10260 Series Actuators Installation, Operation and Maintenance Manual Rev. 2 1/98

Transcription

1 10260 Series Actuators Installation, Operation and Maintenance Manual Rev. 2 1/98

2 10260 Series Actuators Installation, Operation and Maintenance Manual Copyright, Notices, and Trademarks Printed in U.S.A. Copyright 1997, 1998 by Honeywell Inc. Revision 2.0 1/98 While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customer. In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice. CE conformity: This product is in conformance with the protection requirements of the following European Council Directive: 89/336/EEC, the EMC directive and 73/23/EEC, the Low Voltage Directive. Conformance of this product with any other CE Mark Directive(s) shall not be assumed. CSA conformity: When specifically identified by model number this product is in conformance with the protection requirements of the following Canadian Standards Association - Class , CSA Std. C22.2 No , CSA Std. C22.2 No M1987. Conformance of this product with any other CSA Standard(s) shall not be assumed. Attention The emission limits of EN are designed to provide reasonable protection against harmful interference when this equipment is operated in an industrial environment. Operation of this equipment in a residential area may cause harmful interference. This equipment generates, uses, and can radiate radio frequency energy and may cause interference to radio and television reception when the equipment is used closer than 30 m to the antenna(e). In special cases, when highly susceptible apparatus is used in close proximity, the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment! This CAUTION symbol on the equipment refers the user to the Product Manual for additional information. This symbol appears next to required information in the manual WARNING, risk of electric shock. This symbol warns the user of a potential shock hazard where voltages greater than 30 Vrms, 42,4V peak, or 60 Vdc may be accessible Protective earth terminal. Provided for connection of the protective earth (green or green/yell) supply system conductor. Honeywell Industrial Automation and Control Automation College 2820 West Kelton Lane Phoenix, AZ (602) II Series Actuator Installation, Operation and Maintenance Manual 1/98

3 Addendum TO Series Actuators Installation, Operation and Maintenance Manual Introduction This addendum contains changes for revision 2, dated 1/98, of the Series Actuators operator manual document # Please update your manual accordingly. Delete kits , , and from "Field Change Kits" on page 44, as shown below: FIELD CHANGE KITS Description Part No. One extra limit switch Two extra limit switches One extra limit switch to convert from MSG Table II, option 01zz to 02xx and 16xx to 17xx One extra limit switch to convert from MSG Table II, option 02xx to 03xx and 17xx to 18xx Rotary position sensor 0-16 vdc Rotary position sensor 4-20 ma Motor position 4-20 ma input (120V) /01 Addendum of 2

4 Warranty/Remedy Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer s sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a particular purpose. Specifications may change without notice. The information we supply is believed to be accurate and reliable as of this printing. However, we assume no responsibility for its use. While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the customer to determine the suitability of the product in the application. Sensing and Control Honeywell 11 West Spring Street Freeport, IL Printed in USA

5 About This Document Abstract This document is intended for the purpose of supporting the use of the Series Actuators, the Feedback Assembly and Motor Positioner. Revision Notes The following list provides notes concerning all revisions of this document. Rev. ID Date Notes 0 9/96 This is the initial release of the Honeywell version of this document. It is a merging of the original Series Actuator manual (L&N #077652) with the manuals for the Feedback Assembly (L&N #177415) and the Motor Positioner (L&N #277751). All pertinent information has been retained and updated. 1 4/97 This release is being made to correct various typos and to replace the old Catalog system with the new Honeywell MSG. The Section 9, Standard Drawings has been removed. 2 1/98 This release is being made to correct various typos, omissions and to update the MSG. Metric equivalents have been added where appropriate. References Honeywell Documents The following list identifies all Honeywell documents that may be sources of reference for the material discussed in this publication. Document Title ID # Binder Title Binder ID # Contacts The following list identifies important contacts within Honeywell. Organization Telephone Address Honeywell technical Assistance Center TAC Voice 1100 Virginia Drive Fort Washington, PA / Series Actuator Installation, Operation and Maintenance Manual III

6 10260 Series Actuators Installation, Operation and Maintenance Manual Contents 1. INTRODUCTION Overview... 1 Introduction... 1 In this chapter Series Actuators... 1 Description Feedback Assembly... 2 Introduction... 2 Description Motor Positioner... 2 Introduction... 2 Description SPECIFICATIONS AND MODEL SELECTION GUIDE Overview... 5 Introduction... 5 In this chapter Series Actuator Specifications... 5 Physical... 5 Torque Settings of Crank Arm Bolts... 6 Electrical Feedback Assembly Specifications... 7 Physical... 7 Electrical Motor Positioner Specifications... 8 Physical... 8 Electrical Series Actuator Model Selection Guide Feedback Assembly Model Selection Guide Motor Positioner Option Model Selection Guide INSTALLATION Overview Introduction In this chapter Before Starting Installation Unpacking Precautions for the Series Actuators Mechanical Installation General IV Series Actuator Installation, Operation and Maintenance Manual 1/98

7 Linkage General Information Constant Torque Linkage Variable Torque Linkage Turnbuckle Linkage Kits Pipe Linkage Kits Old and New Actuator Crank Arms Electrical (Wiring) Installation General Wiring Recommendations Series Wiring Feedback Assembly Wiring Motor Positioner Wiring FEEDBACK ASSEMBLY CALIBRATION Overview Introduction In this chapter Initial Calibration for Assembly (0-16 VDC Output) Initial Calibration for Assembly (4-20 ma Output) Reversing Cam Program Sensor Output Characterization; Plotting and Cutting Cam Profile Purpose of Characterization Cutting a Cam MOTOR POSITIONER CALIBRATION Overview Introduction In this chapter Available Adjustments ZERO and SPAN Adjustments Fail-safe Adjustments Slidewire Failure Settings Input Signal Loss Settings Other Adjustments Filtering Deadband STARTUP Overview Introduction In this chapter Operations Checklist MAINTENANCE / Series Actuator Installation, Operation and Maintenance Manual V

8 10260 Series Actuators Installation, Operation and Maintenance Manual 7.1 Overview Introduction In this chapter Series Actuator Basic Maintenance Slidewire Main Gear Lubrication Spur Gear Lubrication Feedback Assembly Maintenance Troubleshooting Test Equipment Isolation Checks Replacing Components Motor Positioner Maintenance REPLACEMENT/RECOMMENDED SPARE PARTS Overview Introduction In this chapter Series Actuator Common Spare Parts List Models , , AND Models and Models , and FIELD CHANGE KITS Maintenance Kits for the Series Actuators Models , , and Kit Part Number Models and Kit Part Number Models Kit Part Number Models and Kit Part Number Linkage Parts Linkage Kit Part Numbers Feedback Assembly Motor Positioner Assembly Honeywell Actuator Linkage Design Software VI Series Actuator Installation, Operation and Maintenance Manual 1/98

9 Tables Table 3-1 Recommended Minimum Wire Size 27 Table 5-1 Available Adjustments 33 1/ Series Actuator Installation, Operation and Maintenance Manual VII

10 10260 Series Actuators Installation, Operation and Maintenance Manual Figures Figure 1-1 Rotary Position Sensor Assembly in Series Actuators 3 Figure 1-2 Motor Positioner Printed Circuit Assembly 4 Figure 3-1 Constant Torque Linkage 21 Figure 3-2 Constant Torque Profile 21 Figure 3-3 Variable Torque Linkage 22 Figure 3-4 Variable Torque Profile 22 Figure 3-5 Turnbuckle Linkage Kit 23 Figure 3-6 Pipe Linkage Kit 23 Figure 3-7 Old and New Crank Arms 24 Figure 3-8 Outline and Dimensions of , -620, -640, -660, -670, -680, and -690 Actuators 25 Figure 3-9 Outline and dimensions of and Actuators 26 Figure Series Actuator, Interior View 27 Figure 4-1 Plot of program on cam blank for Series Actuators 32 VIII Series Actuator Installation, Operation and Maintenance Manual 1/98

11 Introduction 1. Introduction 1.1 Overview Introduction The Series Industrial Actuators consist of a motor, a gear train and an output shaft mounted in a die cast aluminum housing. In addition, a motor positioner, switches, slidewires, or a combination of both may be mounted inside the housing. Thus, the motor drives the gear train which in turn drives the output shaft to position a damper, valve, or similar device while operating any internally mounted switches or slidewires. The actuators are designed for use with Honeywell controllers or other 1-5 Volt or 4-20 ma controllers. This chapter gives the user a high level overview of the Series Actuators, the Feedback Assembly and Motor Positioner. In this chapter In this chapter the following topics are discussed. Topic See Page Overview Series Actuators 1 Feedback Assembly 2 Motor Positioner Series Actuators Description All of the actuators in this series are similar. The features that are common to all actuators are listed in the specifications. The features of a particular actuator are designated by the catalog number and suffixes. Differences in the output torque between the , , and Actuators result from using the same motor with different gear trains. A high torque motor is provided with the , and Actuators. The , and motors are longer than the others, and together with other differences give these actuators the highest output torque. All of the actuators are equipped with self-braking motors which contribute substantially to the excellent positioning ability of these actuators. Optional features included with the actuator are identified by suffixes to the catalog number. 1/ Series Actuator Installation, Operation and Maintenance Manual 1

12 10260 Series Actuators Installation, Operation and Maintenance Manual 1.3 Feedback Assembly Introduction Description The inclusion of the rotary position sensor assembly in the actuators is intended to replace the slidewire and wiper assembly for position feedback applications. The rotary position sensor assembly for this application provides two distinct advantages over the use of the slidewire: 1. it is a contactless device which reduces maintenance, and 2. its output is characterizable, i.e., its output versus input characteristic can be changed to meet various process requirements. The feedback assembly consists of a position sensor, an electronics assembly, and a cam and cam follower assembly, as shown in Figure 1-1. As the output shaft rotates, the cam also rotates. The cam follower transfers cam rotation to rotation of the position sensor. The position sensor is a rotary variable differential transformer (RVDT) which converts the physical angular displacement into an electrical signal. The electronic assembly translates this electrical signal into 4-20 ma or 0-16 vdc which is indicative of 0-100% output shaft travel. 1.4 Motor Positioner Introduction Description The Honeywell Motor Positioner accepts a current input signal to control the position of an actuator. The Honeywell Motor Positioner makes positive position control possible with current adjusting type (C.A.T.) controllers. The Motor Positioner operates raise/lower switch contacts (triacs) which control power to the reversing motor in the actuator. The actuator s integral slidewire provides the position feedback signal to the Motor Positioner. Feedback slidewires from 100 to 1000 ohms may be used. (A 1000 ohm slidewire is most common.) Input ranges are adjustable from 0.2 to 1 V dc, up to 1 to 5 V dc. By use of an appropriate shunt resistor, controller current outputs of 4-20 ma dc, 1-5 ma dc, ma dc, can be accommodated. Fail-safe features are also provided. On loss of input signal, the Motor Positioner may be preset to drive the motor upscale, downscale, to a particular position, or to stop where it is. In the event of actuator slidewire failure (broken wiper), the Motor Positioner can be set to drive the motor fully upscale or downscale. The Motor Positioner will also accept slidewire input. For master/follower applications, the Motor Positioner will position a follower actuator in accordance with a slidewire input signal from a master actuator. The ratio between master and follower movement is adjustable by means of a span control. A bias offset may also be induced between master and follower by means of a zero adjustment. For follower operations in master-follower systems, the master actuator retransmitting slidewire can range from 50 to 1000 ohms. The Motor Positioner is a printed circuit board which is integrally mounted in a Series Actuator utilizing a modified slidewire compartment cover. See Figure 1-2. The slidewire compartment cover is gasketted to provide weather resistance Series Actuator Installation, Operation and Maintenance Manual 1/98

13 Introduction TOP VIEW Cam Plain Washer Spring Washer Cam Retaining Nut Cam Follower Assembly Rotary Position Sensor Electronics Assembly Spring Plate Assembly FRONT VIEW a/n Figure 1-1 Rotary Position Sensor Assembly in Series Actuators 1/ Series Actuator Installation, Operation and Maintenance Manual 3

14 10260 Series Actuators Installation, Operation and Maintenance Manual a/n Figure 1-2 Motor Positioner Printed Circuit Assembly Series Actuator Installation, Operation and Maintenance Manual 1/98

15 Introduction 2. Specifications and Model Selection Guide 2.1 Overview Introduction This chapter provides the user with the specifications for the Series Actuators, the Feedback Assembly and Motor Positioner. In this chapter In this chapter the following topics are covered. Topic See Page Overview Series Actuator Specifications 5 Feedback Assembly Specifications 7 Motor Positioner Specifications Series Actuator Model Selection Guide 10 Feedback Assembly Model Selection Guide 17 Motor Positioner Model Selection Guide Series Actuator Specifications Physical Dimensions: and : 8 7/16" x 12" x12" (214 x 305 x 305 mm) All others: 8 5/16" x 9 13/16"x 11 ¾" (211 x 249 x 298 mm) Weight: 40 LB (18 kg) net. 44 LB (20kg) shipping Enclosure: Aluminum alloy casting, precision machined. Finished light gray powder coat Operating Temperature: -20 to +150 F (-30 to C) Motor: No-burnout, continuous duty, synchronous permanent magnet motor. Totally enclosed with Class H insulation. Non-coasting, stays in place on loss of power. Output Torque: 5 to 300 lb-ft (7 to 410 NM) 1/ Series Actuator Installation, Operation and Maintenance Manual 5

16 10260 Series Actuators Installation, Operation and Maintenance Manual Full Travel Stroking time: 10 to 60 seconds (60 Hz), 12 to 72 seconds (50 Hz) Main Slidewire: 1000 ohms ±10%. 3.1 Watts at 32 F (0 0 C)ambient, decreasing linearly with rising ambient temperature to zero at 185 F (85 0 C). Limit Switches: Two SPDT provided, one for CW and one for CCW limit of travel. Rated for 10 A at 125 V ac, 5 A at 250 V ac Scale: Two; one CW, one CCW, 0 to 100 uniform. Corresponds to full crank arm travel. Crank Arm: Effective length is adjustable from 1 7/16" (37 mm) to a maximum of 5" (127 mm). Additional rod adapter sizes are available. See catalog numbering system, Suffix D. Direction of Rotation: Clock wise rotation is obtained by applying line voltage to terminals 2 and 4. Counter clockwise rotation is obtained by applying line voltage to terminals 2 and 5. Handwheel: For manual positioning of the actuator in the event of a power failure. Output Shaft: 1" (25.4mm) diameter, 1 ½" (38 mm) long. A knurled shaft, 2" (51 mm)long, is standard on and ; optional on other models. Crank Arm Rotation: 85 degrees between 0 and 100 on scale. Mechanical Stops: To prevent over-travel during operation. Installation Category: II Pollution degree: 2 Altitude: Less than 200 meters Torque Settings of Crank Arm Bolts Clamp Bolt: Standard arm ( P/N ) - 1 7/16 to 5 inch (37 to 127 mm) adjustment: 85 lb-ft (115 NM) Optional Long Arm (P/N ) - 0 to12 inch (0 to 305 mm) adjustment: 85 lb-ft (115 NM) Rod End Bolt: Standard and long arms: 30 to 35 1b-ft (40 to 47 NM) Electrical Power Input: VA Rating: 120 VAC single phase, 50 or 60 Hz 240 VAC single phase, 50 or 60 Hz No load, full load, locked rotor Series Actuator Installation, Operation and Maintenance Manual 1/98

17 Introduction Primary Model No. Secondary Model No. 120 V, 50/60 Hz 240V, 50/60 Hz , , , except -XX8X 48 VA 36 VA , except -XX8X 120 VA N/A , , , A , , , except -XX8X 96 VA 36 VA -XX8X 93 VA 81 VA , XX8X 165 VA N/A , , , A -XX8X 141 VA 81 VA 2.3 Feedback Assembly Specifications Physical Electrical Dimensions: Sensor: Approximately x (29 x 48 mm); shaft diameter x 0.4 (4.75 x 10.2 mm) Electronics Assembly: x (105 x 54 mm) Ambient Temperature: -22 F to 150 F (-30 C to +65 C) Temperature Coefficient: 0.036% per degree C. Hysteresis: Less than 0.2% of full scale Power Input Electronics Assembly: 15 to 24 volts DC with a maximum current drain of 125 ma Maximum allowable input voltage is 28 volts DC Electronics Assembly: 12 volts DC minimum plus 1 volt additional for each 50 ohms of load impedance. 28 volts DC maximum. Power Output Electronics Assembly: Minimum: volts DC +/ volts. Maximum with maximum profile cam.: 20 volts DC with +/- 10% adjustment Maximum with standard cam: 16 volts DC 1/ Series Actuator Installation, Operation and Maintenance Manual 7

18 10260 Series Actuators Installation, Operation and Maintenance Manual Electronics Assembly: 4 to 20 ma for 60 to 90 span of sensor rotation (standard sensor cam is cut to rotate sensor 68 for 100% actuator stroke). 4 to 20 ma into 600 ohm load (load resistance dependent on power supply). Output impedance: Equal to or less than 500 ohms Load Requirement: ohms less than 600 ohms 2.4 Motor Positioner Specifications Physical Operating Temperature: -40 F to +150 F (-40 C to + 65 C). Storage Temperature: -40 F to +200 F (-40 C to +93 C) Relative Humidity: Fully operable over the range of 0-100% R.H. non-condensing. Radio Frequency Interference: Per SAMA PMC Power Supply: 120 V, 60 or 50 Hz. For Retransmitter Slidewire: Internal 1.2 V dc. Power requirements: 45 VA. Terminations: Internal terminal boards. Electrical Input Range: 1 to 5 V dc. Use appropriate shunt resistor for current range. Input Resistor Part No ma 250 ohms ± 0.1% Input Impedance: * Input Input Impedance 4-20 ma 250 ohms 1-5 V with fail-safe Jumper W2 10K ohms 1-5 V without fail-safe Jumper W2 10M ohms Retransmitter Slidewire: Feedback Slidewire: Span: Zero Suppression: Input Filter: 50 to 1000 ohms. 100 to 1000 ohms. Adjustable from 0.8 to 4.0 V dc. 100% of span. Adjustable to smooth input signal Series Actuator Installation, Operation and Maintenance Manual 1/98

19 Introduction Maximum Input Voltage: Output: 5 V dc. Two triac switches for raise-or-lower motor operation. Rated 1.0 amp. Transient voltage protection provided. Actuator Sensitivity: Adjustable deadband from 1% to 5%. Fail-safe: If input falls below 2% of span, there are four choices selected by a movable jumper: stop, go full upscale, go full downscale, or go to a selected (adjustable) position. If actuator slidewire fails (wiper breaks), a jumper selects either full upscale or downscale position. * If the input is a voltage rather than current, a 10K resistor must be installed across the input terminals to insure proper operation of the signal failure circuit. 1/ Series Actuator Installation, Operation and Maintenance Manual 9

20 10260 Series Actuators Installation, Operation and Maintenance Manual Series Actuator Model Selection Guide KEY NUMBER Selection Output Torque (lb-ft) Full Travel Stroking - Time in Seconds 50 Hz 60 Hz 5 (7 NM) (20 NM) (40 NM) (70 NM) (55 NM) (100Nm) (200 NM) (30 NM) A 200 (270 NM) (400 NM) TABLE I - POWER SUPPLY - SINGLE PHASE 120 VAC 60 Hz VAC 50 Hz 2 220/240 VAC 60 Hz 3 220/240 VAC 50 Hz 4 TABLE II - CONTROLS Auto-Manual Switch/Limit Switches Input/Feedback Signal 1 CW & 1 CCW Limit Switch 1000 Ohm Main Slidewire Ohm Main Slidewire Ohm Main Slidewire Ohm Main Slidewire/ Ohm Auxiliary Slidewire 1000 Ohm Main Slidewire/ Ohm Auxiliary Slidewire 135 Ohm Main Slidewire/ Ohm Auxiliary Slidewire Main Slidewire Omitted 0050 Contactless Rotary Position Sensor 0060 (0-16 VDC Output) Contactless Rotary Position Sensor 0070 (4-20 ma Output) Motor Position 4-20 ma Input Series Actuator Installation, Operation and Maintenance Manual 1/98

21 Introduction A 30 TABLE II - CONTROLS (continued) Selection 50 Auto-Manual Switch/Limit Switches Input/Feedback Signal 1 CW & 1 CCW Limit Switch Motor Position 4-20 ma Input/ 0081 (cont d) Contactless Rotary Position Sensor (4-20 ma Output) Motor Position 4-20 ma Input/ Ohm Auxiliary Slidewire 1 CW & 1 CCW Limit Switch/ 1000 Ohm Main Slidewire Additional Auxiliary SPDT Switch 100 Ohm Main Slidewire/ Ohm Auxiliary Slidewire 135 Ohm Main Slidewire Ohm Main Slidewire/ Ohm Auxiliary Slidewire 1000 Ohm Main Slidewire/ Ohm Auxiliary Slidewire 135 Ohm Main Slidewire/ Ohm Auxiliary Slidewire Contactless Rotary Position Sensor 0160 (0-16 VDC Output) Contactless Rotary Position Sensor 0170 (4-20 ma Output) Motor Position 4-20 ma Input 0180 Motor Position 4-20 ma Input/ Ohm Auxiliary Slidewire 1 CW & 1 CCW Limit Switch/ 1000 Ohm Main Slidewire Additional Auxiliary SPDT 135 Ohm Main Slidewire 0234 Switches 1000 Ohm Main Slidewire/ Ohm Auxiliary Slidewire 1/ Series Actuator Installation, Operation and Maintenance Manual 11

22 10260 Series Actuators Installation, Operation and Maintenance Manual A 30 TABLE II - CONTROLS (continued) Selection 50 Auto-Manual Switch/Limit Switches Input/Feedback Signal 1 CW & 1 CCW Limit Switch/ 1000 Ohm Main Slidewire/ Additional Auxiliary SPDT 135 Ohm Auxiliary Slidewire Switches 135 Ohm Main Slidewire/ Ohm Auxiliary Slidewire Contactless Rotary Position Sensor 0260 (0-16 VDC Output) Contactless Rotary Position Sensor ma Output Motor Position 4-20 ma Input 0280 Motor Position 4-20 ma Input/ Ohm Auxiliary Slidewire 1 CW & 1 CCW Limit Switch Full Stroke/Two Position Controller CW & 1 CCW Limit Switch/ 1000 Ohm Main Slidewire Additional Auxiliary SPDT Switches 1 CW & CCW Limit Switch/ 1000 Ohm Main Slidewire 1500 Auto-Manual Switch 135 Ohm Main Slidewire 1534 with "Out of Auto" Contact 1000 Ohm Main Slidewire/ Ohm Auxiliary Slidewire 1000 Ohm Main Slidewire/ Ohm Auxiliary Slidewire Contactless Rotary Position Sensor 1560 (0-16 VDC Output) Series Actuator Installation, Operation and Maintenance Manual 1/98

23 Introduction A 30 TABLE II - CONTROLS (continued) Selection 50 Auto-Manual Switch/Limit Switches Input/Feedback Signal 1 CW & 1 CCW Limit Switch/ Contactless Rotary Position Sensor 1570 Auto-Manual Switch (4-20 ma Output) with "Out of Auto" Contact Motor Position 4-20 ma Input 1580 Motor Position 4-20 ma Input/ 1581 Contactless Rotary Position Sensor (4-20 ma Output) Motor Position 4-20 ma Input/ Ohm Auxiliary Slidewire 1 CW & 1 CCW Limit Switch/ 1000 Ohm Main Slidewire Additional Auxiliary SPDT 135 Ohm Main Slidewire 1634 Switch/Auto-Manual Switch 1000 Ohm Main Slidewire/ 1641 with "Out of Auto" Contact 1000 Ohm Auxiliary Slidewire 1000 Ohm Main Slidewire/ Ohm Auxiliary Slidewire 135 Ohm Main Slidewire/ Ohm Auxiliary Slidewire Contactless Rotary Position Sensor 1660 (0-16 VDC Output) Contactless Rotary Position Sensor 1670 (4-20 ma Output) Motor Position 4-20 ma Input 1680 Motor Position 4-20 ma Input/ Ohm Auxiliary Slidewire 1 CW & 1 CCW Limit Switch/ 1000 Ohm Main Slidewire Additional Auxiliary SPDT 135 Ohm Main Slidewire 1734 Switches/Auto-Manual Switch 1000 Ohm Main Slidewire/ 1741 with "Out of Auto" Contact 1000 Ohm Auxiliary Slidewire / Series Actuator Installation, Operation and Maintenance Manual 13

24 10260 Series Actuators Installation, Operation and Maintenance Manual A 30 TABLE II - CONTROLS (continued) Selection 50 Auto-Manual Switch/Limit Switches Input/Feedback Signal 1 CW & 1 CCW Limit Switch/ 1000 Ohm Main Slidewire/ Additional Auxiliary SPDT 135 Ohm Auxiliary Slidewire Switches/Auto-Manual Switch 135 Ohm Main Slidewire/ 1743 with "Out of Auto" Contact 135 Ohm Auxiliary Slidewire Contactless Rotary Position Sensor 1770 (4-20 ma Output) Motor Position 4-20 ma Input CW & 1 CCW Limit Switch/ 1000 Ohm Main Slidewire Additional Auxiliary SPDT Switches/Auto-Manual Switch with "Out of Auto" Contact Two Position Control None 2251 Three Position Control None 2351 Four Position Control None 2451 Five Position Control None 2551 Six Position Control None Series Actuator Installation, Operation and Maintenance Manual 1/98

25 Introduction TABLE III - OPTIONS 9A 30 A Shafts Standard 0XXXXXXX 5 Inch Extension 1XXXXXXX d B Weatherproof No X0XXXXXX Yes NEMA 4 X1XXXXXX C Projecting Scale No XX0XXXXX 3/4 Inch Shaft Coupling XX1XXXXX e e 3/4 Inch Shaft Coupling, Reverse Acting XX2XXXXX e e 1 Inch Shaft Coupling XX3XXXXX e e 1 Inch Shaft Coupling, Reverse Acting XX4XXXXX e e D Crank Arm 5 Inch Standard XXX0XXXX None XXX1XXXX 12 Inch XXX2XXXX E Rod Adapter None XXXX0XXX 3/8 Inch XXXX1XXX 5/8 Inch XXXX2XXX 7/16 Inch XXXX3XXX 7/8 Inch XXXX4XXX F Linkage Kits None XXXXX0XX 12 to 16 Inch Turnbuckle Kit XXXXX1XX 16 to 20 Inch Turnbuckle Kit XXXXX2XX 20 to 24 Inch Turnbuckle Kit XXXXX3XX 1 Inch Pipe Kit XXXXX4XX 1.5 Inch Pipe Kit XXXXX5XX 2 Inch Pipe Kit XXXXX6XX G Approval None XXXXXX0X CE-Compliant XXXXXX1X CSA-Compliant XXXXXX2X f f H Tagging None XXXXXXX0 Linen (Note 2) XXXXXXX1 Stainless Steel (Note 2) XXXXXXX2 1/ Series Actuator Installation, Operation and Maintenance Manual 15

26 10260 Series Actuators Installation, Operation and Maintenance Manual TABLE IV - Factory Use Only 9A 30 No Selection 00 Reverse 4-20 ma Input Rotation 01 c c Direct Coupled, Bracket and Coupling for 1" Shaft 04 RESTRICTIONS Restriction Letter Available Only With Not Available With Table Selection Table Selection c II 0080, 0081, 0083, 0180, 0183, 0280, 0283, 1580, 1581, 1583, 1680, 1683, 1780 and III XX0XXXXX d III XX0XXXXX e III XXX100XX f II 0060, 0070, 0081, 0160, 0170, 0260, 0270, 1560, 1570, 1581, 1660, 1670, 1770 Notes: 1. To specify any Standard Actuator select: Key Number I II III IV KKKKKKK X Customer must supply tagging information: Up to 3 lines allowed. (22 characters for each line) 3. If actuator is used with external motor positioner, a thirty ohm current limiting resistor is required. Order Part No Resistor Kit Series Actuator Installation, Operation and Maintenance Manual 1/98

27 Introduction 2.6 Feedback Assembly Model Selection Guide There is no separate MSG for the Feedback Assembly. It is included as part of the Series Model Selection Guide. (Table II - options xx60, xx70 and xx81). 2.7 Motor Positioner Option Model Selection Guide There is no separate MSG for the Motor Positioner. It is included as part of the Series Model Selection Guide. (Table II - xx80, xx81, and xx83). 1/ Series Actuator Installation, Operation and Maintenance Manual 17

28 10260 Series Actuators Installation, Operation and Maintenance Manual Series Actuator Installation, Operation and Maintenance Manual 1/98

29 Installation 3. Installation 3.1 Overview Introduction This chapter provides the user with all the mechanical and electrical information required to get the Series Actuator up and running in the user s specific application. This chapter also includes the installation instructions for the Feedback Assembly and the Motor Positioner options in the event that these options have been purchased by the user. In this chapter In this chapter the following topics are discussed. Topic See Page Overview 19 Before Starting Installation 19 Mechanical Installation 20 Electrical (Wiring) Installation Before Starting Installation Unpacking Examine the shipping container carefully before opening it. If there are visible signs of damage, do not open the container. Notify the carrier and Honeywell immediately. If there is no visible damage, open the container and compare the contents with the packing list. Notify the carrier and Honeywell immediately if there is equipment damage or shortage. Please do not return goods without contacting Honeywell in advance. Precautions for the Series Actuators The following precautions should be taken when selecting an installation site. The actuator should be shielded from rain or snow unless the NEMA 4 option was selected. There must be sufficient space around the actuator for the removal of all covers to permit inspection or cleaning of parts and to provide access to the handwheel. Auxiliary shielding should be used to protect the actuator from excessive heat or cold outside of the rating of the Actuator and from corrosive elements Ambient temperature should not exceed 150 F (65 0 C). The minimum low temperature limit of -20 F (-30 0 C). 1/ Series Actuator Installation, Operation and Maintenance Manual 19

30 10260 Series Actuators Installation, Operation and Maintenance Manual 3.3 Mechanical Installation General Install the series actuator in a convenient location in any orientation. Firmly bolt the to a mounting surface that will not distort when subjected to the torque stresses generated by the actuator. The output shaft of the actuator should be parallel to the output shaft of the driven device. The output shaft crank arm is fully adjustable through 360. Linkage General Information Many applications require the use of a linkage assembly and often the final control element does not have a linear torque curve. The Series Actuator linkage can be set up to achieve an optimal delivered torque distribution for specific applications. To assist with linkage design, Honeywell offers a linkage analysis software package (HAL). The software can be ordered as P/N Two common linkage setups, a constant torque and a characterized torque profile, are described in the following two sections Series Actuator Installation, Operation and Maintenance Manual 1/98

31 Installation Constant Torque Linkage A constant torque linkage is employed when it is desired to provide a linear torque profile throughout the full range of final control element travel. In this situation, the actuator and driven crank arms will be set-up proportionally with respect to each other. Diagram 3-1 shows a general linkage setup to achieve a linear torque profile and diagram 3-2 shows the resultant profile. Vertical Centerline Linkage Vertical Centerline Start Stop Close Open Actuator Crank Arm Horizontal Offset Figure 3-1 Constant Torque Linkage Damper Crank Arm a/n Figure 3-2 Constant Torque Profile 1/ Series Actuator Installation, Operation and Maintenance Manual 21

32 10260 Series Actuators Installation, Operation and Maintenance Manual Variable Torque Linkage A variable torque linkage is employed when it is desired to provide a non-linear torque profile throughout the full range of final control element travel. In this general situation, the actuator and driven crank arms will be set up to provide a higher torque for seating or unseating the final control element. Diagram 3-3 shows a general linkage setup to achieve a non-linear torque profile and diagram 3-4 shows the resultant profile. Note that this linkage can be characterized in many different ways by varying start angles and rotation requirements of both the Actuator Crank Arm and the Driven Arm. Vertical Centerline Vertical Centerline Actuator Crank Arm Linkage Close Open 5 a/n Horizontal Offset Figure 3-3 Variable Torque Linkage Damper Crank Arm Figure 3-4 Variable Torque Profile Series Actuator Installation, Operation and Maintenance Manual 1/98

33 Installation Turnbuckle Linkage Kits (See Section 8.4 for Kit numbers) These kits are to be used where short lengths are required. These lengths range from 12 to 24 inches and refer to the rod end center - to - center distance. All turnbuckle kits include the turnbuckle, load rod end (left-hand thread), connecting rods and locking nuts. The nut and bolt to connect the rod end to the load are supplied by the Customer. The actuator rod end (right-hand thread), nut and bolt are supplied with the actuator. These kits can be ordered with the Actuator via section F of the Model Selection Guide or separately as identified in section 8.4 of this manual. 12 to 24 inches Rod end, nut and bolt are supplied with the actuator Customer supplied nut and bolt 1/2"-20 right-hand threads 0.5"-20 left-hand threads a/n Figure 3-5 Turnbuckle Linkage Kit Pipe Linkage Kits (See Section 8.4 for Kit numbers) These kits are used for linkage lengths from 24 to 120 inches (60 to 305 cm). All pipe linkage kits include the mechanical pipe couplings, load rod end (left-hand thread), connecting rods and locking nuts. The Customer must supply a piece of schedule 40 pipe * (both ends with right-hand NP threads) and a nut and bolt to connect the rod end to the load. The actuator rod end (right-hand thread), nut and bolt are supplied with the actuator. These kits can be ordered with the Actuator via section F of the Model Selection Guide or separately as identified in section 8.4 of this manual. 24 to 120 inches Rod end, nut and bolt are Customer supplied nut and bolt supplied with the actuator Customer supplied pipe* 1/2"-20 right-hand threads 1/2"-20 left-hand threads * cut to size with standard NPT both ends a/n Figure 3-6 Pipe Linkage Kit *Pipe length = Overall linkage length minus (-) 17 inches (43 cm). 1/ Series Actuator Installation, Operation and Maintenance Manual 23

34 10260 Series Actuators Installation, Operation and Maintenance Manual Old and New Actuator Crank Arms Silver Colored Crank Arm (Standard on models shipped prior to June 1996) Gold Colored Crank Arm (Standard on models shipped after June 1996) Link Rod Link Rod Adapter 1/2" Rod End Set Screws Brass Block Insert the Link Rod Completely into the Link rod Adapter and tighten the (2) set screws with sufficient force to hold the link rod. Figure 3-7 Old and New Crank Arms The Series Actuator crank arm has been redesigned to use a standard ½ rod end to compliment the turnbuckle and pipe linkage kits. For applications which use a link rod, a link rod adapter is available allowing a seamless transition to the new crank arm configuration. The silver colored crank arm previously connected the link rod using the brass block swivel. The gold colored crank arm now connects the link rod using a ½ rod end and a hex link rod adapter. Link rod adapters are available as options in the MSG. - 7/16 link rod adapter = Table III, option E3-3/8 link rod adapter = Table III, option E1-5/8 link rod adapter = Table III, option E2-7/8 link rod adapter to replace = Table III, option E Series Actuator Installation, Operation and Maintenance Manual 1/98

35 Installation a/n Figure 3-8 Outline and Dimensions of , -620, -640, -660, -670, -680, and -690 Actuators 1/ Series Actuator Installation, Operation and Maintenance Manual 25

36 10260 Series Actuators Installation, Operation and Maintenance Manual a/n Figure 3-9 Outline and dimensions of and Actuators Series Actuator Installation, Operation and Maintenance Manual 1/98

37 Installation 3.4 Electrical (Wiring) Installation! ATTENTION: All wiring must be done by qualified technicians and must conform to national or local electrical codes. General Wiring Recommendations In general, stranded copper wire should be used. Unless locally applicable codes dictate otherwise, the recommended minimum wire sizes in Table 3-1 should be observed. Gage No. Table 3-1 Recommended Minimum Wire Size 14 Earth ground wire to common power supply. Description 18 Earth ground wire to single actuator. 120/240 V ac line leads. +24 V and common signal leads.! Series Wiring The external wiring connections should be made according to the wiring diagram furnished with the series Actuator. Wiring diagrams are either in the manual supplied with the Actuator or on the inside of the terminal cover. Figure Series Actuator, Interior View a/n / Series Actuator Installation, Operation and Maintenance Manual 27

38 10260 Series Actuators Installation, Operation and Maintenance Manual Feedback Assembly Wiring All wiring connections to the sensor assembly are made at the terminal board located in the lower section of the Series Actuator. Figure 3-15 is a typical wiring diagram for an actuator with feedback electronics. Verify wiring connections using the wiring diagram supplied with each actuator.! Motor Positioner Wiring CAUTION The ground terminal must be connected to a reliable earth ground for proper operation and to comply with OSHA and other safety codes. NOTE: As indicated, if the control signal input is to be a voltage rather than current, connect a 10 K resistor across the input terminals. A one-inch tapped hole exits for customer conduit connections. All wiring connections to the sensor assembly are made at the terminal board located in the lower section of the Series Actuator. Figure 3-15 is a typical wiring diagram for an actuator with feedback electronics. Verify wiring connections using the wiring diagram supplied with each actuator. The following is the procedure for wiring the Motor Positioner to the Series Actuator. Step Action! 1 Connect the AC lines to the power terminal board. 2 Connect the hot side of the line to terminal 22 and the neutral side of the line to terminal 2.* 3 If the neutral side of the line cannot be grounded, add an isolating transformer electrically between the power supply and the Motor Positioner and ground terminal 2. *The hot line terminal number can change depending on options specified. Verify correct terminal using the wiring diagram supplied with actuator Series Actuator Installation, Operation and Maintenance Manual 1/98

39 Feedback Assembly Calibration 4. Feedback Assembly Calibration 4.1 Overview Introduction In calibrating the feedback assembly, it is necessary to determine whether the output is rotating in a clockwise or counterclockwise direction. Clockwise and counterclockwise rotation is the direction of the output shaft when facing the end of the shaft. Clockwise rotation moves the pointer from 100% to 0% on the scale (left hand pointer). If the particular application calls for a counterclockwise rotation (right hand pointer), the cam and cam follower assembly must be changed as instructed in Section 4.4. In this chapter In this chapter the following topics are discussed. Topic See Page Overview 29 Initial Calibration for Assembly (0-16 VDC) 29 Initial Calibration for Assembly (4-20 ma) 30 Reversing Cam Program 31 Sensor Output characterization; Plotting and Cutting Cam Profile Initial Calibration for Assembly (0-16 VDC Output) Energize the equipment by applying the d-c voltage. Then calibrate the sensor according to the following procedure. Step Action 1 Rotate the actuator shaft to the minimum stroke limit (0%). Set the cam (figure 1.1) so that the cam follower is against the zero position on the cam. Tighten the cam retaining nut. 2 Connect a voltmeter (accuracy 3% or better) to pins 3 (+) or 4 (-) of the circuit card and loosen the setscrews on the cam-follower assembly. 3 Rotate the sensor s shaft, in the direction that the follower normally moves due to cam rotation, until the meter indicates an increasing voltage. 4 Reverse the shaft rotation until the voltage decreases to between 0.05 and 0.1 volt d-c. Retighten the setscrews. 5 Check the sensor-shaft adjustment by manually moving the follower off of the cam surface; the output should immediately begin to increase. 3/ Series Actuators Installation, Operation and Maintenance Manual 29

40 10260 Series Actuators Installation, Operation and Maintenance Manual Step Action 6 Rotate the actuator shaft to the 100% position. The cam-follower should now be resting on the 85 degree mark (85 degrees is the maximum actuator stroke). On standard cams, the follower travel will have been 100% of maximum, and the sensor shaft will have rotated 68 degrees. 7 The output voltages should be 16V. If necessary, adjust the R1 potentiometer on the circuit card to obtain a meter reading of 16 ± 0.5V. 8 Check for 8V to 12V across test points T (+) and C (-) on the card. A low reading indicates the cam profile is wrong or the sensor assembly is faulty, resulting in poor operation at the ambient temperature limits. 9 Return the actuator to the 0% position and recheck the zero position voltage as in steps 2 and Initial Calibration for Assembly (4-20 ma Output) Energize the equipment. Then calibrate the sensor according to the following procedure. Step Action 1 Position actuator to the minimum stroke limit (0%). 2 Zero the cam-follower on the cam so that the cam-follower is against the zero position on the cam. Tighten the cam retaining nut. 3 Connect a high impedance digital voltmeter (DVM) between TP2 and terminal 4 (-). The voltmeter will measure between 0.4 VDC and 2.0 VDC. 4 Rotate the Zero potentiometer R11 fully counterclockwise. Loosen the set screws on the camfollower assembly. 5 Rotate the sensor s shaft, in the direction that the follower normally moves due to cam rotation, until the meter indicates an increasing voltage. 6 Reverse the shaft rotation until the voltage is a minimum. Retighten the set screws. 7 Turn the Zero potentiometer R11 clockwise until 0.4 VDC is measured on the meter. 8 Position the actuator shaft to the maximum stroke limit (100%). 9 Adjust the Range potentiometer R10 for 2 VDC +/-.02 VDC. 10 Turn the Zero potentiometer R11 clockwise until 0.4 VDC is measured on the meter. 11 Position the actuator shaft to the maximum stroke limit (100%). The voltage should be 0.4 VDC. If not, loosen the set screw and turn the sensor shaft to obtain the desired 0.4 VDC reading. 12 Tighten the set screw and repeat steps 5 through 7 until the.4 VDC +/- 0.1 VDC and 2 VDC +/ VDC indications correspond to their respective limits Series Actuators Installation, Operation and Maintenance Manual 3/97

41 Feedback Assembly Calibration 4.4 Reversing Cam Program If the cam program requires a 0% to 100% output instead of the conventional 100 to 0% output for clockwise rotation of the output shaft, proceed as follows: Step Action 1 Remove the cam from the shaft by removing the cam retaining nut and washers as indicated in Figure Unhook the cam follower spring from the screw in the upper stud mounting. Then loosen the setscrews in the cam follower assembly and remove this assembly. 3 Reverse the positions of the spring and cam roller on the follower assembly. This entails removing the spring and roller. Unscrew the roller retaining screw and replace the roller in the hole where the spring was hooked. Then hook the spring in the hole where the roller was located. 4 Remove the screw in the upper stud to which the other end of the spring was hooked and replace it in the lower stud. Tighten it securely. 5 Replace the cam follower assembly on the sensor shaft. Hook the free end of the spring on the screw in the lower stud. 6 Replace the cam on the shaft, in reverse position from that of step 1 above before removal. 7 Calibrate the sensor assembly as outlined in Section 4.2 or 4.3, except that instead of setting the cam in the 0 -degree position, set it at the position corresponding to 100% output. 8 Figure 4-1 shows the assembly for clockwise rotation. To change from counterclockwise rotation to clockwise rotation, ensure that the final assembly is as shown in Figure Sensor Output Characterization; Plotting and Cutting Cam Profile Purpose of Characterization The purpose of characterization is to provide a linear and proportional relationship between the feedback signal to the controller and the process effect caused by the corresponding actuator motion. Control signal, actuator travel, and valve angle opening, may all be directly proportional to each other on a straight line basis. However, the medium affected by the valve or final control element, i.e., flow, may not be. For example, full output (100% flow) occurs at a 60-degree opening, 20% output at a 30-degree opening, and so on. Under the conditions outlined above, this is then a plot indicative of the feedback signal versus process effect characteristic. If, due to interconnecting linkages, the actuator travel and valve angle opening are not directly proportional, then this non-linearity would need to be plotted. From this curve and the plot of the example described above, a relationship of actuator travel versus output (flow) could be obtained to define the feedback signal versus process effect characteristic. The idea now is to design a cam to match these characteristics. Starting with the VALVE OPENING, 10, 20, 30, 40, etc., proceed upward until these lines intersect the curve; then read off the corresponding PERCENT OF MAXIMUM FLOW. Transfer these values to graph. This is the plot of the program for which the cam must be cut. The procedure for cutting a cam is discussed in the section, Cutting a Cam. If the characteristics of the final control device (valve in this case) cannot be obtained directly from a graph supplied with that device, then a curve must be plotted by the user to determine the non-linearity. For example, if flow cannot be measured directly for corresponding valve openings, the effect of the flow on the 3/ Series Actuators Installation, Operation and Maintenance Manual 31

42 10260 Series Actuators Installation, Operation and Maintenance Manual process can be measured instead. As stated above, control signal, actuator travel, and valve angle opening, were all assumed to be proportional to teach other on a straight line basis. Thus, by setting the valve at various openings and observing the corresponding change of the measuring instrument from a desired control point, a plot of the non-linearity can be obtained. Note that the process must be allowed to soak out after each change in valve setting. Otherwise, results will be erroneous. Another typical application in which characterization is useful is in those requiring overrun, i.e., going past the point of zero change in feedback to provide spring take-up or tight shutoff. Cutting a Cam The method of cutting a program is essentially the same for either cam. In planning a profile, the point to remember is that the plot is made of angular rotation in percent of maximum angular rotation versus percent of maximum output voltage. For example, suppose a cam is desired with the characteristics described in the section, Purpose of Characterization. Proceed as follows: Step Action 1 Starting with the zero degree line on the cam, mark the percent of angular range (which corresponds to the angular rotation in degrees, i.e., 8.5, 17, 23.5, or 12, 24, 36, etc.) versus percent of output voltage for each major division. 2 With these points as centers, scribe 3/16 diameter circles or drill 3/16 diameter holes as indicated in Figure Draw a smooth tangent to these 3/16 circles or holes at the points nearest the center of the cam. 4 Cut away all material outside this outline. Remove all burrs and smooth the periphery of the cam. a/n Figure 4-1 Plot of program on cam blank for Series Actuators Series Actuators Installation, Operation and Maintenance Manual 3/97