its standard 1 3 /4" length. Cut two pieces of insulating tubing (fluoropolymer approximately 1 /32" I.D.) to 1" and 1 1 /2" long, respectively, and place on the capacitor leads. Position the capacitor under the terminal bracket and route the leads into the internal side of terminals A and B. The shorter lead goes into terminal A. The leads are strong enough to hold the capacitor in place. 2. 12 or 24 VDC OPERATION Connect the black wire from the lead wire/connector to the internal side of terminal A (negative DC power) on the side terminal strip. Connect the red wire to the internal side of terminal B (positive DC power). b. SINGLE-ACTING AND DOUBLE-ACTING MODULATING TYPE (POSITIONER/CONTROLLER) 1. Follow the wiring diagrams shown on the next page closely. Note that the spring-return version uses a pressure switch that opens when air pressure below approximately 35 psi is detected. CAUTION: It is important that the power source be connected properly to the M.A.S. terminal strip. This terminal strip is the one located next to the solenoid block assembly. Terminal A of this strip is to have the negative or neutral wire connected to it. Terminal B is to have the positive or hot wire connected to it. The board has a diode and a fuse installed to prevent damage, as in the case of reverse voltage polarity, but if the diode happens to be defective, the damage could be done before the fuse blows. 2. Purpose of Pressure Switch in Fail-Safe M.A.S. Positioner/Controller Packages. In order to position a Series 39 spring-return actuator, it is necessary to trap air in the actuator between the pistons. This air balances the spring force to keep the actuator in position. One of the three-way solenoid valves used on the SR-PC Block is used to permit air into the actuator s center chamber to drive the actuator open. This solenoid valve (solenoid B ) is normally de-energized. The other solenoid valve on the SR- PC Block is used to trap the air in the actuator s center chamber. In order to make the actuator fail-safe, this valve (solenoid A ) is kept normally energized so that on loss of power, the valve will de-energize, thus allowing the air to vent from the actuator and the springs to drive it to the fail-safe position. To make the actuator fail-safe on loss of air pressure we need a means to detect that we have in fact lost air pressure. This is the function of the pressure switch. Air line pressure above 40 psi will keep the pressure switch closed and therefore keep the two solenoid valves connected to the power supply as required. However, on a loss of air pressure, the close solenoid (solenoid A ) is de-energized no matter what position the circuit board is calling for, and thus the valve and actuator will move to the fail-safe position. In fact, the open solenoid (solenoid B ) is also disconnected from the power supply to prevent venting air continuously as long as there is air pressure in the supply line and the circuit board is trying to drive the valve open. WCAIM2043 Solenoid Block Kit for Series 90 Modular Accessory System 5
Spring-Return 120 VAC Double-Acting Internal External External Spring-Return 12/24 VDC Double-Acting Internal External External 6 Solenoid Block Kit for Series 90 Modular Accessory System WCAIM2043
3. OPERATION a. SINGLE-ACTING AND DOUBLE-ACTING ON/OFF TYPE (POSITIONER/CONTROLLER) 1. Solenoid is ported such that when not energized, the actuator will be in its closed (clockwise) position. 2. Energizing the solenoid will cause the LED to light and will provide air to the actuator to open (counterclockwise). b. SINGLE-ACTING AND DOUBLE-ACTING MODULATING TYPE (POSITIONER/CONTROLLER) 120 VAC ONLY 1. Refer to POSITIONER/CONTROLLER Instruction Sheet (WCAIM2045) for information regarding the operation of the solenoid valves with these options. c. FAILURE MODES See table below. Indications Actuator/Valve Failure Mechanism* Failure Symptom Direct-Acting Reverse-acting SPRING-RETURN LOA VALVE WON T OPEN Closed N/A (single three-way) LOP VALVE WON T OPEN Closed N/A DOUBLE-ACTING LOA VALVE WON T MOVE May Rotate N/A (single four-way) LOP VALVE WON T OPEN Closed N/A SPRING-RETURN POSITIONER LOA VALVE WON T OPEN Closed** Closed (dual three-way, SR-PC Block) LOS VALVE WON T OPEN Closed Open LOP VALVE WON T OPEN Closed Closed DOUBLE-ACTING POSITIONER LOA VALVE WON T MOVE May Rotate May Rotate (dual three-way, DA-PC Block) LOS VALVE WON T OPEN Closed Open LOP VALVE WON T OPEN Closed Closed SPRING-RETURN CONTROLLER LOA VALVE WON T OPEN Closed** Closed (dual three-way, SR-PC Block) LOS VALVE WON T CLOSE Open Closed LOP VALVE WON T OPEN Closed Closed SPRING-RETURN CONTROLLER LOA VALVE WON T MOVE May Rotate May Rotate (dual three-way, DA-PC Block) LOS VALVE WON T CLOSE Open Closed LOP VALVE WON T OPEN Closed Closed * LOA Loss of Air; LOP Loss of Power; LOS Loss of Signal ** A pressure switch to detect an LOA condition is required in the M.A.S. unit to make it fail-safe. 1. May Rotate means that if one of the actuator chambers has more air in it than the other chamber, the difference in pressure caused by one chamber bleeding down before the other may cause actuator rotation depending on the torque load on the actuator. 2. For Open and Closed conditions, cross-line mounting the actuator or in-line mounting the actuator upside down will reverse the Failure Indication. For example, a spring-return (single three-way) will go open on loss of power or air if it is set up as a fail-open valve. 3. Direct-Acting means that an increasing input signal will cause the positioner circuit board to drive the valve/actuator in a counterclockwise (open) direction. (Controller is opposite). Reverse-Acting means that an increasing input signal will cause the positioner circuit board to drive the valve/actuator in a clockwise (closed) direction. (Controller is opposite). WCAIM2043 Solenoid Block Kit for Series 90 Modular Accessory System 7
4. TROUBLESHOOTING CAUTION: Do NOT disassemble any solenoid valves a special fixture is required for reassembly. PROBLEM POSSIBLE CAUSE(S) SOLUTION Air leak between Loose solenoid screw Tighten screw. solenoid/block or between block/housing Gasket out of position Remove solenoid, realign gasket and reattach solenoid. Defective gasket Rough surfaces on solenoid block Contact Flowserve for replacement. Contact Flowserve for replacement. Solenoid does not Power supply not connected/not working Check power supply. energize (go on) Defective lead wires or (if AC) rectifier Defective solenoid valve coil Check leads with ohmmeter or try new lead wires. Contact Flowserve. Solenoid does not Current leakage from DCS or PLC Install capacitor at terminal strip. de-energize controller (AC only) (Reference section 2.a.) Defective switch Check switch and wiring. Solenoid ok actuator not High valve torque Disconnect valve and check operation/torque. working correctly Air supply not connected/low pressure Tubing connections to M.A.S.; or solenoid block tubing not correct. If double-acting on-off type block Debris in solenoid valve or block No obvious cause(s) Check supply air piping and pressure. Check M.A.S. air connections per Section 1.a-c. 1 /8" NPT port must not be plugged. Remove and clean solenoid valve and block-check filtering per introduction. Disconnect M.A.S. from actuator; test each unit separately. 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 function safely 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 industrial service 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 therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation Operation 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 of satisfactory 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 Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning these 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 CORPORATION FLOW CONTROL DIVISION 1978 Foreman Drive Cookeville, Tennessee 38501 USA Phone: 931 432 4021 Facsimile: 931 432 3105 www.flowserve.com 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and are registered trademarks of Flowserve Corporation. WCAIM2043 10/03 Printed in USA