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Flowserve StarPac 3, Инструкция пользователя

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Flowserve StarPac 3 Скачать руководство пользователя страница 43

43

StarPac Intelligent Control System  FCD VLENIM0066-02   02/10

flowserve.com

®

5.

  Unplug the wire harness that terminates the pressure sensors and thermocouple from the main PCB assem-

bly.

6

.  Remove the three retaining screws (item 6) from the main PCB assembly.  

7.

  Carefully unplug and remove the top display board from the main PCB assembly.  The bottom two boards of 

the main PCB assembly will remain in the housing.

8.

  Remove the two screws (item 8) retaining the lower two boards of the main PCB assembly.  Remove the metal 

pressure sensor board stiffener. 

9.

  Carefully lift the lower two boards out of the main PCB assembly.  Disconnect the three wire connections and 

user interface ribbon cable from the back of the lowest board of the main PCB assembly.  

10.

 Remove the lower two boards of the main PCB assembly out of the housing.

11.

 Prior to installing the new main PCB assembly, remove the top display board of the new main PCB assem-

bly.

12.

 Connect the three wire connections and user interface ribbon cable on to the back of the lowest board of the 

main PCB assembly.

13

. Verify that the two pressure sensor O-rings (item 10) are in place in the housing.

14.

 Place the lower two boards of the main PCB assembly into the positioner and onto the bosses in the housing.  

Make sure all wires are clear and do not get pinched between bottom circuit board and the housing bosses.

15

. While holding the metal pressure sensor board stiffener in place, insert the two retaining screws through the 

metal pressure sensor board stiffener and circuit board and fasten the lower two boards to the housing.  An 
outline of where the where the metal stiffener needs to be placed can be seen on the middle board of the main 
PCB assembly.  Tighten the screws evenly to 8 in-lb.

16.

 Connect the pressure sensor/thermocouple wire harness to the middle board of the main PCB assembly.

17

. Carefully plug the top display board of the main PCB assembly into the middle board of the main PCB assem-

bly.

18.

 Insert the three retaining screws through the mounting holes of the fully assembled main PCB assembly and 

tighten evenly.

19.

 Carefully re-install the keypad assembly.  Make sure that the connector on the back of the keypad assembly 

connects correctly to the connector on the main PCB board.

20.

 Insert the two retaining screws through the keypad and tighten evenly.  Do not over-tighten.

14.16 Customer Interface Board Replacement

The customer interface board provides a connection point inside the explosion-proof housing for all hookups to the 
positioner.

To replace the customer interface board, refer to Figures 5 and 24 and proceed as outlined below.  The following tools 
are required:

•  Phillips screwdriver

Содержание StarPac 3

Страница 1: ...StarPac Intelligent Control System FCD VLENIM0066 02 02 10 flowserve com Experience In Motion USER INSTRUCTIONS Installation Operation Maintenance StarPac 3 Intelligent Control System FCD VLENIM0066 0...

Страница 2: ......

Страница 3: ...and Installation 14 8 1 Mounting to Flowserve Valtek Linear Mark One Valves 14 8 2 Mounting to Standard Flowserve Valtek Rotary Valves 14 8 3 Optional Flowserve Valtek Rotary Mounting Procedure 17 8...

Страница 4: ...t 30 14 7 Keypad Assembly Replacement 31 14 8 Driver Module Assembly Replacement 31 14 9 Regulator Replacement 35 14 10 Checking or Setting Internal Regulator Pressure 35 14 11 Checking or Setting the...

Страница 5: ...All Flowserve User Instruction Manuals are available at www flowserve com 1 3 Terms Concerning Safety The safety terms DANGER WARNING CAUTION and NOTE are used in these instructions to highlight parti...

Страница 6: ...t be refitted Apart from the operating instructions and the obligatory accident prevention directives valid in the country of use all recognized regulations for safety and good engineering practices m...

Страница 7: ...he vent assembly is located in the upper left side of the positioner The gaps around the assembly as noted by the arrows should be sealed for long storage Joints to be sealed A small desiccant package...

Страница 8: ...system be aware that the center of gravity may be above the lifting point Therefore support must be given to prevent the valve from rotating Failure to do so can cause serious injury to personnel and...

Страница 9: ...Connect the air supply and instrument signal lines 4 Quick check Prior to start up check the control valve by following these steps 1 Stroke the valve and observe the plug position indicator on the st...

Страница 10: ...d brackets are securely fastened 8 If possible remove air supply and observe actuator for correct fail safe action 9 Check rubber actuator bellows for splits cuts or wear 10 Spray a soap solution arou...

Страница 11: ...B 230 mA Group C 590 mA Group D 800 mA Overload protection Minimum 500 volt isolation 24 V power fuse protected Serial Interface Dual RS 485 ports Modbus Protocol USB Interface 2 0 mini B Modbus Prot...

Страница 12: ...gs Table VI Positioner Specifications Deadband 0 1 full scale Repeatability 0 05 full scale Linearity 0 5 rotary 0 8 sliding stem full scale Air Consumption 0 3 SCFM 0 5 Nm3 hr 60 psi 4 barg Table VII...

Страница 13: ...feedback loop which determines how much current to send to the electromagnet for a desired spool valve position The electromagnet in the feedback loop varies the nozzle flapper spacing which regulate...

Страница 14: ...er will then make small null adjustments to fine tune the desired position and compensate for changes in dynamic loading A decrease in the command signal reverses the described actions causing a propo...

Страница 15: ...insert through washers into the stem clamp Leave bolts loose 6 Slide the appropriate pin slot of the take off arm based on stroke length over the follower arm pin The appropriate stroke lengths are s...

Страница 16: ...ttach bracket to actuator transfer case pad Leave these bolts slightly loose until final adjustments are made 6 Rotate take off arm so the follower pin will slide into the slot on the take off arm Adj...

Страница 17: ...ck values were exceeded and the arm must be adjusted away from the positioners limits Return to step 2 and rotate the arm back approximately 10 degrees NOTE Remember to remove the air supply before re...

Страница 18: ...ot direction of rotation WARNING If rotating in wrong direction serious damage will occur to the positioner and or linkage Check air action and stroke direction carefully before initiating operation 8...

Страница 19: ...pneumatic side of the actuator regardless of air action The Output 2 port must be plugged 9 Wiring and Grounding Guidelines WARNING This product has electrical conduit connections in either thread si...

Страница 20: ...RS 485 Communications RS 485 wiring requires the use of a shielded twisted pair cable which is grounded only at the source and not in the unit For maximum performance wire should have a characteristic...

Страница 21: ...it isolated so that unex pected valve stroking will not adversely affect the process WARNING The following procedures may cause the valve to stroke causing pressures and temperatures to vary from thei...

Страница 22: ...mode Normally the unit arrives from the factory set in the manual analog operating mode This means a command signal will position the valve the same as a traditional control valve providing a plug po...

Страница 23: ...position jumper labeled JP3 There are 2 jumpers that must be moved together to set the voltage input range The jumpers are oriented vertically and with both jumpers in the upper position the input is...

Страница 24: ...ing Address 1 Parity Odd Baud Rate 19 200 Modbus Communication Mode RTU RS 485 Termination Resistors Installed 11 2 Selecting Correct Address Setting If the StarPac 3 unit is the only StarPac unit on...

Страница 25: ...e next section Using more than two termination resistors in a network can cause the RS 485 communications to operate erratically or fail On the top electronic board there are two termination jumpers f...

Страница 26: ...nge 14 2 Mechanical Subsystem Maintenance Refer to the appropriate Flowserve Installation Operation Maintenance IOM instructions for details on repair and maintenance of the control valve actuator com...

Страница 27: ...pin for excess wear and replace if needed The take off arm attached to the stem clamp must be firmly secured to the stem clamp and perpendicular to the actuator stem If this takeoff arm is canted or...

Страница 28: ...or into the sensor port making sure the O ring or gasket remains properly in place while tightening the sensor Tighten the sensor until it seats metal to metal at the gasket section of the sensor port...

Страница 29: ...cables may be potted inside the fitting at the bottom of the positioner housing To remove the cable it will be necessary to cut the existing cable on both sides of the fitting The fitting will need t...

Страница 30: ...from the main PCB board and remove the keypad 4 Disconnect the red and yellow thermocouple wire Refer to Figure 11 5 Loosen the tubing nuts on both ends of the thermocouple assembly refer to Figure 12...

Страница 31: ...he main PCB board Unplug the keypad ribbon cable from the main PCB board and remove the keypad 5 Install the new keypad assembly by first plugging the keypad ribbon cable into the connector on the mai...

Страница 32: ...alve cover Figure 14 Spool Valve Cover Assembly 5 Remove the Phillips head screw that attaches the driver module to the main housing Figure 15 Be careful not to lose the nylon washer as the screw is r...

Страница 33: ...15 of this manual 11 Disconnect the flexible tubing from the barbed fitting at the driver module assembly see Figure 16 12 Use the 1 4 nutdriver to remove the barbed fitting from the driver module ass...

Страница 34: ...around the screw using an RTV sealant 20 Insert a driver to housing screw into the driver housing through the counterbored hole in the positioner main housing Tighten with a Phillips screwdriver 21 Re...

Страница 35: ...ctrostatically sensitive devices 1 Make sure valve is bypassed or in a safe condition 2 Disconnect the power and air supply to the unit 3 Remove the main cover 4 Remove the two keypad retaining screws...

Страница 36: ...ubing a few inches in length each 8 Position the barbed tee between the internal regulator and the driver module by connecting the 1 16 flexible tubing found in the positioner to one side of the barbe...

Страница 37: ...rve precautions for handling electrostatically sensitive devices 1 Make sure valve is bypassed or in a safe condition 2 Disconnect power and air supply from the positioner 3 Remove the main cover 4 Re...

Страница 38: ...y several times and recheck the minimum pressure and re adjust if necessary to ensure that the pressure has settled within the range specified 16 When the pressure is set remove the air supply 17 Remo...

Страница 39: ...t and set aside Figure 19 3 Remove the molded filter element by pulling it straight out of the chamber cover vent piece 4 Install O ring into base of chamber cover vent piece as shown in Figure 19 5 P...

Страница 40: ...e housing base as a register Figure 15 Slide the block toward the driver module until the two retaining holes line up with the threaded holes in the base 9 Install two spool valve screws and tighten s...

Страница 41: ...nect to the main PCB assembly 11 Re install the main PCB assembly following the instructions found in section 14 15 of this manual 12 Re install the keypad Insert the two retaining screws and tighten...

Страница 42: ...ostatically sensitive devices 1 Make sure the valve is bypassed or in a safe condition 2 Disconnect the power and air supply to the unit 3 Remove the main cover 4 Remove the keypad by removing the two...

Страница 43: ...bosses in the housing Make sure all wires are clear and do not get pinched between bottom circuit board and the housing bosses 15 While holding the metal pressure sensor board stiffener in place inse...

Страница 44: ...rews see Figure 5 11 Reconnect the field wiring to the customer interface board terminals 12 Install the keypad assembly and secure with the two retaining screws 13 Reinstall all covers 15 Optional Ve...

Страница 45: ...ting into the spool valve cover part no 179477 Connect the necessary tubing piping to this fitting to route the exhausted na tural gas to a safe environment The maximum allowable back pressure in the...

Страница 46: ...essure Regulator 5 to 30 psig Includes 2 O rings 37 Spool Valve Shroud 12 Screw Regulator Plate to Housing 4 38 Spool Valve Cover 13 Hex Barbed Fitting with Captive O ring 39 Hydrophobic Filter Spool...

Страница 47: ...rol System FCD VLENIM0066 02 02 10 flowserve com 35 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 1 5 Figure...

Страница 48: ...48 O ring Feedback Shaft 1 49 Torsion Spring 1 50 E ring 1 Kit 6 Feedback Shaft Kit Namur P N 215805 999 000 46 Feedback Shaft 1 47 Screw Spring to Feedback Shaft 1 48 O ring Feedback Shaft 1 49 Torsi...

Страница 49: ...9 135437 135430 135433 0 75 135429 135438 135430 137212 0 88 135429 135439 135430 137213 135431 135434 1 12 135430 137214 135431 137218 1 50 135431 137216 1 75 135431 137217 Standard All rotary valves...

Страница 50: ...83888 83901 Item No Description Quantity Kit 2 Spiral Wound Gasket Replacement Kit Part No 134560 999 000 6 Environmental O ring Viton 2 8 Environmental O ring Viton 4 10 O ring seal Viton 2 20 Envir...

Страница 51: ...mote Mount Pressure Sensor Hardware Kit with Purge and Isolation Valves Part No 134558 999 000 3 Swagelok nut 4 4 Swagelok ferrules 4 15 Temperature extended fitting 2 16 Purge valve 2 17 Isolation va...

Страница 52: ...urations Boss on valve body 12 11 10 8 9 8 1 7 6 5 4 3 2 1 Electrical connection cable 2 Tubing 0 035 wall thickness 3 Tube nut 4 Tube ferrule set 5 Sensor nut 6 Environmental O ring 7 Sensor fitting...

Страница 53: ...fitting 12 O ring seal 15 Temperature extended fitting 16 Purge Valve 17 Isolation valve 18 Wet leg tubing 0 065 inch wall 19 Adapter fitting 20 Environmental O ring 21 O ring seal 21 Temperature Sens...

Страница 54: ...IX 316 Stainless Steel Tubing Description Number Pressure sensor wire tubing 0 50 inch diameter 0 035 inch thick 063200 150 000 Extended temperature wet leg tubing 0 50 inch diameter 0 065 inch thick...

Страница 55: ...work connections for correct positive and negative connections Individual units not properly wired Begin with shortest RS 485 run checking polarity and communication continue checking units throughout...

Страница 56: ...h Low Slightly off Recalibrate sensor Make sure sensor is plugged in Yes Is sensor working No Swap sensors Yes No Same problem appear Problem is in wiring or board Contact Factory Replace sensor Repla...

Страница 57: ...and hold down the ZERO 0 key on the keypad while turning the 24V power ON 3 Release the key after the display has booted and is active approx 5 seconds The following conditions are set upon re initia...

Страница 58: ...oups A B C D 30 Explosionproof FM Class I Div 1 Groups B C D 31 Feedback Shaft DD Shaft 316 SS Valtek Standard D6 D6 Namur Shaft 316 SS VDI VDE 3845 N6 Conduit Connections 1 2 NPT E E M20 M Action Fou...

Страница 59: ......

Страница 60: ...e 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 use...

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