PSN1 INSTRUCTION MANUAL

(linear type; max. thrust 3000 N, max. stroke 40 mm)

SERVO-TOP II

MODEL

PSN1

BEFORE USE ....

Thank you for choosing M-System. Before use, check the package you received as below. If you have any problems or questions on the product, please contact M-Systems Sales Office or representatives. s PACKAGE INCLUDES: SERVO-TOP II body ................................................... (1) Indicator (when the stem button is selected; attached to the actuator body with a Scotch tape) . (1) Remark: Yoke and other components necessary to attach the PSN1 to a valve are to be provided by the customer. s MODEL NO. Check that the model No. described on the specification label is exactly what you ordered.

s INSTRUCTION MANUAL This manual describes necessary points of caution when you use this product, installation and connection, hardware setting, and basic maintenance procedures. When you need to change software settings, please refer to the Operation Manual for Model PU-2u (EM-9255), Section B. This unit is factory adjusted and calibrated according to the Ordering Information included in the product package. If you don't need to change the pre-adjusted setting, you can skip the sections on PU-2u programming in this manual and the Operation Manual for Model PU-2u.

COMPONENT IDENTIFICATION
Modular Jack Stepping Motor Input Resistor (for current input) Temperature Sensor Control PCB

SW-1 8

POWER INPUT ALARM UP INPUT SIGNAL POSITION SIGNAL OPEN FORCED CLOSE OPEN/CLOSE COMMAND POWER
1 2 3 4 5 6 7 8 CLOSE/OPEN ACCORDING TO SW1/STOP REVERSE/DIRECT

+ COM1 +

Ground Terminal Gasket

DOWN

1 2

U(+) V()

COM1

SEQUENTIAL CONTROL

FULL OPEN FULL CLOSE ALARM

FULL-OPEN POSITION SET FULL-CLOSED POSITION SET RUN/PU

3 4 5 6 7 8 9 10 11

FUSE

COM2

12

Fuse Manual Operation Angle Sensor

Sealing Spring

POWER INPUT ALARM UP DOWN

: Power LED (green light turns on when applied) : Input LED (green light turns on when applied) : Alarm LED (red light turns on with alarm) : UP Control Button : DOWN Control Button

Output Stem

Figure 1. COMPONENT IDENTIFICATION

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OUTPUT STROKE & ADJUSTABLE RANGE

The servo-control PCB compares input signal (position setpoint signal) and actual position signal from a potentiometer, and drives the motor to reduce the deviation. When a full-close signal is provided, the output stem is pressed onto the sealing spring after the valve is fully closed, until the sealing pressure reaches a preset value.
R1 6 (.24) 4 (.16) 6 (.24) 1 (.04)
Figure 2. OPERATIONAL RANGE OF THE OUTPUT STEM

40

9 (.35) 14 (.55)
Yoke Surface

Figure 3. STEM DETAILS

MODEL PSN1-4u1 PSN2-4u2

L (mm ) 66 106 52 92

L (inch) 2.60 4.17 2.05 3.62

15 (.59) 140

Valve, yoke and other components necessary to connect the PSN1 to the valve are provided by the customer. DO NOT CHANGE the ex-factory settings of the PSN1. The following procedure should be done with the power supply removed, except when otherwise specified. (General Procedure) 1) Apply power input and 0% input signal (100% for direct action) in order to expose the output stem to the maximum degree. 2) Set the valve stem at the lowest position. 3) Connect the PSN1 to the yoke. 4) Screw the valve stem into the output stem until there is little opening between them. For applying a sealing pressure, refer to flexure values in Table 3 (e.g. 1 mm for applying 1500 N for PSN1-u1) and screw it until the opening equals the value. 5) Fix both stems with a lock nut. 6) Apply power input and approx. 50% input signal and check that there is no opening between the yoke and valve bonnet. Fix the yoke and the valve. 7) Connect the indicator and other components if necessary.

10 (.39) 15 (.59)
Figure 4. INDICATOR DETAILS

SERVO-TOP II

Bolt Output Stem

Indicator Scale Plate Valve Stem Button Lock Nut Yoke

Valve Bonnet

Figure 5. CONNECTING THE PSN WITH A VALVE, EXAMPLE

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16 (.63)

INSTALLATION
40

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Table 1. ABNORMAL LOW INPUT OPERATION & SWITCH POSITIONS

ELECTRICAL CONNECTIONS
Remove the cover of the PSN1 body and wire to the terminal block according to Figure 6. The PSN1 requires the power input (1 2) and input signal (3 4) connections for operating.

MODE Stop Fully Close Fully Open

SW-1 *1 OFF ON

SW-2 ON OFF OFF

*1. SW-1 position is disregarded in STOP mode.

SW-1 SW-8

+ INPUT SIGNAL R * COM1 POSITION SIGNAL +

3 4 5

1 U(+)
POWER

2 V()
MODULAR JACK PU-2u

COM1 8 FORCED OPEN/CLOSE COMMAND OPEN 6 CLOSE 7 FULL OPEN 9

1 2 3 4 5 6 7 8

O N

UP Control Button DOWN Control Button

POWER

SEQUENTIAL CONTROL

FULL CLOSE 10 ALARM 11 COM2 12

INPUT ALARM UP DOWN

INPUT SIGNAL POSITION SIGNAL OPEN FORCED CLOSE OPEN/CLOSE COMMAND

COM1

*Input resistor attached for a current input.

1 2

U(+) V()

POWER
1 2 3 4 5 6 7 8 CLOSE/OPEN ACCORDING TO SW1/STOP REVERSE/DIRECT

COM1

SEQUENTIAL CONTROL

FULL OPEN FULL CLOSE ALARM

Figure 6. CONNECTION DIAGRAM

FUSE

FULL-OPEN POSITION SET FULL-CLOSED POSITION SET RUN/PU

3 4 5 6 7 8 9 10 11

COM2

APPLICABLE SOLDERLESS TERMINAL 3.2 (.13) min.

5.9 (.23) max.

12

Figure 7. ADJUSTMENTS, DETAILS

4.6 (.18) min.

to stop the actuator at the factory. Refer to Table 1. s ACTUATOR ACTION (SW-3) 1) Use SW-3 for switching the actuator action. It is set to
Table 2. ACTUATOR ACTION

ADJUSTMENT PROCEDURE
Open the PSN1 body cover and adjust the full-open and closed positions referring to Figure 1. Other adjustments can be also conducted as explained below: switching actuator action, emergency operation at abnormally low input, and positions for the open/close limiters and for the full-open/ close signal, and restart limiting timer. For adjusting positions for the open/close limiters and for the full-open/close signal, and restart limiting timer, the PU-2u is required. All explanations given in this manual are for the upper end of output stem as full-open position, for the lower end of output stem as full-closed position. s OPERATION AT ABNORMALLY LOW INPUT (SW-1, SW2) 1) When the input goes down to 0.37 0.1V DC or below, the PSN1 goes to the abnormal low input operation. It is set

MODE Direct Reverse

SW-3 ON OFF

ACTION Output stem moves up with 0% input. Output stem moves down with 0% input.

In DIRECT action, the input signal 0 100% corresponds to the position output signal 20 4mA DC. "REVERSE" at the factory. Refer to Table 2. s FULL-OPEN/CLOSED POSITIONS 1) Turn ON the SW-8 in order to put the PSN1 in the local calibration mode, and the input signal is disregarded. 2) Turn ON the SW-5 and adjust the full-open position pressing UP/DOWN control buttons. 3) When the output stem reaches a desired position, turn OFF the SW-5. The position is memorized as the full-open position. 4) Turn ON the SW-6 and adjust the full-closed position pressing UP/DOWN control buttons. 5) When the output stem reaches a desired position, turn OFF the SW-6. The position is memorized as the fullclosed position. 6) Turn OFF the SW-8 in order to put the PSN1 in the operating mode. Apply input signals and confirm the fullopen/closed positions.

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s SEALING SPRING For applying a sealing pressure at the fully closed position, adjust flexure of the sealing spring when calibrating the fullclosed position. For applying a sealing pressure at the fully open position, such like the case of a three-way valve, adjust flexure of the sealing spring when calibrating the full-open position. Excessive flexure may shorten life of the actuator and spring. Observe the maximum flexure at the maximum pressure. The output stem is provided with scales by millimeters.

PU-2u ADJUSTMENTS
s DISPLAY
ITEM No. Response Messages

G D

LCD Display Data to be entered or Messages

Response Messages NG: No good The PU-2u may not be securely connected. Check connection of the modular jack. ER: Communication error Turn the SW-8 ON. Data Indicator OK: OK DATA-ERR: Invalid data input NON-ITEM: ITEM No. not applicable
Figure 8. SEALING SPRING

s PROGRAMMABLE ITEMS
RATED SPRING (N/mm) Table 4. PROGRAMMABLE ITEMS ITEM No. ITEM USABLE RANGE MINIMUM DEFAULT INCREMENT

TYPE 1500 N use 3000 N use 1500 N use 3000 N use

MAXIMUM FLEXURE AT SET PRESURE MAXIMUM PRESS. (N) PRESS. (mm) (N)

1500 3000
(lbs)

1 1
(inch)

1170 2410
(lbs)

330 590
(lbs/in.)

10 11 12 13 14 15 16 17 18 19 20 21

Full-open position Full-closed position Full-open limit Full-close limit Full-open output Full-closed output Split ON/OFF Split type LO/HI Split point

8 100 0 92 75 105 -5 25 75 100 0 25 0 or 1 0 or 1 30 70

0.1 0.1 0.1 0.1 0.1 0.1

100 0 100 0 98 2 0 0 50 16 0.5 2

337 674

0.04 0.04

263 542

1180 3370

Remark: The seal spring starts flexing when a pressure exceeding the set pressure is applied. Control pressure within 80% of the set pressure except when the valve is fully closed. If excessive pressure is applied within the control range, flexure of the spring may jeopardize the linearity.

0.1 1 0.1 1

Opening/closing speed limit 1 50 Deadband 0.5 5 Restart limiting timer 1 30

s ROM VERSION INDICATION Press ITEM 99 in the local calibration mode in order to display the ROM version of the PSN1. s HOW TO PROGRAM THE PSN1 1) Apply power supply voltage to the PSN1. 2) Turn ON the SW-8 in order to put the PSN1 in the local calibration mode, and the input signal is disregarded. 3) Connect the modular jack cord of the PU-2u to the PSN1. ITEM display is blank. 4) Indicating Current Setting Key in the ITEM No. that you want to check. (N = 0 9) Press [ITEM] [N] [N]. 5) Indicating New ITEM No. Press [ITEM] [N] [N] or press [UP] or [DOWN]. 6) Modifying Current Setting Display the ITEM No. that you want to change, and press [DATA], new setting, and [ENTER]. If an irrelevant setting is entered, the PU-2u indicates "DATA-ERR" on its message display. Key in an appropriate setting again. 7) Remove the modular jack cord of the PU-2u.

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8) Turn OFF the SW-8 in order to return the PSN1 in the operating mode. Apply input signals and confirm every setting. Remark 1: DO NOT remove power to the PSN1 with the PU2u connected to it. Remark 2: Be sure to remove the PU-2u before driving the motor (in the operating mode). s EXPLANATIONS ABOUT THE PROGRAMMABLE ITEMS 1) Full-Open/Closed Positions (ITEM No.10, 11) Key in a percentage value within 0% for the longest output stem and 100% for the shortest. [Full-Open Position] [Full-Closed Position] 5 2) Full-Open/Close Limits (ITEM No.12, 13) The adjustable ranges shown in Table 4 are applicable against the stroke determined by the full-open/closed positions. 3) Full-Open/Closed Outputs (ITEM No.14, 15) The adjustable ranges shown in Table 4 are applicable against the stroke determined by the full-open/closed positions. 4) Split Range (ITEM No.16 18) Refer to Figure 9 and determine the type and point of split range. When the split range is set to OFF (ITEM No.16), the split range type and point (ITEM No.17, 18) are invalid.
Split Range Type Set to LO (Set to DIRECT Action) Split Range Type Set to HI (Set to REVERSE Action) UPPER END Thick, solid lines indicate examples of I/O characteristics, while broken lines indicate limits of adjustable range.

3500 Rated Thrust Speed

3000

2500

RATED THRUST (N)

1500

1000

500

10

20

30

40

0 50

SPEED SCALE
Figure 10

OUTPUT STEM POSITION

6) Deadband (ITEM No.20) Deadband is adjustable as % of the maximum stroke within 0.1 to 5%. 7) Restart Limiting Timer (ITEM No.21) The timer is provided to protect the motor from overheating, preventing it from restarting for a certain interval once the motor has been stopped within deadband. When the high temperature protection is activated in a high temperature ambient, adjust the timer to a longer interval. Adjustable range is within 1 to 30 sec.

LOWER END

50 INPUT (%)

100% Adjustable Split Point Range

MANUAL OPERATION
s WHEN POWER IS AVAILABLE TO SUPPLY TO PSN1 1) Turn on the power supply. 2) Turn on the SW-8 to put the PSN1 into the local calibration mode. 3) Use UP/DOWN buttons to manually operate the PSN1. 4) Turn off the SW-8 after turning off the power supply. s USING THE MANUAL OPERATION STEM 1) Be sure that the power supply is removed. 2) The output stem is designed to go up when the manual operation stem turns clockwise (seen from the operation stem side). Turn the handle with a torque under 1 Nm (0.74 ftlbs) in checking the stem position with the indicator. 3) The output stem moves by 10 mm per approx. 24 turns of the manual operation stem. 4) When the operation is completed, be sure to remove the handle and cover the stem with a rubber cap. 5) Be sure that the handle is not attached before turning on the power supply. 6) Use a 8-mm spanner as a handle.

30

70

Figure 9

5) Opening/Closing Speed Limit (ITEM No.19) Opening/closing speed affects the rated thrust. Refer to Table 5 for checking required thrust and attainable speed.
Table 5 SPEED SCALE SPEED (mm/s) OPERATION TIME (s/20 mm) RATED THRUST N lbs

1 16 35 44 50

0.43 2.03 4.05 5.01 5.65

45.52 9.87 4.94 3.99 3.54

3000 3000 2500 2000 1600

674 674 562 450 360

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SPEED (mm/s)

2000

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PROTECTIVE FUNCTIONS
s OVERLOAD PROTECTION When the position signal is deviated from the input signal but the output stem is stuck due to overload or certain malfunction, the PSN1 repeats starting the motor at the maximum torque for several items. If the stem is still stuck after that, the PSN1 outputs an alarm signal (LED turned ON) and stops power supply to the motor. In order to reset the PSN1, apply several times 0% and 100% input signals in turn, or turn off and on the power supply. In case the alarm is off frequently, check for foreign obstacles in the valve, inappropriate adjustments, or retightened gland packing or other possible causes of the overload. Be sure to remove the cause of alarm in order to ensure appropriate life span. s ABNORMAL HIGH TEMPERATURE PROTECTION When the incorporated temperature sensor detects an abnormal temperature increase in the motor, the PSN1 outputs an alarm signal (LED flashes) and stops power supply to the motor until the temperature decreases to an acceptable level. The PSN1 is designed to automatically recover power supply to the motor. It take longer to recover normal operation when ambient temperature is higher. s PROTECTIVE FUSE A fuse is incorporated for protection against overcurrent in the control PCB and motor. If the power LED does not turn on with the power supplied to the actuator, check the fuse status. If a replaced fuse is blown quickly, it is possible that the control PCB and/or motor are damaged. Consult M-System or M-System's representative.

s ENVIRONMENT Inside building. If outside, keep away from direct sunlight. Operating temperature -5 to +55C (23 to 131F) Vibration 2 G max. The actuator must be installed in a place where maintenance and inspection can be conducted. Observe at least 15 cm (0.6 in.) of open space at the top of its cover for maintenance and inspection. Keep away from hazardous atmosphere such like explosive or corrosive gases. s MOUNTING POSITION When installing the PSN1 outdoor or where it is exposed to rain or water drops, adequate precaution must be done for preventing water from entering inside through wiring conduits. DO NOT mount the PSN1 in such direction that the output stem is at the top of the actuator. s PID CONTROL SIGNAL Choose PID parameters carefully so that the MV remains as stable as possible. Unstable control shortens the life of actuator and valve. s GASKET Be sure to return the gasket when you close the cover after wiring or adjustments. s SCREW TORQUE The torque for tightening screws for the cover is between 2.4 3.1 Nm (1.8 2.3 ftlbs). s DESIGNING YOKE When a foreign object is caught in the valve, a thrust as great as 7500 N (1686 lbs) could be applied to the yoke. Observe enough strength when designing mechanical components such like the yoke. When the PSN1 is used on a steam stream in temperature control, its temperature may rise beyond ambient temperature caused by a heat conducted or radiated from piping. Use a longer yoke for effective heat dissipation and apply insulation material.

POINTS OF CAUTION
s GENERAL Remove power supply to the actuator before wiring to it. The motor inside cover and the plate at the top of it may become extremely hot during operation. DO NOT touch them with bare hands. DO NOT loosen the hexagonal screw fixing the lever of angle sensor. Loosening it may cause a malfunction. DO NOT install signal wires and power supply wires together in one duct because it may cause a malfunction due to inductive noises. If they must be installed together, use shielded cables. DO NOT step onto the actuator. DO NOT rest a heavy object on or against it. If input signals are to be turned on/off with power supplied to the actuator, be sure to set the abnormal low input operation mode. The adjustments which are paint locked are for factory use only and should be changed only by qualified M-System personnel. M-System is not liable for any malfunction or inconvenience caused by unauthorized change of them by the user.

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MAINTENANCE
For effective use and longer life of the PSN1, regular checking appropriate for its operating conditions are recommended. Refer to the following table. For repair or parts replacement, contact M-System or representative. ITEM Functioning CHECKING POINT Apply input 0%, 50%, 100%, then back to 50%, 0%. Check the actuator operations and positions at each input value. No abnormal sound is heard during operation. The connector is firmly connected. No breakdown of leadwires. The insulation covers are not torn, not bruised. HOW TO PROCEED Repair or calibration If the alarm indicator LED is on, check that the valve operates lightly and smoothly. Repair or calibration Repair or calibration

Abnormal sound Connector Leadwire

Inside humidity, rust No condensation. No rust. If there is water inside, check the packing. Screws Nut Check that screws and bolts are securely fastened. Check that the nut at the valve stem is not loose.

Remove water, dry the case and inside parts. Replace rusted parts. Calibration. If the packing is damaged, replace it. Re-tighten them. Re-tighten it and calibrate.

s LUBRICATION There is no need of oiling the PSN1 in normal operating conditions. s REGULAR TEST RUNNING If the valve is not frequently operated, run a test operation regularly (once a week, for example) to check proper functions.

TROUBLESHOOTING
TROUBLE Not functioning POSSIBLE CAUSE Power and/or input signal is not supplied. HOW TO PROCEED Check power and input signals, remove the causes of malfunction and secure the signals. Check the wiring. Check the connector and other connecting sections. Replace it with a new one. Turn SW-8 OFF. Repair and calibration. Repair and calibration. Remove the causes of malfunction and secure the signals. Secure the required thrust by slowing. Secure the required level of voltage. Check the controller and cables. Eliminate noise. Repair and calibration. Remove the causes of overload. Repair and calibration. Use the restart limiting timer. Review MV value from the controller. Check the connector and leadwires.

Power and/or input indicator OFF Wiring error. Bad contact. Fuse melted. Power and input indicator ON The actuator is in local calibration mode (SW-8 ON). Control PCB damaged. Motor damaged. Abnormality in power voltage or input signal. Unstable functioning Operating speed is too fast. Power voltage is too low or fluctuating. Input is unstable. Angle sensor is damaged. Alarm indicator ON Overload caused by a foreign object caught in the valve. Actuator mechanism damaged. Alarm indicator flashing Motor temperature is abnormally high. Wiring of the temperature sensor is broken or the connector is detached. For repair or parts replacement, contact M-System or representative.

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LIGHTNING PROTECTION
In order to protect the instruments from surges induced by lightning, use of dedicated lightning arresters is recommended. The M-RESTER lighting arresters are available in M-Systems product catalog.

M-SYSTEM WARRANTY
1. What is covered. M-System Co., Ltd. (M-System) warrants, to the original purchaser only of new M-System products purchased directly from M-System, or from MSystems authorized distributors or resellers, for its own use not for resale, that the M-System products shall be free from defects in materials and workmanship and shall conform to the specifications set forth in the product catalogue applicable to the M-System products for the Warranty Period (see Paragraph 5 below for the Warranty Period of each product). THE ABOVE WARRANTY IS THE ONLY WARRANTY APPLICABLE TO THE M-SYSTEM PRODUCTS AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. 2. What is not covered. This warranty does not cover any M-System product which has been: (1) modified, altered or subjected to abuse, misuse, negligence or accident; (2) improperly installed or installed in conjunction with any equipment for which it was not designed; or (3) damaged or destroyed by disasters such as fire, flood, lightning or earthquake. In no event shall M-System be liable for any special, incidental, consequential or other damages, costs or expenses (including, but not limited to, loss of time, loss of profits, inconvenience or loss of use of any equipment). 3. Remedies. If a defective product is returned to M-System in accordance with the procedures described below, M-System will, at its sole option and expense, either: (1) repair the defective product; (2) replace the defective product; or (3) refund the purchase price for the defective product paid by the purchaser. Except as otherwise provided by applicable state law, these remedies constitute the purchasers sole and exclusive remedies and M-Systems sole and exclusive obligation under this warranty. 4. Warranty Procedure. If the purchaser discovers a failure of the M-System products to conform to the terms of this warranty within the Warranty Period, the purchaser must promptly (and, in any event not more than 30 days after the discovery of such failure) notify the relevant party as described below either by telephone or in writing at the below address to obtain an Authorized Return (AR) number and return the defective product to the relevant party. The designated AR number should be marked on the outside of the return package and on all correspondence related to the defective product. The purchaser shall return, at purchasers expense, defective products only upon receiving an AR number. In order to avoid processing delays, please be sure to include: copies of the original purchase order and sales invoice; the purchasers name, address and phone number; the model and serial numbers of the returned product; and a detailed description of the alleged defect. 5. Warranty Period. Signal Conditioner: 36 months from the date of purchase. M-Rester: 12 months from the date of purchase. Valve Actuator: 18 months from the date of shipment from M-System or 12 months from the date of its installation, whichever comes first. Other Products: 12 months from the date of purchase. From the United States of America, Canada and Mexico: M-SYSTEM TECHNOLOGY, INC. 15028 Beltway Drive Addison, TX 75001 Phone: (972) 385-2277 From all other countries: M-SYSTEM CO., LTD. 5-2-55, Minamitsumori, Nishinari-ku, Osaka 557-0063 JAPAN Phone: (06) 6659-8201

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