Flowserve Valtek StarPac 1 Intelligent Control Systems - Manual (Page 16)

41-16 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
8. Attach the I/P cable wires to the two-screw terminal
block marked 'I/P.' (Red wire to the positive termi-
nal and black wire to the negative terminal.)
9. Detach the second NT board from the new stack.
Attach the three-wire hallpot harness from the new
stack into the hallpot connector. The small 'ears' on
the outer edges of the new brown plug should point
to the outside edge of the hallpot.
10. Plug the board into the bottom board, mounted on
the base, making sure all pins are aligned. Use an
assembly screw to temporarily hold the board in
place.
11. Plug the thermocouple wires into the two-screw
terminal block on this board, noting the correct
polarity. Red wire to 'R' and yellow wire to 'Y.' If
additional wire length is needed, gently pull more
wire from the base. Also, bend the wires close to
the terminal block (excessive looping is not needed
due to the notches cut in the boards).
12. Plug the process sensor connector into the J4
connector on the bottom of this board. On older
StarPac models this connector is a single soldered
eight-pin connector. On more recent models have
two sensor cables which are terminated separately
with crimped on pins and a brown housing. If the
cable arrangement has been separated, be sure to
plug the correct sensor into the correct half of the
board connector (P
1
to P
1
and P
2
to P
2
section).
13. Plug in the remaining boards. (Be sure to check the
alignment of the pins.) Secure the board stack
together by placing the one spacered assembly
screw in the upper right hand corner.
14. Set the dip switches on the digital board to match
the settings on the old board stack.
15. Reaffirm that all connections are properly aligned
and secure.
16. Apply 24 VDC power. The liquid crystal display
should display the version number and then the
default display mode.
17. Establish communications and use the StarTalk
software to upload the saved .CCT file for this
system into the new NT module.
18. Replace the plastic shroud and the remaining two
assembly screws. Make sure all wiring is beneath
the shroud and that no wires are trapped between
the bottom board and the vibration isolators in
which the assembly screws attach.
19. Turn the air supply back on to the actuator.
20. After verifying that stroking the valve is safe, use
the calibration menu to first recalibrate the actuator
pressure sensor, and then perform a valve stroke
calibration. During this calibration, watch the posi-
tion ADC values to ensure that the hallpot adjust-
ment is not at its limit on either end of stroke. (If
needed, readjust the hallpot shaft setting to keep
the shaft rotation within the operating range of the
hallpot, then recalibrate.)
21. Secure both the large electronics and the smaller
interface covers.
22. Use the StarTalk software to calibrate the process
sensors and verify the other operational param-
eters of the system.
23. Return the system to operation.
Board Stack Replacement (Models SPxx)
Inside the electronic housing cover and under the white
plastic shroud of a StarPac unit are five printed circuit
boards, together referred to as the board stack. This
design allows each board to have a single purpose,
which simplifies troubleshooting and diagnostic
procedures.
If, after consulting with the local Flowserve or factory
representative, the StarPac system’s computer board
stack is found defective and needs replacement, refer
to Figures 2, 7, 13 and 14 then proceed as follows.
NOTE: Make sure a current copy of the configuration
file exists.
1. Download or find a backup copy of .CCT File.
2. Disconnect the power and air supply to the unit.
3. Remove the StarPac electronics assembly cover.
WARNING: Never remove the StarPac electron-
ics assembly cover if explosive atmospheres
are present; otherwise, injury to personnel can
occur.
4. Remove the plastic shroud by unscrewing the three
board assembly screws. Carefully grasp the top
four computer boards and pull them away from the
bottom board holding it in place. Disconnect the
three-wire hallpot and eight-wire process harness
connectors and set the four computer boards aside.
5. Disconnect the temperature sensor wires from the
terminal block marked 'J102' on the bottom com-
puter board.
6. Loosen the set screw on the hallpot base connec-
tor. Refer to Figure 13.
7. Disconnect the three remaining wire harness con-
nections and carefully remove the bottom computer
board from the StarPac housing base. Some resis-
tance will be felt as the air pressure connections
disengage.
8. From the new computer board stack, install the
bottom computer board on the StarPac device