ABSTRACT MANUAL FOR ROTARY This manual is intended as an information guide for operating SEDEMAC's Rotary Actuator. Doc #SED-MAN-Rotary Actuators-002 Date: 11-Sep-2017 ACTUATORS Product Manual Version #1.00
Copyright All rights reserved. No part of this publication may be reproduced, distributed or transmitted by any means (including photocopying or storing in any medium by electronic means or other) without the prior written permission of the copyright holder. Any reference to trademarked product names used within this publication is owned by their respective companies. SEDEMAC Mechatronics Pvt. Ltd. reserves the right to change the contents of this document without prior notice. For permission requests and applications to reproduce any part of this publication should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned contact details. SEDEMAC Mechatronics Pvt. Ltd. C9-10, C Block, MIDC Bhosari Pune 411026, INDIA Web Support: Email: support@sedemac.com Website: www.sedemac.com Telephonic Support: +91-20-67313500 +91-8551039888 +91-8551041888 +91-8551043888
Safety Instructions General Instructions This document includes important instructions that should be followed during installation and maintenance of the Generator Set controller. For safety reasons, the manufacturer recommends that this equipment be installed and serviced by an Authorized Service personnel. Follow all applicable state and local electrical codes. Efficient and safe operation of the controller can be acquired only if the equipment is correctly operated and maintained. Many accidents arise due to ignorance or illiteracy towards the elemental rules of safety and precautions. The following safety notations found throughout this document indicate potentially hazardous conditions to the operator, service personnel or the equipment. Highlights an essential element of a procedure to ensure correctness Indicates a procedure or practice, which, if not strictly observed, could result in damage or destruction of equipment Indicates a procedure or practice, which could result in injuring personnel or loss of life, if not followed correctly Electrical safety Electric shock can cause severe personal injury or death. Ensure the generator set must be grounded before performing any installation or service. Generators produce high electrical voltages direct contact with it can cause fatal electrical shock. Prevent contact with terminals, bare wires, connections, etc., while the generator and related equipment are running. Do not tamper with interlocks. To handle the maximum electrical current, sizes of wire gauge used for electrical connections and wirings must be appropriate to which they will be subjected to. In operation safety Before installing Genset controller, ensure that all power voltage supplies are positively turned off at their source. Disconnect the generator s battery cables and remove panel fuse to prevent accidental start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or ( ) first. Reconnect the negative cable last. Failure to do so will result in hazardous and possibly fatal electrical shock. Remove electric power supply before removing controller or touching other electrical parts. Use extreme caution when working on electrical components. High voltage can cause injury or death. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when working near Generator set or other electrical equipment. Do not wear damp clothing (Particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Page 1 of 15
Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or feet are wet. IT MAY RESULT IN SEVERE ELECTRICAL SHOCK. Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock or burning. In case of an accident caused by electric shock, immediately shut down the electrical power source. If this is not possible, try to release the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help. Page 2 of 15
List of Abbreviation This list contains the list of acronyms used in this document and it can be used to refer their respective description. This List Does not contain units of measure. Acronym AC ACK ALT AMF AUX BTS CHG CKT CT Ratio DC DG DIG IN ENG TEMP GCU Genset GND HMI HSD HWT LCD LED LLOP LOP LVL MCP MPU OV PID PWM RMS RPM R-Y-B SCP SMD TEMP USB UV Description Alternating Current Acknowledge Alternator Auto Mains Failure Auxiliary Base Transceiver Station Charging Circuit Current Transformer Ratio Direct Current Diesel Generator Digital Input Engine Temperature Genset Control Unit Generator Set Ground Human Machine Interface High Side Driver High Water Temperature Liquid Crystal Display Light Emitting Diode Low Lube Oil Pressure Lube Oil Pressure Level Manual Control Panel Magnetic Pickup Unit Over Voltage Proportional Integral Derivative Pulse Width Modulation Root Mean Square Revolutions Per Minute Red-Yellow-Blue Sensor Common Point State Machine Diagram Temperature Universal Serial Bus Under Voltage Page 3 of 15
Table of Contents 1 Introduction... 7 1.1 Key Highlights of the Product... 7 1.2 Product Variants... 7 2 Specifications... 8 3 Operation... 8 4 Installation... 9 4.1 Dimensions... 9 4.2 Mounting on Genset... 11 4.3 Pin Description... 12 4.4 Connection Details... 13 5 Troubleshooting... 13 6 Maintenance... 13 Notes... 14 Page 4 of 15
List of Figures Figure 1: Rotary actuators... 7 Figure 2: Small size actuator... 9 Figure 3: Medium size actuator... 10 Figure 4: Large size actuator... 11 Figure 5: Actuator assembly on genset... 12 Figure 6: Actuator connector pin out when viewed from the terminal insertion side... 12 Page 5 of 15
List of Tables Table 1: Environmental specifications... 8 Table 2: Technical specifications... 8 Table 3: Actuator variant specifications... 8 Table 4: Actuator wiring connection details... 13 Table 5: Troubleshooting... 13 Page 6 of 15
1 Introduction This document describes details of SEDEMAC s Rotary Actuators. SEDEMAC SEDEMAC B12 Rotary Actuators are designed and customized for precision motion control application on wide variety of diesel/gas/gasoline engines with mechanical fuel systems. Rotary Actuators are designed to operate along with SEDEMAC s genset controller (GCU) or B12 Electronic Control Unit (ECU) to perform electronic speed governing duty. It acts as air/fuel charge control to deliver the tight speed governing performance. Its robust architecture supported by a heavy-duty plastic enclosure offers high rigidity and strength to sustain against harsh environmental conditions and mechanical vibrations for engine mounted application. 1.1 Key Highlights of the Product Tough construction for engine mounted application Precision motion combined high torque density Control capability for both rotary and inline mechanical diesel injection pumps Supports both fuel stop lever control as well as throttle lever control for mechanical diesel injection pumps Low power consumption 1.2 Product Variants ACTZ02A (Standard Torque) SM0000015 ACTZ01A (Standard Torque with return spring) SM0000014 ACTZ06A (Medium Torque) SM0003648 ACTZ09A (Medium Torque with return spring) SM0000020 ACTZ11A (High Torque) SM0001956 ACTZ10A (High Torque with return spring) SM0000021 Figure 1: Rotary actuators Page 7 of 15
2 Specifications SEDEMAC SEDEMAC s Rotary Actuators are to be powered only by SEDEMAC s GCU or ECU. All SEDEMAC s GCUs and ECUs are 12V and 24V complaint. Table 1: Environmental specifications Operating/Storage Temperature -20 to 105 C as per IEC 60068-2-1, 2 Vibration 5G in X, Y and Z axes for 8 500 Hz as per IEC 60068-2-6 Humidity 0 to 95% RH as per IEC 60068-2-78 Ingress Protection IP56 as per IEC 60529 Table 2: Technical specifications Power Consumption Motion ~1A @12 or 24V 150 deg travel Electrical Interface Construction Mounting Foot Print Dimension (For All Variants) 4 wire connector Encased in tough plastic casing made of Nylon 6 with 30% glass filled 78 mm x 40 mm 4 Number of holes - 6.7 mm Diameter each Table 3: Actuator variant specifications Types Standard Torque Medium Torque High Torque Output Torque 0.35 Nm 0.56 Nm 0.93 Nm Weight (With 870 g 1270 g 1600 g Return Spring) Dimensions 94 mm x 84 mm x 85 mm 94 mm x 84 mm x 121 mm 94 mm x 84 mm x 140 mm 3 Operation When connected to a proportional Rotary Actuator and supplied with a magnetic speed sensor signal, GCU or ECU controls the wide variety of engines. Rotary Actuators provides accurate and efficient speed control for governing. GCU or ECU reads the engine RPM through speed sensor and commands the Actuator to maintain the target governing RPM. Actuators operates the fuel stop/throttle lever via a linkage and controls the air/fuel charge. The actuator can vary on size based on the torque output it can provide. Some Actuators are designed with return spring mounted on them. This spring pulls back the fuel stop lever to stop upon loss of power as a safety feature. Page 8 of 15
4 Installation 4.1 Dimensions SEDEMAC uses three types of Rotary Actuators, small, medium and large depending on the different applications. Dimensions for these three types of actuators are given below. Figure 2: Small size actuator Page 9 of 15
Figure 3: Medium size actuator Page 10 of 15
4.2 Mounting on Genset Figure 4: Large size actuator This section gives the generic stepwise recommendation for installation of the SEDEMAC s Rotary Actuator on the genset. The required parts are as follows: Actuator Actuator mounting bracket Linkage* *Linkage transfers Actuator torque to operate the fuel stop/throttle lever to control engine RPM. The following is the stepwise procedure for assembling Rotary Actuator on genset. (Refer figure) Page 11 of 15
Assemble the Actuator-mounting bracket on the engine with help of fasteners. Fix the Actuator on the bracket with help of fasteners and bolts (M6 Bolts), size of which depends on the Actuator thickness. Place the wire connector cover of the Actuator on the left side, when looking from the Actuator s shaft side. 4.3 Pin Description Figure 5: Actuator assembly on genset Following figure provides the pin details of 4 wire Actuator connector. Figure 6: Actuator connector pin out when viewed from the terminal insertion side Page 12 of 15
4.4 Connection Details Following table provides the connection details while connecting Actuator with GCU or ECU. Table 4: Actuator wiring connection details SEDEMAC Actuator Connector Pin No. Description B12 ECU Pin No. GCU Terminal No. 1 ACT 1 (Orange coloured wire) 5 17 4 ACT 4 (Blue coloured wire) 6 18 2 ACT 2 (Red coloured wire) 11 19 3 ACT 3 (Yellow coloured wire) 12 20 Follow the recommended connection details for connecting Actuator with ECU or GCU. 5 Troubleshooting This section explains the common faults and their remedial actions. Table 5: Troubleshooting Sr. No. Faults Remedial Actions 1 Engine does not start after crank command 2 Engine cranks, but does not performing governing Check the Linkage for loose connections Check if actuator powered properly by GCU or ECU Check the Actuator for loose connections Check if Actuator wires connected correctly For further details, please refer to Manual for B12 Electronic Governor. This manual is available on SEDEMAC s website: www.sedemac.com 6 Maintenance For the smooth functioning of Actuator, following maintenance is required after 3 month s operations. Tightening all fasteners and bolts Greasing to spring, for the Actuators with spring Page 13 of 15
Notes Page 14 of 15
Disclaimer: Due to continuous development, the details provided in this document are subject to change without any prior notice. SEDEMAC Mechatronics Pvt Ltd Technical Centre C9-10, C Block, MIDC Bhosari Pune 411026, India Manufacturing Plant G-1, MIDC, Phase-III Chakan Industrial Area, Nighoje Pune 410501, India Manufacturing Plant Survey No. 64/5, Off Sinhagad Road Vadgaon Budruk, Narhe Pune 411041, India Page 15 of 15