Laboratory Methods for Testing Actuators

Laboratory Methods for Testing Actuators AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL INC. The International Authority on Air System Components

AMCA Publications Authority AMCA International Standard 520 was approved by the membership of the Air Movement and Control Association International Inc. on July 26, 2008. It was approved as an American National Standard by the American National Standards Institute (ANSI) and became effective on December 2, 2009. As of 2014, this document no longer undergoes routine maintenance and has been withdrawn due to the removal of actuators from AMCA's scope. Since the document is no longer regularly reviewed by engineers as part of AMCA's document review cycle, it is to be used as a historic reference. It is not a current American National Standard. Copyright 2004 by Air Movement and Control Association International Inc. All rights reserved. Reproduction or translation of any part of this work beyond that permitted by Sections 107 and 108 of the United States Copyright Act without the permission of the copyright owner is unlawful. Requests for permission or further information should be addressed to the executive director, Air Movement and Control Association International Inc. at 30 West University Drive, Arlington Heights, IL 60004-1893 U.S.A. Objections Air Movement and Control Association International, Inc. will consider and decide all written complaints regarding its standards, certification programs, or interpretations thereof. For information on procedures for submitting and handling complaints, write to: Air Movement and Control Association International 30 West University Drive Arlington Heights, IL 60004-1893 U.S.A. AMCA International, Incorporated c/o Federation of Environmental Trade Associations 2 Waltham Court, Milley Lane, Hare Hatch Reading, Berkshire, United Kingdom RG10 9TH Disclaimer AMCA uses its best efforts to produce standards for the benefit of the industry and the public in light of available information and accepted industry practices. However, AMCA does not guarantee, certify or assure the safety or performance of any products, components or systems tested, designed, installed or operated in accordance with AMCA standards or that any tests conducted under its standards will be nonhazardous or free from risk.

Related AMCA Documents Related Publications ANSI/AMCA Standard 500-D ANSI/AMCA Standard 500-L Laboratory Methods for Testing Dampers for Rating Laboratory Methods for Testing Louvers for Rating

Contents 1. Purpose....................................................................................1 2. Scope......................................................................................1 3. Definitions / Units of Measure / Symbols.........................................................1 3.1 Definitions..............................................................................1 3.2 Units of measure.........................................................................1 3.3 Symbols and subscripts...................................................................3 4. Instruments and Methods of Measurement.......................................................3 4.1 Instrumentation..........................................................................3 4.2 Accuracy...............................................................................3 4.3 Torque.................................................................................3 4.4 Meters.................................................................................3 4.5 Chronometers...........................................................................3 4.6 Temperature............................................................................3 4.7 Air pressure.............................................................................3 4.8 Force..................................................................................3 4.9 Linear measurement......................................................................3 4.10 Angular measurement.....................................................................3 5. Equipment and Setups........................................................................3 6. Objective, Observations and Conduct of Test.....................................................3 6.1 Long term holding tests....................................................................3 6.2 Operational life tests......................................................................5 6.3 Ambient and elevated temperature performance testing..........................................5 6.4 Periodic maintenance testing...............................................................6 6.5 Production tests..........................................................................6 6.6 Sound level testing.......................................................................7 Annex A References.............................................................................8 Annex B Rated Load.............................................................................9 Annex C Rated Stall Load.......................................................................10

ANSI/AMCA 520-09 Laboratory Methods of Testing Actuators 1. Purpose To establish an industry standard for minimum rating and testing of actuators used on fire/smoke dampers. 2. Scope The testing requirements will cover torque or force rating, long term holding, operational life, elevated temperature performance, periodic maintenance, production, and sound testing for both pneumatic and electric operators. 3. Definitions / Units of Measure / Symbols 3.1 Definitions 3.1.1 Load The external force or torque that an actuator must oppose. This can be specified while either moving or stationary (stalled), and in either drive or return directions. The damper is the source of the load and is due to bearing/seal friction and any unbalanced air loading. 3.1.2 Rated load [4] The actuator manufacturers stated load for a given amount of time for full stroke at nominal electrical or rated pneumatic power and elevated exposure temperature per UL555S. 3.1.3 Rated stall load [4] The actuator manufacturer s stated (minimum) torque or force output (in both drive and return directions) at nominal electrical or rated pneumatic power and the rated elevated exposure temperature per UL555S when the actuator output shaft is prevented from rotating at a given position. See Annex C. 3.1.4 Full stroke The movement of a device from the resting position (end stop, zero position) to its nominal position in its intended application. Example: For a linear actuator with a nominal 55 mm ± 5 mm (2.2 in. ± 0.2 in.) travel, a full stroke would be 0 55mm (2.2 in.). Example: For a rotary actuator with a nominal 105 ± 5 rotation, a full stroke would be 0 105. Example: For a 360 rotary actuator, a full stroke shall be no less than 90 and not exceed 180 of rotation. These actuators should have an external lever, stops and return spring so as to duplicate an actual application or installation on a damper. 3.1.5 Full stroke cycle The movement of a device from its resting position (end stop, zero position) to its nominal position in its intended application, and then back to the resting position. Example: For a linear actuator with a nominal 55 mm ± 5 mm (2.2 in. ±.2 in.) travel, a full stroke cycle would be 0 55 (2.2 in.) 0mm. Example: For a rotary actuator with a nominal 105 ± 5 rotation, a full stroke cycle would be 0 105 0. 3.1.6 Stall torque/force The amount of torque/force that stops the actuator from moving. 3.1.7 Dynamic stall torque/force The peak torque/force that an actuator, running under nominal conditions (nominal voltage/pressure and rated load), develops when subjected to a hard stop. 3.1.8 Spring return torque/force The unpowered output at the actuator/damper shaft due to the return spring (or other stored energy source) that returns the actuator to the normal unpowered position. 3.1.9 Reposition A modulating actuator reposition or repositioning cycle is a minimum rotation of the damper actuator 5 (± 2 ) or 10% in one direction and in the reversed direction. 3.1.10 Nominal voltage Sometimes referred to as nameplate voltage. A standard value assigned to a circuit for the purpose of conveniently designating a voltage class (i.e. 120 VAC). 3.1.11 Sound power level [3] The acoustic power radiating from a sound source. 3.1.12 Noise criteria A standard for comparison or judgment of sound levels. 3.2 Units of Measure SI units (The International System of Units) are the primary units employed in this standard, with I-P units (Inch-Pound) given as the secondary reference. SI units are based on the fundamental values of the International Bureau of Weights and Measures [1], and I-P values are based on the values of the National Institute of Standards and Technology that are, in turn, based on the values of the International Bureau. 3.2.1 System of units The unit of length is the meter (m), or millimeter (mm); I-P ANSI/AMCA 520-09 1

Table 1 - Symbols and Subscripts Symbol Description SI I-P F Force N lb F s Stall force N lb L Crank arm length mm in L p Sound pressure level db db L w Sound power level db db NC Sound noise criteria dimensionless P Pneumatic pressure kpa PSI T Torque N-m lb-in. t a Ambient temperature C F T s Stall Torque N-m lb-in. 2 ANSI/AMCA 520-09

units are the foot (ft) or the inch (in.). The unit of mass is the kilogram (kg); the I-P unit is the pound mass (lbm). The unit of time is either the minute (min), or the second (s). The unit of temperature is either the degree Celsius ( C), or the degree Kelvin (K), I-P units are either the degree Fahrenheit ( F), or the degree Rankine ( R). The unit of force is the Newton (N); the I-P unit is the pound (lb). 3.2.2 Torque The unit of torque is the Newton-meter (N-m); the I-P unit is the pound-inch (lb-in.). 3.3 Symbols and subscripts See Table 1. 4. Instruments and Methods Of Measurement 4.1 Instrumentation The test instruments used for the rating and testing of actuators for fire/smoke dampers shall be calibrated as required by the manufacturer with the period between calibrations not exceeding one year with calibration standards traceable to the National Institute of Standards and Technology. 4.2 Accuracy [2] The specifications for instruments and methods of measurement that follow include both accuracy requirements and specific examples of equipment that is capable of meeting those requirements. Equipment other than the examples cited may be used provided the accuracy requirements are met or exceeded. 4.2.1 Instrument accuracy The specifications regarding accuracy correspond to the criteria in Section 6. Instruments shall be set up, calibrated, and read by qualified personnel trained to minimize errors. 4.3 Torque [2] A torque device shall have a static calibration and may have a running calibration through its range of usage. The static calibration shall be made by suspending weights from a torque arm. The weights shall have certified accuracies of ± 2%. The length of the torque arm shall be determined to an accuracy of ± 2%. Applied torque shall be measured with a weight and pulley system, a torque transducer and digital readout with an accuracy of ±1%, or with a torque wrench with an accuracy of ± 4%. 4.4 Meters [2] Electrical meters shall have certified accuracies of ± 1% of the observed reading. 4.5 Chronometers [2] A quality watch, with a sweep second hand or a digital display of seconds that keeps time within two minutes per day is considered a primary instrument. 4.6 Temperature [2] Temperatures shall be measured with thermometers or other instruments with demonstrated accuracies of ± 1 C (± 2 F) and readabilities of 0.5 C (1 F) or finer. 4.7 Air pressure Air pressure shall be measured with a pressure transducer and digital readout or a pressure gauge. These instruments shall have a demonstrated accuracy of ± 1% and a resolution of 3.448 kpa (0.5 PSI). The air pressure shall be measured in the feed line when the unit under test is stabilized in the full stroke (pressurized) position. 4.8 Force Applied force shall be measured either with a load cell and digital readout, a force gauge, or with a scale. These instruments shall have a demonstrated accuracy of ± 2% of reading and a resolution of 2.28 N (0.5 lb.) 4.9 Linear measurement Linear measurement shall be measured with an instrument with a minimum resolution of 1mm (.04 in.) (this need not be NIST traceable). 4.10 Angular measurement Angular measurement shall be measured with an instrument having a resolution of 1 (this need not be NIST traceable). 5. Equipment and Setups See Figures 7.1A and 7.1B. ANSI/AMCA 520-09 3

Figure 7.1A Rotary Actuator Load Capability Test Setup (Conceptual) Figure 7.1B Linear Actuator Load Capability Test Set-Up (Conceptual) 4 ANSI/AMCA 520-09

6. Objective, Observations, and Conduct of Test 6.1 Long term holding tests 6.1.1 Purpose The purpose of this test is to verify both electrical and pneumatic actuators in two position applications, during periods in extended holding in its nominal position and its intended application. 6.1.2 Test criteria A sample of thirty-two actuators will be tested for six months to determine their ability to return to the non-powered position. Representative samples of each design or design variation shall be individually tested. An "Un-Interruptible Power Supply" (UPS) should be utilized and monitored to verify the devices were not cycled during the duration of this test. The actuator must return to the normal (fail safe) position each time electrical power is removed. For pneumatic actuators, the actuator must return to the normal (fail safe) position after supply air is removed. All actuators must return to the normal (fail safe) position within their rated time. Normal (fail safe) position must be repeatable within 3 mm for linear actuators or 3 for rotary actuators. 6.1.3 Method The voltage or pressure to the actuator must be maintained for the duration of this test. Place the actuator in an orientation to simulate mounting on a horizontal damper shaft, undisturbed as much as possible for the duration of the test. Actuators shall have no external load except actuators with external springs, which must be tested at the minimum spring force recommended by the actuator manufacturer. Apply the test voltage specified in Table 2 for an electrically operated actuator, or apply ten percent (10%) above the rated pressure of pneumatically operated actuator, for a period of six months. Following the six month holding test, remove the electrical/pneumatic power and record observations of actuator timing. This test is to be performed at ambient 10 C to 55 C (50 F to 130 F) conditions. Note: Actuators must be pre-tested prior to this procedure in order to demonstrate proper operation. See production test. 6.2 Operational life tests 6.2.1 Purpose To verify the actuator produced will perform 20,000 full stroke cycles for two position actuators (100,000 for modulating actuators) under specified load, nominal voltage or PSI range. 6.2.2 Test criteria (pass/fail criteria) Cycle the actuator continuously through electrical or pneumatic power, and fail-safe return, for the required number of cycles and test parameters, and still be able to perform at rated load and rated stall load. For modulating actuators, 32 samples shall be cycled 20,000 times and repositioned 100,000 times, with a maximum of one failure in 32 samples. 6.2.3 Method Actuators, of the same design family (example:same drive components, operating time and torque/force output with differing power source requirements), may be mixed for this test. This test is to be performed at ambient 10 C to 55 C (50 F to 130 F) conditions. The electrical or pneumatic power supplied to the actuator shall be at the nominal voltage or specified pressure. The actuator shall have no external load, except for a return spring if external to actuator, and operated in both directions thereby simulating an abrupt stop, with a minimum two second hold period at each end of the stroke. If actuator has an external return spring, the spring shall have the maximum spring load as allowed by the actuator manufacturer. Following the cycling described above, the minimum rated load and rated stall load must be verified in both directions for each actuator. 6.3 Ambient and elevated temperature performance testing 6.3.1 Purpose [4] Determine that the rated load and rated stall load can be achieved before (at room ambient) and after being temperature soaked for thirty minutes at the rated elevated exposure temperature per UL555S as specified by the actuator Table 2 Voltage Rating of Product 110-120 220-240 254-277 440-480 550-600 Test Voltage 120 240 277 480 600 If the device voltage rating does not fall within any of the indicated ranges, it is to be tested at its rated voltage. ANSI/AMCA 520-09 5

manufacturer in their product data sheets. Actuators with different input electrical or pneumatic power must be tested separately. 6.3.2 Test criteria The actuator must be capable of completing three full stroke cycles at the manufacturer's rated load and temperature at nominal nameplate voltage or specified pressure. The time required to complete each stroke shall not exceed the manufacturers rated stroke time or at a maximum of seventy-five seconds. Three actuator samples must be tested and all must deliver the rated load. 6.3.3 Method Mount the device in the chamber. While still at room ambient temperature apply rated electrical or pneumatic power to the actuator. Apply opposing rated load to the actuator for three complete stroke cycles. The operating time shall not exceed seventy-five seconds for each stroke and shall be recorded. With the device still mounted in the chamber, apply rated electrical or pneumatic power to the actuator, and heat to the rated temperature not to exceed 27.8 C (50 F) per minute. Maintain temperature +27.8 C / -0 C (50 F / -0 F) for thirty minutes after reaching test temperature. While at elevated temperature, apply the opposing rated load to the actuator for three complete stroke cycles. The operating time shall not exceed seventy-five seconds for each stroke and shall be recorded. After completing the three cycles, the stall torque of the operator shall be determined at 15, 30 and 80 of operation. Note: It is not the intent of this test to verify transformer operation at elevated temperatures when the transformer is not factory mounted internal to the actuator. If the method of driving the actuator when power is removed is external to the device, the actuator manufacturer is required to specify the return spring characteristics for the rated load. 6.4 Periodic maintenance testing Periodic elevated temperature testing. 6.4.1 Purpose This test is intended to give an indication of performance changes in the product production processes. Three devices shall be submitted for testing every six months. They will be randomly selected from the production line with a minimum of fifty production parts between samples. All models need not be tested (models with the same motor, gear train and bearing design can be grouped together to represent one like sample). A random system of selecting product from each manufacturer is to be established. Actuators shall be obtained from each producing factory. 6.4.2 Test criteria The actuator must be capable of completing three full stroke cycles at the manufacturer's rated load and temperature at rated electrical or pneumatic power input. The time required to complete each stroke shall not exceed the manufacturers rated stroke time or at a maximum of seventy-five seconds. Three actuator samples must be tested and all must deliver the rated load. 6.4.3 Method Mount the device in the chamber. While still at room ambient temperature apply rated electrical or pneumatic power to the actuator. Apply opposing rated load to the actuator for three complete stroke cycles. The operating time shall be recorded. After completing the three cycles, the stall torque of the operator shall be determined at 15, 30 and 80 of operation. With the device still mounted in the chamber, apply nominal nameplate voltage or specified pressure to the actuator, and heat the chamber to the elevated exposure temperature at a rate not to exceed 27.8 C (50 F) per minute. Maintain temperature +27.8 C / -0 C (50 F / -0 F) for thirty minutes after reaching test temperature. While at elevated temperature, apply the opposing rated load to the actuator for three complete stroke cycles. The operating time shall be recorded. After completing the three cycles, the stall torque of the operator shall be determined at 15, 30 and 80 of operation. Note: It is not the intent of this test to verify transformer operation at elevated temperatures when the transformer is not factory mounted internal to the actuator. If the method of driving the actuator when electrical or pneumatic power is removed is external to the device, the actuator manufacturer is required to specify the return spring characteristics for the rated load. 6.5 Production tests 6.5.1 Purpose The production test is intended to verify that the actuator being produced meets the product design criteria, as specified by the manufacturer. Each unit must pass the test requirements prior to being released from production. 6.5.2 Test criteria The final production test must include at least one full stroke cycle of the actuator and test all relevant functions. This test 6 ANSI/AMCA 520-09

is to be performed at ambient 10 C to 55 C (50 F to 130 F) conditions. 6.5.3 Method The actuator test apparatus must provide a torque or force load equal to the manufacturers rating. The nominal nameplate voltage or specified pressure supplied to the actuator should be the nominal nameplate voltage (± 5%) or specified PSI range. The actuator operating time, both under electrical or pneumatic power and under fail-safe mode, must meet the standards set by the manufacturer. the motor thirty minutes and after closing and reopening the damper. The damper shall be tested per ANSI/AMCA Standard 300 as a freestanding unit that would be placed entirely in the test room (See ANSI/AMCA Standard 300, Figure 1). After determining the maximum sound power level from the two tests, a NC (noise criteria) number shall be determined by subtracting ten db from each sound power level band test reading, and plotting the results on an NC curve to determine the NC level. If the actuator is electrically powered, the current draw must be measured during the power cycle of the test. The measured current must meet the standards set by the manufacturer. Should the actuator be built with internal auxiliary switches, the operation of the switch(s) must be tested at their designed activation point. The point of activation must be within the range specified by the manufacturer. If the actuator is designed for proportional position control, the test apparatus must be able to measure the modulated position of the actuator. The actual position must be able to be compared to the input signal and be within the design parameters of the actuator. If the actuator provides a proportional feedback signal, the feedback signal must be within the specifications of the manufacturer to actual position. All actuators that meet the above test criteria are identified and contain a date code for trace ability. The electrical or pneumatic power supplied to the actuator shall be recorded at the time of the test. 6.6 Sound level testing [3] 6.6.1 Purpose To determine the noise criteria level produced by the actuator in the full stroke position. 6.6.2 Test criteria The sound power level (L w ) of electrically operated actuators shall be determined by testing the actuator on a 610 mm 610 mm (24 in. 24 in.) triple V groove fire/smoke damper installed in a 432 mm (17 in.) long 0.81 mm (0.032 in.) gauge sleeve in the energized position. 8.6.3 Method The sound power level (L w ) shall be taken after energizing ANSI/AMCA 520-09 7

Annex A References (Normative) [1] NIST Special Publication 330-08 The International System of Units (SI) National Institute of Standards and Technology, U.S. Department of Commerce [2] ANSI/AMCA Standard 500-D-07 Laboratory Methods for Testing Dampers for Rating AMCA International, Inc., Arlington Heights, IL 60004 U.S.A. [3] ANSI/AMCA Standard 300-08 Reverberant Room Method For Sound Testing of Fans AMCA International, Inc., Arlington Heights, IL 60004 U.S.A. [4] UL Standard UL555S Smoke Dampers Standard for Safety, Underwriters Laboratories Inc., Northbrook, IL 60062 U.S.A. 8 ANSI/AMCA 520-09

Annex B Rated Load [4] (Informative) Rated load is the maximum external torque or force that the actuator can reliably* move three full stroke cycles in the time specified by the actuator manufacturer at electrical or pneumatic power ± 2% after one half hour at the rated elevated exposure temperature per UL555S. Notes: 1. The drive (D) and spring return (SR) rated loads does not have to be the same. 2. Rated load performance is to be verified as follows. At least three typical new (not altered) sequentially built or randomly selected new actuators are to be loaded using weights that produce the rated torque or force ± 1% and timed in each direction (D and SR) after one half hour at the rated elevated exposure temperature per UL555S. The average time and conventional standard deviation (SD) for both D and SR times are to be calculated. The average stroke time minus three of their SD must be less than or equal to the time specified for the actuator. Normal ambient temperature timing data may be utilized for comparison in production. Note: If the actuator does not have an internal spring the actuator manufacturer s specified spring(s) must be attached prior to confirming the rated load and specified timing. 3. If the average force or torque required to stroke (D or SR) a given damper at the rated elevated exposure temperature per UL555S is less than or equal to the actuators rated load(s) then the damper will open in the actuator s specified time provided that the stall torque of the actuator is not exceeded at any point in it s stroke. ANSI/AMCA 520-09 9

Annex C Rated Stall Load [4] Rated stall load is the torque or force that an actuator will reliably produce at any specified point(s) in it s stroke after one half hour at the rated elevated exposure temperature per UL555S. In the drive (D) direction power is to be at nominal ± 2%. The actuator manufacturer must specify the stall torque or force at the following points (as a minimum): 15 for nominal 90 stroke or 16.7% of stroke, 30 for nominal 90 stroke or 33.3% of stroke, and 80 for nominal 90 stroke or 88.9% of stroke. Note: The rated stall load performance is to be verified as follows. At least three typical new (not altered) sequentially built or randomly selected actuators are to be stopped at the specified points and the dynamic torque or force measured after one half-hour at the rated elevated exposure temperature per UL555S. The average torque or force at each point minus three SD must be greater than or equal to the rated stall load specified for the actuator at that point. Normal ambient stall torque or force data may be utilized for comparison in production. 10 ANSI/AMCA 520-09

AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL INC. 30 West University Drive Arlington Heights, IL 60004-1893 U.S.A. Tel: (847) 394-0150 Fax: (847) 253-0088 Email : info@amca.org Web: www.amca.org The Air Movement and Control Association International Inc. is a not-for-profit international association of the world s manufacturers of related air system equipment, primarily but not limited to fans, louvers, dampers, air curtains, airflow measurement stations, acoustic attenuators and other air system components for the industrial, commercial and residential markets.