HercuLine 2000 Series Gear Kit Replacement Instructions

HercuLine 2000 Series Gear Kit Replacement Instructions 51452443-501 Document Information Form: 62-86-33-35 Effective: 5/04 Supersedes: None Summary This kit contains all the gears, idler shafts and hardware for your HercuLine 2000 Series Actuator. You can replace your existing gear with a different gear speed. Procedure See Tables 1-3 for procedure. WARNING Disconnect power before accessing components inside the instrument. ATTENTION When working with circuit cards always protect against electrostatic discharge by wearing a grounded wrist strap. 62-86-33-35 Page 1 of 5

Step 1 Remove bottom cover. Table 1 Motor Gear Installation Procedure 2 Replace motor gear (small gear with allen screw, if applicable) Later versions of the motor have a pressed on hardened gear, there is no replacement gear available for this configuration. Loosen allen screw. Slide gear off shaft, noting orientation of the gear. Install new gear and tighten allen screw. Apply grease to teeth of gear. Use excess grease from the other gears or use Starplex 2 grease. 3 If replacing other parts, proceed to Tables 2 and 3. Otherwise install new gasket and reattach bottom cover. Page 2 of 5 62-86-33-35

Step 1 Remove bottom cover 2 Table 2 Idler Gears / Shaft Installation Procedure Replace idler gear and shaft Remove retaining ring. Slide gear off the shaft. If replacing idler gear shaft go to step 3 and return here. Using figures below as a guide, find your gear and install new gear and attach new retaining ring. Apply grease to teeth of gear. Use excess grease from other gears or use Starplex 2 grease. 1/2 RPM 1/3 RPM 1RPM 2 RPM 4 RPM 62-86-33-35 Page 3 of 5

Step 3 Replace idler shaft With idler gear removed, remove idler shaft noting location of shaft. Gear Shaft Locations Replace with new shaft. Reinstall idler gear. Idler Shafts 4 If replacing spur gear go to Table 3. Otherwise install new gasket and reattach bottom cover. Page 4 of 5 62-86-33-35

Table 3 Spur Gear Installation Procedure Step 1 Remove bottom cover 2 Replace spur gear Remove nut and lockwasher. Remove gear from shaft (may require a gear puller). Install new gear and new lockwasher and nut. Apply grease to teeth of gear. Use excess grease from the other gears or use Starplex 2 grease. Spur Gear 3 Install new gasket and reattach bottom cover. 62-86-33-35 Page 5 of 5

HercuLine 2000 Series Motor Kits Replacement Instructions 51452337-501(120VAC) 51452337-502 (240VAC) Document Information Form: 62-86-33-36 Effective: 5/04 Supersedes: None Summary These kits contain the motor, resistor, capacitor and hardware for your HercuLine 2000 Series Actuator. Procedure See Tables 1 through 3 for Motor Gear, Capacitor, and Resistor installation. WARNING Disconnect power before accessing components inside the instrument. ATTENTION When working with circuit cards always protect against electrostatic discharge by wearing a grounded wrist strap. Table 1 Motor Gear Installation Procedure Step 1 Remove top cover. 2 Remove bottom cover 3 Remove motor (motor connected with wire caps) Cut the red, black and white motor wires, leaving approximately 2 inches of wire on the motor. Remove the socket head cap screws holding the motor to the center housing. Discard the motor and motor gear. (motor gear is part of motor assembly.) Reinstall motor using new socket head cap screws supplied. Connect mating connector to motor. Splice the connector red wire to the cut red wire using the butt splice supplied. Splice the white wires and the black wires using the butt splices supplied. Remove motor (motor connected using connector) Disconnect the motor connector. Remove the socket head cap screws holding the motor to the center housing. Discard the motor and motor gear. (motor gear is part of motor assembly.) Reinstall motor using new socket head cap screws supplied. Connect mating connector to motor. 4 Install new gasket and reattach bottom cover. 5 Install new gasket and reattach top cover 62-86-33-36 Page 1 of 2

Step 1 Remove bottom cover 2 Replace capacitor Table 2 Capacitor Installation Procedure Remove wires to capacitor. Remove bracket holding capacitor to the bottom cover. Remove capacitor and discard. Install new capacitor and bracket. Reconnect wires to capacitor. 3 Install new gasket and reattach bottom cover. Step 1 Remove top cover 2 Replace resistor Table 3 Resistor Installation Procedure Remove wires associated with resistor. Note color and location of each wire. Remove resistor and discard. Install new resistor and reconnect the wires per notations taken above. 3 Install new gasket and reattach top cover. Page 2 of 2 62-86-33-36

HercuLine 2000 Actuator 1000 Ohm Potentiometer Kit (For both 90 and 150 Degrees) Replacement Instructions 51451656-505/506 Document Number Form: 62-86-33-38 Effective: 7-27-05 Supersedes: 3-05 Summary These kits contain a new potentiometer and associated parts for your HercuLine 2000 Actuator. Procedure See Table 1 for procedure. WARNING Disconnect power before accessing components inside the actuator. Failure to do so may result in death or serious injury. Page 1 of 4

Step 5 Mount the potentiometer. Mount the potentiometer to the bracket using 2 screws, 2 lock washers and 2 nuts. DO NOT TIGHTEN THE HARDWARE AT THIS TIME. 6 Assemble the potentiometer. Slide the end of the potentiometer shaft into the end of the cam shaft. Secure the bracket to the casting using 2 Sems screws. TIGHTEN THE BRACKET HARDWARE. DO NOT TIGHTEN THE SET SCREW. 5 Wire the potentiometer. Wire per the chart and reference the picture below. Page 3 of 4

Step 6 Adjust the potentiometer. Connect a multi meter set to OHMS (Ω) to terminals 10 and 11. Replace the set screw with the one supplied. Use a small allen wrench in the hole on the potentiometer shaft to turn the potentiometer. Adjust the potentiometer to 500Ω +/- 5Ω. When the potentiometer is set for 500Ω TIGHTEN THE SET SCREW. 7 Optional: To convert 1000 ohm potentiometer to 135 ohms, connect the 158 ohm resistors. 8 Replace the gasket. 9 Reattach the top cover. Page 4 of 4

HercuLine 2000 Actuator 1000 Ohm Potentiometer Kit (For both 90 and 150 Degrees) Upgrade Instructions 51451656-510/511 Document Number Form: 62-86-33-39 Effective: 07-26-05 Supersedes: None Summary This kit contains a new potentiometer and associated parts for your HercuLine 2000 Actuator. Tools Needed To perform the installation procedure, you will need the following tools: Medium Flat-blade screwdriver Medium Phillips screwdriver Small needle-nosed pliers Procedure WARNING Disconnect power before accessing components inside the actuator. Failure to do so may result in death or serious injury. ATTENTION When working with Printed Wiring Assemblies (PWAs) always protect against electrostatic discharge by wearing a grounded wrist strap. Failure to do so may result in equipment damage. 62-86-33-39 Page 1 of 4

Step 5 Wire the potentiometer. Connect wires to terminals as shown in picture and chart below. 6 Adjust the potentiometer. Connect a multi meter set to OHMS (Ω) to terminals 10 and 11. Replace the set screw with the one supplied. Use a small allen wrench in the hole on the potentiometer shaft to turn the potentiometer. Adjust the potentiometer to 500Ω +/- 5Ω. When the potentiometer is set for 500Ω tighten the set screw. 7 Optional: To convert 1000 ohm potentiometer to 135 ohms, connect 158 ohm resistors. 8 Replace the gasket. 9 Reattach the top cover. 62-86-33-39 Page 3 of 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. Industrial Measurement and Control Honeywell 1100 Virginia Drive Fort Washington, PA 19034 62-86-33-39 07/05 Printed in USA www.honeywell.com/imc

HercuLine 2001 Actuator 1000 Ohm Potentiometer Kit Replacement Instructions 51452342-501 Document Number Form: 62-86-33-40 Effective: 07-26-05 Supersedes: None Overview These instructions apply to the following kit: 51500324-501 Top Cover Assembly with Display Upgrade Kit and its application to the 10260S Series Actuators. This kit allows you to add or replace the local display/keypad control function to 10260S actuators. Summary This kit contains a new potentiometer and associated parts for your HercuLine 2001 Actuator. Tools Needed To perform the installation procedure, you will need the following tools: Procedure Medium Flat-blade screwdriver Medium Phillips screwdriver Small needle-nosed pliers WARNING Disconnect power before accessing components inside the actuator. Failure to do so may result in death or serious injury. ATTENTION When working with Printed Wiring Assemblies (PWAs) always protect against electrostatic discharge by wearing a grounded wrist strap. Failure to do so may result in equipment damage. 62-86-33-40 Page 1 of 3

Table 1 1000 Ohm Installation Procedure Step 1 Disconnect power from the actuator. 2 Move the actuator output shaft to 50%. If the actuator has a hand wheel, rotate the hand wheel until the pointer is at 50% on the scale. If the actuator does not have a hand wheel, remove the top cover and rotate the shaft at the bearing retainer plate until the pointer is at 50% on the scale. 3 Remove top cover. 4 Potentiometer Assembly Slide the end of the potentiometer shaft into the end of the cam shaft. Secure the bracket to the casting using 2 Sems screws. Tighten the bracket hardware. DO NOT TIGHTEN SET SCREW. 5 Connect to backplane. Plug potentiometer cable into receptacle on backplane. 6 Adjust the potentiometer. See document 62-86-25-10 HercuLine 2000 Series Actuator Installation, Operation and Maintenance Manual. Refer to Set Up and Calibration Procedures section. 7 Replace the gasket. 8 Reattach the top cover. Page 2 of 3 62-86-33-40

HercuLine 2000 Auxiliary Switch Kit Replacement and Upgrade Instructions 51452443-502 Document Number Form: 62-86-33-45 Effective: 1/07 Supersedes: none Summary These kits contain the hardware for your HercuLine 2000 Series Auxiliary Switch Kit. Tools Needed To perform the installation procedure, you will need the following tools: Medium Flat-Blade screwdriver Medium Phillips screwdriver Small needle-nose pliers Allen Key screw driver set WARNING Disconnect power before accessing components inside the actuator. Failure to do so may result in death or serious injury. ATTENTION When working with circuit cards always protect against electrostatic discharge by wearing a grounded wrist strap. 1/07 Kit Number 62-86-33-45 1

Table 1 HercuLine 2000 Series Auxiliary Switch Replacement and Upgrade Procedure Step 1 Disconnect power from the actuator. 2 Remove the 6 screws and the extended top cover of the actuator case. Top cover Screws If your actuator has a cable attached to the cover, lay the cover assembly on a flat surface next to the case. You do not have to detach the cable. ATTENTION Your Actuator may contain a Potentiometer assembly (Model 2000 or 2001) or a Non- Contact Feedback Sensor (Model 2001 or 2002) that will have to be removed temporarily in order to add or replace the Auxiliary switches. 2 Kit Number 62-86-33-45 1/07

Step 3 Move the actuator output shaft to 50%. This will expose the set screw on the drive shaft near the Potentiometer or Non-contact sensor and position it at approximately center position. It will ensure that the existing switch cams are not against the switch contact. If the actuator has a hand wheel, rotate the hand wheel until the pointer is at 50% on the scale. If the actuator does not have a hand wheel, rotate the shaft at the bearing retainer plate until the pointer is at 50% on the scale. 50% Position Move Pointer 4 If your actuator contains a Potentiometer or Non-contact Feedback sensor, see step 5 or 6. 1/07 Kit Number 62-86-33-45 3

Step 5 Removing the Potentiometer Assembly (Models 2000 and 2001) Locate the pot assembly. Remove the set screw which secures the pot shaft to the CAM shaft. Potentiometer Set Screw SEM Screws Remove 2 sems screws that secure the bracket to the casting and then remove the mounting bracket. Slide out the pot shaft and carefully place the pot assembly aside. 6 Removing the Non-contact Feedback Sensor Assembly (Models 2001 and 2002) Locate the sensor assembly. Loosen the set screw on the shaft. Remove the sems screws on the feedback sensor mounting bracket and slide the feedback sensor off the end of the shaft and carefully move it aside. Sensor Sensor Mounting Bracket Set Screw Cam Shaft SEM Screws 4 Kit Number 62-86-33-45 1/07

Step 7 a) Remove and tag the wires from the existing switch contact block and note location. See figure below. b) Remove the existing contact block (2 screws) Contact Block Mounting Screws Set Screw Cams Switch Contact Block Wire Locations 8 Loosen the cam set screw and slide the existing cam assembly off the end of the shaft. 9 Slide the new auxiliary switch cams onto the end of the shaft and slide into position on the shaft. See Figure above. Align the keyway slot on the end of the shaft with the cam set screw and tighten the setscrew. 10 Install the new expanded switch contact block. Reconnect the wires previously removed to the new switch contact block. 11 Reinstall the Potentiometer or Feedback Sensor (if present) onto the end of the shaft. Reinstall the bracket screws. 12 NCS Position Sensor Calibration See document 62-86-25-10 HercuLine 2000 Series Actuator Installation, Operation and Maintenance Manual. Refer to Table 28 in the Setup and Calibration Procedures section for the NCS position sensor calibration. Potentiometer Position Sensor Calibration 13 14 15 16 See document 62-86-25-10 HercuLine 2000 Series Actuator Installation, Operation and Maintenance Manual. Refer to Table 29 in the Setup and Calibration Procedures section for the Potentiometer position sensor calibration. Set the End-of Travel Limit Switches. See Figure 2 and Table 2 Set the new Auxiliary switches. See Figure 3 and Table 3 Replace the cover gasket. Reattach the top cover and secure with the screws. 1/07 Kit Number 62-86-33-45 5

Location of End-of-Travel Limit and Auxiliary Switches ATTENTION Make sure you do not to set the switches too close to the hard stop. Relay PWAs Relay #1 Relay #2 Relay #3 Relay #4 Aux switch #1 Aux switch #2 Aux switch #3 Aux switch #4 End of travel switch #1 (stops CW rotation) End of travel switch #2 (stops CCW rotation) Figure 1 Location of End-of-Travel Limit and Auxiliary Switches Setting End-of-Travel Limit Switches ATTENTION Referring to Figure 1. The first two cams (starting from the front) are for the 0% and 100% limit switches (Switch #1 and Switch #2). See Figure 2 for limit switch settings. END OF TRAVEL LIMIT SWITCH S ETTINGS (FACTORY SET AT 0% AND 100%) LEFT HAND POINTER SCALE SW#1 14 0% 100% 8 (SW1 COM) 9 (SW2 COM) NC 7 Clockwise Rotation SW#2 5 NC Counterclockwise Rotation 15 Clockwise and counterclockwise rotation is the direction of the output shaft when facing the end of the shaft. As shown, clockwise rotation of the output shaft activates SW 1 (at 0% on the left hand pointer scale) and CCW rotation activates SW 2 (at 100% on the left hand pointer scale). Terminal numbers are next to the circles. Figure 2 End of Travel Limit Switch Settings 6 Kit Number 62-86-33-45 1/07

REFERENCE An unactuated switch will have its normally closed (NC) contacts closed and its normally open (NO) contacts open. An actuated switch will have its NC contacts become open and its NO contacts become closed. Both NC and NO contacts are available at the terminal block. An unactuated switch has its roller arm in the up position when adjacent to the reduced diameter portion of the cam. While the unit is powered, a potentially lethal shock hazard exists inside the case. Table 2 End-of-Travel Limit Switch Setting Procedure Step 1 Using a flat blade screwdriver in the slots at the edge of the cams, or your finger, rotate the cams until the switches are set. (See Figure 1). Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the 0% position (this is the 0% for CCW operation using the bottom scale or 100% for CW operation using the top scale). If the actuator is installed on a damper or valve, also make sure that this position is synchronized with the travel of the final control element. Rotate the #1 limit switch operating cam to activate at this position. The switch roller arm should go from being in an up, not depressed state, to a depressed state as the cam is rotated in the direction of the shaft rotation going toward the limit position. This will cause the switch to go from NC to NO and turn off the power to the motor when the switch activates. Switch activation may be detected by the clicking sound or with a continuity tester connected to the terminals. Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the 100% position (this is 100% for CCW operation using the bottom scale or 0% for CW operation using the top scale). If the actuator is installed on a damper or valve, also make sure that this position is synchronized with the travel of the final control element. Rotate the #2 limit switch operating cam to activate at this position. The switch roller arm should go from being in an up, not depressed state, to a depressed state as the cam is rotated in the direction of the shaft rotation going toward the limit position. This will cause the switch to go from NC to NO and turn off the power to the motor when the switch activates. If optional auxiliary switches were ordered, these switches may also be set at this time. (See Table 3) 2 Double check limit switch actuation by first manually driving the actuator to each end of travel and hearing the switch click or by detecting it with a continuity tester. Secondly, drive the actuator to both ends of travel (using the auto/manual switch or by providing minimum and full input signal) and make sure the switches activate and turn off the motor. 1/07 Kit Number 62-86-33-45 7

Setting Auxiliary Switches ATTENTION Referring to Figure 1. The next four cams (starting from the front) are for the Auxiliary switches (Switches #3, #4, #5, #6,). See Auxiliary Switch Setting Procedure (Table 3). Additional switch settings should be set so that switch #3 operates in synchronism with switch #1 (i.e., both activating when the actuator is going in the same direction) and switch #4 to operates in synchronism with switch #2, etc. See Figure 3 for auxiliary switch settings. LEFT HAND POINTER SCALE 0% 17 (SW3 COM) 18 NO SW #3 (SW 6 COM) 26 23 (SW5 COM) NC 100% 20 (SW4 COM) 16 SW #4 19 NC NO 21 SW #5 24 NO NC 22 SW #6 25 NC 27 NO Figure 3 Auxiliary Switch Settings Table 3 Auxiliary Switch Setting Procedure Step 1 Using a flat blade screwdriver on the slots on edge of cams, or your fingers, rotate the cams until the switches are set. (See Figure 1) The auxiliary switches should be set so switches #3 and #5 operate in synchronism with switch #1 (i.e., both activating when the drive is going in the same direction) and set switches #4 and #6 to operate in synchronism with switch #2. See Figure 3 for auxiliary switch settings. 2 For Switches #3 and #5: Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the desired low scale position. Rotate the #3 switch operating cam to activate at this position. The switch roller arm should go from being in an up, not depressed state, to a depressed state as the cam is rotated in the direction of the shaft rotation going toward the limit position. This will cause the switch to go from NC to NO and turn off the power to the motor when the switch activates. Switch activation may be detected by the clicking sound or with a continuity tester connected to the terminals. Repeat for Switch #5 if applicable. 8 Kit Number 62-86-33-45 1/07

Step 3 For Switches #4 and #6: Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the desired up scale position. Rotate the #4 switch operating cam to activate at this position. The switch roller arm should go from being in an up, not depressed state, to a depressed state as the cam is rotated in the direction of the shaft rotation going toward the limit position. This will cause the switch to go from NC to NO and turn off the power to the motor when the switch activates. Repeat for Switch #6 if applicable. 4 Double check limit switch actuation by first manually driving the actuator to each end of travel and hearing the switch click or by detecting it with a continuity tester. Secondly, drive the actuator to both ends of travel (using the auto/manual switch or by providing minimum and full input signal) and make sure the switches activate and turn off the motor. 1/07 Kit Number 62-86-33-45 9

HercuLine 2001 Actuator Upgrade to Non Contact Position Sensor Replacement Instructions 50018180-501 Document Number Form: 62-86-33-46 Effective: 4/06 Supersedes: None Overview These instructions apply to the following kit: HercuLine 2001 upgrade to non-contact position sensor kit and its application to the HercuLine 2001 Actuators. This kit allows you to replace the existing pot assembly with a non contact position sensor. Summary This kit contains a Non Contact Position Sensor and associated parts for your HercuLine 2001 Actuator. Tools Needed To perform the installation procedure, you will need the following tools: Procedure Medium Flat-blade screwdriver Medium Phillips screwdriver Small needle-nosed pliers Allen key screw driver set WARNING Disconnect power before accessing components inside the actuator. Failure to do so may result in death or serious injury. ATTENTION When working with Printed Wiring Assemblies (PWAs) always protect against electrostatic discharge by wearing a grounded wrist strap. Failure to do so may result in equipment damage. 62-86-33-46 Page 1 of 7

Table 1 NCS Installation Procedure Step 1 Disconnect power from the actuator. 2 Remove the 6 screws and the extended top cover of the actuator case. Top cover Screws 62-86-33-46 Page 2 of 7

Step 3 Move the actuator output shaft to 50%. If the actuator has a hand wheel, rotate the hand wheel until the pointer is at 50% on the scale. If the actuator does not have a hand wheel, remove the top cover and rotate the shaft at the bearing retainer plate until the pointer is at 50% on the scale. 62-86-33-46 Page 3 of 7

Step 4 Removing the Potentiometer Assembly Locate the pot assembly. Remove the (50002635-403) set screw which secures the pot shaft to the CAM shaft. Set Screws Sem Screws Remove 2-(51109695-312) sems screws that secure the bracket to the casting and then remove the mounting bracket. Slide out the pot shaft and remove the pot assembly. 5 Assembling the Rvit-z board on the mounting bracket. Mount a (51500657-001) Rvit-Z Board to a (51451441-001) mounting bracket using 4-(23000) sems screws. Sem Screws Install a (51451384-001) steel pin through the end of the Rvit-Z riser & secure with a (51452604-001) set screw through the CAM Shaft. Steel Pin 62-86-33-46 Page 4 of 7

Step 6 Mounting the Rvit-Z assembly. Locate the place to mount the Rvit-z assembly. NCS PWA NCS Spoiler NCS Set Screw Slide the Rvit-Z assembly over the end of the CAM Shaft. Secure the bracket to the casting using 2-(51109695-312) sem screws. Spacer Use the plastic Rvit-Z Spacers to set an equal gap between the Risers on each side of the Rvit-Z board. Set screw Sem Screws Install a (50002635-403) set screw. Hold the risers and secure the assembly through the CAM Shaft with the set screw. 62-86-33-46 Page 5 of 7

Step Rvit-z cable Install (51500553-005) Rvit-Z cable to the board which completes the Rvit-z assembly. 7 NCS Position Sensor Calibration See document 62-86-25-10 HercuLine 2000 Series Actuator Installation, Operation and Maintenance Manual. Refer to Table 28 in the Setup and Calibration Procedures section for the NCS position sensor calibration. 8 Replace the gasket. 9 Reattach the top cover and secure with the screws. 62-86-33-46 Page 6 of 7