Flowserve F75 Series Fail-Safe Module - Manual (Page 2)

2 Series F75 Fail-Safe Module WCAIM2029
2.2 Proper wire size should be selected from the table below for DC
power wiring between Series F75 Module and actuator to ensure
proper operation.
Cable Distance From Wire Size for
Module to Actuator 10-23 75 Actuator
Up to 50 Feet 14 AWG
100 Feet 12 AWG
200 Feet 10 AWG*
For longer distances consult factory.
* Because actuator strip wire size is limited to 12 AWG, 10 AWG wires will have to be
run to an appropriate NEMA rated box located close to actuator and 12 AWG wire run
from junction box to actuator.
2.3 Wire Series F75 Module to actuator as shown in Figure 1. AC
power input can be either 120 VAC or 240 VAC, single-phase
50/60 Hz (see Figure 2 for the 120/240 connections).
CAUTION: Internal batteries should not be connected until
actuator operation verification procedure 2.3.1 through 2.3.5 is
accomplished. Note that one lead is disconnected and insulated.
NOTE: All wiring to terminal strips should be inserted only to mid-
point of terminal strips.
See 75 Actuator Installation, Operation and Maintenance
Instruction Manual for proper actuator grounding procedure.
Procedure to be followed:
2.3.1 Connect the proper single-phase AC power to the module
at terminals 9-10. Fuse protection on this line should be no
less than two amps. This AC power should be extended
from the F75 Module to the actuator terminals 11 and 12
to be used for heater if the actuator is so equipped.
2.3.2 Customer-provided external circuit for controlling the
open and closed function of the actuator/valve assembly
is to be wired between terminals 4 and 5.
2.3.3 Apply AC power to the module.
Press the “Reset” switch on the module’s front panel.
2.3.4 Close contacts between terminals 4 and 5 of the external
control circuit. The actuator will operate CCW. (For
standard fail-closed operation, the actuator/valve
assembly will be moving CCW to open.)
2.3.5 Open the contacts between terminals 4 and 5 of the
external control circuit. The actuator/valve assembly will
now move clockwise to the fail-safe position.
Leave the actuator/valve assembly in the fail-safe (closed)
position, and disconnect the module from AC power.
2.3.6 Having verified proper actuator operation under normal
line power conditions, the fail safe module’s batteries may
now be connected. AC power should be disconnected.
If two 12-volt batteries are shipped and not installed, they
have to be installed and wired as shown in Figure 3 and 4.
Before placing batteries into position inside the enclosure,
attach the black, red, and brown connector wires to the
battery terminals as shown in Figure 4.
2.3.7 Slide the batteries into position and secure with the
battery retention clamps 15 and 21 as shown in Figure 3
and 4.
2.3.8 After all battery wires are connected, verify that a minimum
of 24 VDC is available at terminals 6 and 7 and terminals 2
and 3 of the F75 Module. See note after paragraph 2.3.10.
If voltage is lower, allow at least 4 hours of operation on
the charger before operating the actuator.
2.3.9 Reapply AC power to the F75 Module.
2.3.10 Standard failure mode of operation is fail-close
(clockwise). For other failure modes see wiring per
paragraph 2.4 “Wiring for different failure modes”.
NOTE: Voltage for fully charged batteries with the F75 AC
input power off should be a minimum of 24 VDC ± .5 volts.
When power is applied, this voltage should increase by a
minimum of .5 volts within the first few hours of operation,
indicating proper charging action. When first installed, the
batteries should be allowed to reach the fully charged
condition before the F75 module is put into service. The
full-charge condition is indicated when the green panel
indicator is lighted and terminals 6 and 7 voltage is
between 27 and 28 volts with the F75 AC power input on.
2.4 Wiring for Different Failure Modes
Valve Wiring Between
Failure Actuator Actuator and Series
Mode Size Actuator Motor Wiring F75 Module
Actuator Module
Terminal # Terminal #
Close 10, 20 Red to Terminal #1. 1 2
(Clockwise) *(Fast) Black to Blue Wire Connecting 3 1
(Standard) Limit Switches. 4 3
Open 10, 20 Black to Terminal #1. 1 2
(Counter- *(Fast) Red to Blue Wire Connecting 3 3
Clockwise) Limit Switches. 4 1
Close 12, 22, 23 Black to Terminal #1. 1 2
(Clockwise) *(Slow) Red to Blue Wire Connecting 3 1
Limit Switches. 4 3
Open 12, 22, 23 Red to Terminal #1. 1 2
(Counter- *(Slow) Black to Blue Wire Connecting 3 3
Clockwise) Limit Switches. 4 1
* Marked indication “FAST” or “SLOW” on gear box of actuator will be located next to
the actuator’s shaft.
2.4.1 If heater option is used, an AC heater must be used. The
heater is wired to terminals 11 and 12 of 75 actuator
terminal strip that are then wired to terminals 9 and 10 of
the fail-safe module.
Flow Control Division
Worcester Actuation Systems