Limit Switch Kit for Series 90 Modular Accessory System Installation, Operation and Maintenance Instructions

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1 WCAIM2044 (Part 18472) Limit Switch 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. A variety of mechanical and proximity switch options are available for the Series 90 Modular Accessory System. The switches can be used to provide actuator position indication or to control other equipment. Only one option is available in an M.A.S. unit at a time. An Adjustment Plate is used to mount the proximity and some single-pole mechanical switches to the baseplate. This allows the proximity switches to be adjusted to their optimum sensing distance for the most accurate operation. If mechanical switches are to be mounted to this adjustment plate, then the plate should be set to a middle position not rotated toward or away from the shaft. There are two sets of mounting holes in the adjustment plate which are used to accommodate the various switches. See figure below. Their use will be detailed later. Options always available (regardless of other options) are: M2 Two Single-Pole, Double-Throw Mechanical Switches P6 Two Two-Wire AC Proximity Switches P8 Two Three-Wire DC Proximity Switches Options with limited availability (not available with output potentiometer options or with positioner/controller): M4 Four Single-Pole, Double-Throw Mechanical Switches D2 Two Double-Pole, Double-Throw Mechanical Switches The switch options require differing numbers of terminal connections. Where required, (M4, D2), the additional terminal strip will be provided in the M.A.S. unit or switch kit. It will be located in the secondary location as shown. The cams used to actuate the switches offer unlimited positioning without the use of tools. These cams are essentially wrap-springs and grip the shaft tightly enough to prevent accidental rotation. Squeezing together the two small protrusions from the cam loosens the spring and allows adjustment. Needle nose pliers may prove to be helpful when installing the cams, but are not required. SQUEEZE SQUEEZE NOTE: If potentiometer option is also going to be installed, the potentiometer face gear should be installed before the switches and cams.

2 1. ASSEMBLY a. M2 TWO SPDT MECHANICAL SWITCHES M4 FOUR SPDT MECHANICAL SWITCHES P6 TWO AC PROXIMITY SWITCHES P8 TWO DC PROXIMITY SWITCHES b. D2 - TWO DPDT MECHANICAL SWITCHES 1. Attach the mounting plate (item 2) to the baseplate (item 4) in the location shown using the two #4-40 x 3 /8" flat head screws (item 3) and the one #4-40 x 3 /8" round head screw (item 6). 2. Assemble the switches (item 1) to the mounting plate with the two #6-32 screws (item 5). 1. STACK two switches (item 1) and attach to the adjustment plate (item 2), as shown above, using two #4-40 x 1" screws (item 3) provided. Note: M2, M4 only One of the screws will thread into a tapped hole in the adjustment plate while the other engages a clearance hole without threads. 2. For M2, M4 only Assemble the switches and adjustment plate to the baseplate (item 4), as shown below, using the loose #4-40 x 1" screw and the #4-40 x 3 /8" screw (item 5) and #4 washer (item 6). For P6, P8: Assemble the switches to the baseplate using the two #4-40 x 3 /8" screws and the #4 washer. Move the adjustment plate to a middle position and tighten the screws. 3. FOR M4 ONLY: Stack the other two switches and assemble to the baseplate using the remaining two #4-40 x 1" screws (item 7). 2 Limit Switch Kit for Series 90 Modular Accessory System WCAIM2044

3 2. CAMS To work the spring cams down the shaft, squeeze the two protrusions and turn. Follow the sketch for the appropriate option: M2, P6, P8: Assemble the first spring cam, the spacer, and second spring cam. M4: Assemble the four spring cams with no spacers. D2: Assemble one spacer, one spring cam, second spacer, and second cam. 3. WIRING NOTE: All wiring is to be run smoothly and neatly and away from any rotating parts, using wire ties if necessary. Use caution to avoid pinching wires and/or solenoid rectifiers (if used) between the base and cover flanges. All wiring to terminal strips shall be inserted only to mid-point of terminal strips. a. For M4 and D2 options, add the second terminal strip in the secondary location using the four #4 x 3 /8" self-tapping screws provided. d. NOTE: For M2 switch option when used with Positioner or Controller (PC90) option: Due to wiring requirements of the positioner or controller (PC 90) options, only four switch leads can be accommodated. The user must decide whether the switches are to be wired as normally open (N.O.) or normally closed (N.C.). Normal two-wire switch operation is to use the N.O. contact. If switch operation requires the N.C. contact to be used, the wiring diagram inside the cover should be marked to reflect this modification. In either case, the unused wire should be removed. If both sets of contacts must be used, the third wire from each switch (N.C.) can be directly connected. e. NOTE: For P8 switch option when used with positioner or controller (PC 90) option: Due to wiring requirements of the positioner or controller (PC 90) options, only four switch leads can be accommodated. In the case of the P8 DC proximity switches, three wires for each switch are required for operation. The load wires (brown/white on switch I and red on switch II) must be connected directly to the customer s incoming wiring, without going through the terminal strip. b. The wire leads will be connected to the switches as provided. Pay close attention to the switch labels, schematics, wire colors, etc. when wiring the switches. c. Route the wires between the legs of the black terminal brackets whenever possible. Be certain that the wires will not get fouled on the shaft when it rotates. WCAIM2044 Limit Switch Kit for Series 90 Modular Accessory System 3

4 4. OPERATION a. Once the M.A.S. unit has been assembled and connected to the actuator, the switch cams can be set per user s requirements. Normally switch I (and III) indicates closed and switch II (and IV) indicates open. b. FOR P6 and P8: Loosen the #4-40 screws used to mount the switch adjustment plate. Set the switches such that the cams will approach the switch face as closely as possible without making contact. Retighten the screws. c. The unit should be operated to ensure that switch actuation occurs at the end of rotation (or in whatever position is desired by the customer) repeatably. M2 M2 Without Positioner/Controller Option M2 With Positioner/Controller Option See paragraph 3.d 4 Limit Switch Kit for Series 90 Modular Accessory System WCAIM2044

5 M4 D2 WCAIM2044 Limit Switch Kit for Series 90 Modular Accessory System 5

6 P6 AC Sensors P8 DC Sensors For M.A.S. without Postioner/Controller Option For M.A.S. with Postioner/Controller Option Switch Loading Diagram 6 Limit Switch Kit for Series 90 Modular Accessory System WCAIM2044

7 4. TROUBLESHOOTING PROBLEM POSSIBLE CAUSE(S) SOLUTION Switches do not Improper cam settings Reset cams indicate at proper positions Switch does not Switch too far from cam M2, M4, P6, P8 Loosen the adjustment actuate (never plate screws and rotate switches trips) toward shaft until actuation is correct; retighten screws. D2 Loosen switch retaining screws and push switches towards shaft; retighten screws. Switch does not Switch too close to cam M2, M4, P6, P8 Loosen the adjustment reset (always plate screws and rotate switches away tripped) from shaft until actuation is correct; retighten screws. D2 Loosen switch retaining screws and push switches away from shaft; retighten screws. No indication at Broken, defective, or misplaced Check wiring with appropriate wiring terminal strip wire diagram per Section 3. Cams not aligned Cams/spacers in wrong Check and reassemble cams per with switch arms order Section 2. Cams not pushed into place Push cams into proper locations; align with switch arms or targets (if proximity switch). WCAIM2044 Limit Switch Kit for Series 90 Modular Accessory System 7

8 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 or call USA FLOWSERVE CORPORATION FLOW CONTROL DIVISION 1978 Foreman Drive Cookeville, Tennessee USA Phone: Facsimile: Flowserve Corporation, Irving, Texas, USA. Flowserve and are registered trademarks of Flowserve Corporation. WCAIM /03 Printed in USA

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