Honeywell 2000 manual

Honeywell Field Solutions Her cuLine ® 2000 Series Actuator Installation, Operation and Maintenance Manual Doc. No.: 62-86-25-10 Revision: 7 Date: 7/08[...]

ii HercuLine™ 2000 Series Actuator - Insta llation, Operation and M aintenance Manual Revision 7 7/08 Notices and Trademarks Copyright 2008 by Honeywell Revision 7 July 2008 Warranty/Remedy Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact your local sales office for warranty informat[...]

Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O peration and M aintenance Manual iii 7/08 About This Document Abstract This manual describes the installation, set up, op er ation, maint enance, and troubl eshooting of the HercuLine 2000 ser ies actu ators. References The following list identifies all documents that may be sources of[...]

iv HercuLine™ 2000 Series Actuator - Insta llation, Operation and M aintenance Manual Revision 7 7/08 Symbol Definitions The following table lists those symbols that may be used in this document to denote certain cond itio ns. Symbol Definition This DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in d[...]

Contents Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual v 7/08 Contents Introduc tion ............................................................................................. 1 Product De scription ..................................................................................................[...]

Contents vi HercuLine™ 2000 Series Actuator - Insta llation, Operation and M aintenance Manual Revision 7 7/08 Lock Set Up Group ..................................................................................................... 53 Read Status Se t Up Group ........................................................................................[...]

Contents Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual vii 7/08 Tables Table 1 Specifications - General............................................................................................... .............................. 5 Table 2 Recommended Mi nim um Wire Size.............................[...]

Contents viii HercuLine™ 2000 Series Actuator - Insta llation, Operation and M aintenance Manual Revision 7 7/08 Figures Figure 1 HercuL ine ® 2000 Series Actuator 2 Figure 2 HercuL ine ® 2002 Ac tuator Internal View 3 Figure 3 Outline and Dimensions of HercuLine ® 20 00 Series Actuators 14 Figure 4 Consta nt Torq ue Li nka ge 15 Figure 5 Vari[...]

Introduction Product Description Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 1 7/08 Introduction Product Description Honeywell’s HercuLine ® 2000 series actuators are available in four versions: HercuLine ® 2000 , HercuLine ® 2001 , HercuLine ® 2002, and HercuLine ® 2003 . All are low torqu[...]

Introduction Product Description 2 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maintenance Manual Revision 7 7/08 Displa y and key pad Shaft and position indicator Handwheel Auto/m anual swit ch Conduit entry Figure 1 HercuLine ® 2000 Series Ac tuator[...]

Introduction Product Description Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 3 7/08 TB3 Connector for customer input and output connection on CPU PWA Display Keypad PWA Wiring Label Non-contact sensor External auto-manual switch TB1 customer power connection Relay PWAs Cams an d limit switches Mec[...]

Introduction Product Description 4 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maintenance Manual Revision 7 7/08[...]

Specifications Technical and Operat ing Specifications Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 5 7/08 Specifications This section provides you with the tech nical sp ecifications and the model selection guide for the HercuLine ® 2000 Series A ctuators. Technical and Operating Specifications T[...]

Specifications Technical and Operat ing Specifications 6 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maintenance Manual Revision 7 7/08 Electrical Mains Supply 100-130 Vac single ph ase, 50 Hz or 60 Hz 200-240 Vac single ph ase, 50 Hz or 60 Hz Motor Instant start/stop, non-coasting, non- burnout, continuo us duty, permanent mag[...]

Specifications Technical and Operat ing Specifications Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 7 7/08 HercuLine ® 2002 Herc uLine ® 2001 HercuLine ® 2000/2003 Feedback Slidewire emulation - Provides output voltage ratiometric to shaft position and potentiometric to supply voltage (1 Vdc to [...]

Specifications Technical and Operat ing Specifications 8 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maintenance Manual Revision 7 7/08 HercuLine ® 2002 Herc uLine ® 2001 HercuLine ® 2000/2003 Programmable Functions Selectable and configurabl e operating parameters: NA • Input range • Input filtering • Input characteri[...]

Specifications Technical and Operat ing Specifications Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 9 7/08 Specifications – Communications Communications Communications Option RS 485 Serial Communicatio n, Modbus RTU Protocol Connection Twisted pair cable with shield Maximum loop length 600 meter[...]

Specifications Model Selection Guide 10 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maintenance Manual Revision 7 7/08 Model Selection Guide Instructions Select the de sired key numb er. The arrow to the righ t marks the selec tion availab le. Make the desired selections from Tables I thru VIII usin g the column belo w t he arr[...]

Specifications Model Selection Guide Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 11 7/08 2002 2003 TABLE VI - OPTIONS Selection Local keypa d/ No local display interface supplied (Note 2) 0_ _ _ _ _ display Integrally mount ed local display/keypad interfa ce 1_ _ _ _ _ Local Auto/ No auto/manual s[...]

Installation Installation Overview 12 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maintenance Manual Revision 7 7/08 Installation Installation Overview The procedures to install the HercuLin e ® 2000 Series actuator and place it in se rvice require that you: • Select a suitable location for installation. (See Installat ion C[...]

Installation Before Starting Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 13 7/08 Before Starting Unpacking If there are vi sible signs of dam age to the shipping co ntaine r, notify the carrier and Honeywel l im m ediately. If there is no vi sible damage, compare the contents w ith the packing lis[...]

Installation Actuator Mounting 14 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maintenance Manual Revision 7 7/08 CLEARANCE FOR TOP REMOV AL: 101,6 4.0 289 11.379 25.4 1.00 CLEARANCE FOR TOP REMOV AL: 101,6 4.0 289 11.379 25.4 1.00 mm inches Figure 3 Outline and Dimensions of HercuLine ® 2000 Serie s Actuators[...]

Installation Mechanical Installation Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 15 7/08 Mechanical Installation Linkage Set-up Many applicat ions require the use of a linkage assem bly and often the final control element does not have a linear torque curve. The actuator linkage can be set up to a[...]

Installation Mechanical Installation 16 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maintenance Manual Revision 7 7/08 Ver ti cal C e nt e r li ne 5° Vert ica l Cen ter li n e 45° 45° Clos e Open Act ua tor Cran k Arm Damper Cran k Arm Lin k age Horizon tal Off set a /n 2320 0 Figure 5 Variable Torque Linkage Actuator Cran k[...]

Installation Electrical Installation Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 17 7/08 Electrical Installation General Wiring Recommendations Only qualified personnel should p erform wiring. Wiring must conform to national and loc al electrical codes. In general, copper wire used. Unle ss local[...]

Installation Electrical Installation 18 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 HercuLine ® 2000 Terminal Connectio ns Table 3 Terminal Connections: Herc uLine ® 20 00 Connection Terminal Numbers and LABEL See Figure 8 Descriptions Hot 1 Hot wire for 120/240VAC mains supply. Use onl y i[...]

Installation Electrical Installation Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 19 7/08 HercuLine ® 2001/2002 w ith Auto/Manual Terminal Connection s Table 4 Terminal Connections: Herc uLine ® 2001/2002 with auto/manual Connection Terminal Numbers and LABEL See Figure 9 Descriptions TB1 Hot 1 [...]

Installation Electrical Installation 20 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 HercuLine ® 2003 Wiring Connection s and Operation (Actionator 640D Replacemen t) Wiring Figure 10 HercuLine ® 2003 connectio ns Operation The 2003 actuator is uni-directional (it do es not rev e rse rotatio[...]

Installation Electrical Installation Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 21 7/08 Power Connections Depending on which powe r supply selection is o rdered for you r actuator, wire the power input (MAINS POWER) as de scribed in the previ ous tables and figures. Wiring must conf orm to natio[...]

Installation Electrical Installation 22 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Step Action 8 • AC power connection • Auxiliary switches connecti on • Relay contact connection Rel ays 3 an d 4 Rel ays 1 an d 2 Aux switches 1 and 2 (SW 3 and SW 4) Aux switches 3 and 4 (SW 5 an d SW 6[...]

Burner Control/Flame Safet y Electrical Installation Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 23 7/08 Output Signal Connections 0/4-20 mA, 0/1-5 Vdc Feedback Signal Connec tion s ATTENTION Shielded and groun ded cables are recomme nded. Actuator output is a 4 to 20 mA an alog signal. If a volt[...]

Burner Control/Flame Safet y Series 90 Control – HercuLi ne® 2001 model onl y 24 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Series 90 Control – HercuLine ® 2001 model only Series 90 Cont rols are commonl y used in buil ding environmental systems and flam e safeguard systems to provide [...]

Burner Control/Flame Safet y Series 90 Control – HercuLi ne® 2001 model onl y Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 25 7/08 GND to HercuLine2 001 ( 2) W W W R R B B A uto Man I out from HercuLine2 001 + Signal to HercuLine2 001 T775 B 3 T775 W 1 T775 R 2 Figure 15 T775 Controller connect[...]

Burner Control/Flame Safet y Split Range 26 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Split Range The HercuLine ® 20 01/2002 actuators can be set up to ope rate within a nar row input range (for example, 4 to 12mA input) in certain applications. The procedure in Table 5 describes how to se[...]

Burner Control/Flame Safet y Master/Slave Arrangement Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 27 7/08 Basic Flow Control When the pr ocess variable signal is below set point , the controller in creases current (4 to 20mA) to the actuator input and op en s the valve. Controller set point gover[...]

Burner Control/Flame Safet y Master/Slave Arrangement 28 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Proportional wit h B ia s Ratio Position mA PV SP 4 to 2 0 mA Cont roll er Positione r & Actua tor Linkage Valv e Or if ice Pla te FT MP #1 MP #2 MP #3 FIC Li nkage Linkage Valv e Valv e F[...]

Burner Control/Flame Safet y Master/Slave Arrangement Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 29 7/08 Hot 10260S Series Actuator #1 Neutral Ground 120/240 VAC 250 Ohms 1 to 5 VDC + - Current Out put Controller 4 to 2 0 mA Hot 10260S Series Actuator #2 Neutral Ground 120/240 VAC Hot 10260S Ser[...]

Burner Control/Flame Safet y Master/Slave Arrangement 30 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Split Valve Configuration A comm on heat or cool type proces s requires two valves. In this case the control ler has only one out put. The two motor positioners ar e calibrated differently, on[...]

Set Up and Calibration Procedures Overview Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 31 7/08 Set Up and Calibration Procedures Overview Once you have installed the actuator , you can verify, set or change certain operat ing parameters. Set up is accomplished through use of the local display and[...]

Set Up and Calibration Procedures Local Display and Keyp ad 32 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Table 6 Keypad Description Key or LED Indicator Function SET UP Places the actuator in the set up group select mode. Sequ entially displays the set up groups and allo ws the FUNCTION key[...]

Set Up and Calibration Procedures Set Up Tips Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 33 7/08 Set Up Tips Table 7 contains tips that will help you view, verify and enter the operating parameters more quickly. If you cannot c hange the param eters, check the status of t he “SET LOCK” param[...]

Set Up and Calibration Procedures Set Up Groups 34 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Set Up Groups Pressing the SET UP key on the key p ad provides access to the various set up groups and allows you to set up operating p arameters, (such as in put types and alarms ), calibrate the a[...]

Set Up and Calibration Procedures Set Up Groups Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 35 7/08 SET MA INT Display various operating statistics. Reset accumulated operating statistics Table 22 CA L POSOUT Use the displa y as an indicator, (in this case a voltmeter) so you can verify that the [...]

Set Up and Calibration Procedures Set Up Procedure 36 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Set Up Procedure Each of the set up groups and their functions are either pre-configured at the fact or y or set to their default values. Tables 8 through 19 li st and describe the optio ns avail[...]

Set Up and Calibration Procedures Set Up Procedure Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 37 7/08 Step Operation Press Result 5 Change the Value or Selection or These keys increase or decrease the value, or disp lay the next available selection for the sel ected function prompt. See Table 7,[...]

Set Up and Calibration Procedures Configuration Prompt Hierarchy 38 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Configuration Prompt Hierarchy TEMP TEMPHI TEM PLO ACSTAL START S RL1CNT RL2CNT RL3CNT RL4CNT REGN0 REGN9 TOTDEG DATSAV PASSWD MANRST LD CAL LD CFG RESTRT … VERSON SPEED POWER ROT[...]

Set Up and Calibration Procedures Input Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 39 7/08 Input Set Up Group Table 10 lists the parameters and selections available when the SET INPUT group is selected. On the keypad and local display: • Press the SET UP key to enter the Input Set[...]

Set Up and Calibration Procedures Input Set Up Group 40 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Actuator Lower Display Prompt Selections or Range of Setting Parameter Definition/PDA HercuLink Prompt FILTYP NONE SPIK S+LP LPAS default = LPAS INPUT FILTER TYPE — Allows the selection of a [...]

Set Up and Calibration Procedures Input Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 41 7/08 Actuator Lower Display Prompt Selections or Range of Setting Parameter Definition/PDA HercuLink Prompt FSFTYPL LA ST UP DOWN USER default = DOWN FAILSAFELO TYPE —Selects the motor position y[...]

Set Up and Calibration Procedures Input Set Up Group 42 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Equal Percentage Valve Characteristi c Table 11 conta ins values that appr oximate an equal pe rcentage valve characteristic in the actuator. When the EQUL custom characteriz ation ty pe is sel[...]

Set Up and Calibration Procedures Input Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 43 7/08 Quick Opening Valve Characteris tic Table 12 contains values t hat approximate the charact eristic of a quick op ening con trol valve. When the QUIK custom character ization type is selected, [...]

Set Up and Calibration Procedures Relays Set Up Group 44 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Relays Set Up Group ATTENTION The Relay set up group parameters are acc essible only if relay PWAs are installed in the actuator. HercuLine ® 2001 actuators can be equ ipped with one PWA –f[...]

Set Up and Calibration Procedures Relays Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 45 7/08 Table 14 Relay Type Descriptions When this Relay Type is selected… (RTYP) The Relay ca n be set up to indicate … Input Range The upper / lower limits of the input signal have be en exceed[...]

Set Up and Calibration Procedures Relays Set Up Group 46 HercuLine™ 2000 Series Actuator - Installa tion, Operation and Maint enance Manual Revision 7 7/08 Relay connec tor #1 Relay connec tor #2 Relay connec tor #3 Relay connec tor #4 Figure 22 Relay connectors Relay Examples Relay Type - Position Range Selecting PosR relay type, you can cause t[...]

Set Up and Calibration Procedures Relays Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 47 7/08 Relay Type - Deviation Setting up a relay to alarm (energize) when the motor position deviates 10% (+ or -) from the actuator setpoint can be set up as f ollows. Set Up Group Para mete r Value[...]

Set Up and Calibration Procedures Relays Set Up Group 48 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Relay Type – Upper Limit Travel with Hyster esis Selecting relay type ULim will cause the relay to energize when the motor po s ition exceeds the upper limit trip point, and can be set up as[...]

Set Up and Calibration Procedures Current Out Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 49 7/08 Current Out Set Up Group Table 15 lists the parameters and selections available for the SET CUROUT group. Table 15 Current Out Set Up Group Paramete rs Actuator Lower Display Prompt Selec[...]

Set Up and Calibration Procedures Communications Set Up Group 50 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Communications Set Up Group Table 16 lists the parameters and selections available for the SET COMM group. Table 16 Communications Set Up Group Parame ters Actuator Lower Display Promp[...]

Set Up and Calibration Procedures Digital Input Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 51 7/08 Digital Input Set Up Group Table 17 lists the parameters and selectio ns availible for the SET DIGINP group. Table 17 Digital Input Set Up Group Parameters Actuator Lower Display Prompt[...]

Set Up and Calibration Procedures Display Set Up Group 52 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Display Set Up Group Table 18 lists the parameters and selections availible for the SET DISPLAY group. Table 18 Display Set Up Group Parameters Actuator Lower Display Prompt Selections or Ran[...]

Set Up and Calibration Procedures Lock Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 53 7/08 Lock Set Up Group Table 19 lists the parameters and selections available for the SET LOCK group. Table 19 Lock Set Up Group Parameters Actuator Lower Display Prompt Selections or Range of Settin[...]

Set Up and Calibration Procedures Lock Set Up Group 54 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Set/Change Password A password is required to disable the ability to read ily chang e features of th e actuator. Lock out of calibration capability and other su pervisory functions can be contro[...]

Set Up and Calibration Procedures Read Status Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 55 7/08 Read Status Set Up Group Table 20 lists the parameters and selections available for the READ STATUS group. Table 20 Read Status Set Up Group Paramete rs Actuator Lower Display Prompt Sele[...]

Set Up and Calibration Procedures Drive Set Up Group 56 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Drive Set Up Group Table 21 lists the parameters and selections available for the SET DRVINF group. Table 21 Drive Set Up Group Parameters Actuator Lower Display Prompt Selections or Range of S[...]

Set Up and Calibration Procedures Drive Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 57 7/08 Actuator Lower Display Prompt Selections or Range of Setting Parameter Definition/PDA HercuLink ® Prompt LREP mmddyy * or ddmmyy DATE OF LAST REPA IR — Factory set only. Displays date of las[...]

Set Up and Calibration Procedures Drive Set Up Group 58 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Set Tag Name The actuator ta g name can be an alp hanumeric name up t o six characters. The ta g name is set by usi ng the keys on the keypad and the local d isplay. Follow the steps below to s[...]

Set Up and Calibration Procedures Maintenance Set Up Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 59 7/08 Maintenance Set Up Group The Maintena nce set up group consists of information about actuator operation acc umulated through ti me. This information (or maintenance statistics) can be use[...]

Set Up and Calibration Procedures Maintenance Set Up Group 60 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Actuator Lower Display Prompt Selections or Range of Setting Parameter Definition/PDA HercuLink ® Prompt PDA users: The prompts are or ganized differently on y our PDA’s HercuLink ® s[...]

Set Up and Calibration Procedures Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 61 7/08 Actuator Lower Display Prompt Selections or Range of Setting Parameter Definition/PDA HercuLink ® Prompt PDA users: The prompts are or ganized differently on y our PDA’s HercuLink ® software. Grayed prompt s [...]

Set Up and Calibration Procedures Regions of Motor Travel 62 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Regions of Motor Travel The full span of motor travel can b e 90 ° or 150 ° rotation. The span is divided in to 10 regions of motor travel as shown in Figure 23 (regions ar e numbered 0 [...]

Set Up and Calibration Procedures CAL POSOUT Group Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 63 7/08 CAL POSOUT Group The CAL POSOUT group is used to veri fy that the position sensor is operatin g and adjusted properly. This group allows the local disp lay to indicate the output vo ltage of the [...]

Set Up and Calibration Procedures Auto - Manual Drive Switch 64 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Auto - Manual Drive Switch The Auto - Manual switch is located on the side of the actuator case below the handwheel. T he switch allows manual mode control of the actuator motor for set[...]

Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 65 7/08 Calibration Calibration of the HercuLine ® 2000 Series Actuator may consist of calibrating th e motor circuit that positions the actuato r with 0/4-20mA input signal, calibrating the poten tiometer o[...]

Set Up and Calibration Procedures Calibration 66 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Calibration Set up Follow the steps below to set up the test equipment and actuator to verify calibration or perform calibration procedures. Step Action 1 Determine input type (c urrent or voltage). 2[...]

Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 67 7/08 Actuat or Input 5 4 -+ Output 2 1 3 -+ + - Calibrated Signal Source Digital Voltme ter + - FB Terminal Block Power Supply 1-18 VDC + - Internal 250 ohm resistor settable through Jumper W 2 Current Vol[...]

Set Up and Calibration Procedures Calibration 68 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Jumper W 2 Figure 27 Jumper Location on CPU PWA Calibrate Input The HercuLine ® 2001/2002 a ctuator accepts a variety of signal inputs. 1. 0 to 20 m A, or 4 to 20 m A 2. 0 to 5 Volts,1 to 5 Volts, or[...]

Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 69 7/08 Table 25 Input Calibration Procedure Step Operation Press Result 1 Enter Calibration Mode SETUP until you see Upper Display = CA L Lower Display = INPUT FUNCTION Upper Display = DIS Lower Display = CA[...]

Set Up and Calibration Procedures Calibration 70 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Calibrate Motor Use the procedure in Table 26 to calibrate the actu ator motor for 0% and 100% input signal ATTENTION For a motor calibration to be saved, you must co mplete the procedure. The calibra[...]

Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 71 7/08 Calibrate Output HercuLine ® 20 01/2002 actuator can be one of three output types: 1. 0 to 20 m A, or 4 to 20 m A output 2. 0 to 5 V olts, or 1 to 5 Vol ts with 250 ohm range resistor 3. Slidewire em[...]

Set Up and Calibration Procedures Calibration 72 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Step Operation Press Result 2 Calibrate Zero (0%) FUNCTION Upper Display = xxx Lower Dis play = ZERO • Read meter connected to actuator output. or key • Adjust actuator output to a va lue equal to[...]

Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 73 7/08 Table 28 Slidewire Emulation Calibration Procedure Step Operation Press Result 1 Enter Calibration Mode SETUP until you see Upper Display = CA L Lower Display = OUTPUT FUNCTION Upper Display = DIS Low[...]

Set Up and Calibration Procedures Calibration 74 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 While the unit is powered, a potentia lly lethal shock hazard exists insi de the case. Table 29 NCS Position Sensor Calibration Procedure Step Action 1 Remove AC power to the actuator. 2 Remove the si[...]

Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 75 7/08 NCS Spoi ler (shown at full 150 degre e trave l CCW ) NCS P W A NCS set screw Relay P W A card guides (rela y P W As removed) Figure 28 Location of NCS Assembly[...]

Set Up and Calibration Procedures Calibration 76 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Table 30 Potentiometer Position Sensor Calibrati on Procedure Step Action 1 Remove AC power to the actuator. 2 Remove the six screws and the top co ver from the actuator case. See Figure 2. Lay extend[...]

Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 77 7/08 Potentiom e ter posit ion sens or Mountin g brack et Figure 29 Location of potentiometer position sen s or Table 31 Load Position Sensor Factory Calibration Step Action 1 Reapply AC power to the actua[...]

Set Up and Calibration Procedures Setting End-of-Travel Limit Switches 78 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 Setting End-of-Travel Limit Switches ATTENTION Referring to Figure 31. The first two cams (starting from th e fro nt) are for the 0% and 100% limit switches (Switch #1 and Swi[...]

Set Up and Calibration Procedures Setting End-of-Travel Limit Switches Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 79 7/08 Table 32 End-of-Travel Limit S w itch Setting Procedure Step Action 1 Remove AC power to the actuator. 2 Remove the six screws and the cover from the actuat or case. See Figur[...]

Set Up and Calibration Procedures Setting End-of-Travel Limit Switches 80 HercuLine™ 2000 Series Act uator - Installation, Operation and Maintenance Manu al Revision 7 7/08 ATTENTION Make sure you do not to set the s wit ches too close to the hard stop. Relay #1 Relay #2 Relay #3 Relay #4 Aux switch #1 Aux switch #2 Aux switch #3 A ux switch #4 E[...]

Set Up and Calibration Procedures Setting Auxiliary S witches Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, Oper ation and Maintenance Manual 81 7/08 Setting Auxiliary Switches ATTENTION Referring to Figure 31. The first two cams (starting fro m the front) are for the 0% and 100% end of tra vel limit switches ( Switches #1 and #2 ) [...]

Set Up and Calibration Procedures Setting Auxiliary S witches 82 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Table 33 Auxiliary Swit ch Setting Procedure Step Action 1 Remove AC power to the actuator. 2 Remove the six screws and the cover from the actuat or case. See Figure 2. Lay cover assembl[...]

Start-Up/Operation Introduction Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 83 7/08 Start-Up/Operation Introduction After the actuator is completely installed, wired, and the preliminary adjustments made, it is advisable to check the operation of the actu ator an d controlled device before placin[...]

Start-Up/Operation Operating Displays 84 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Operating Displays Pressing the DISPLAY key c ycles the displa y through a number of op erating parameters. Table 34 shows a number of sam ple displays that can be shown durin g operation. Table 34 Typical Oper[...]

Start-Up/Operation Position Sensor Operation Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 85 7/08 Position Sensor Operation On HercuLine ® 2000 an d HercuLine ® 2001 the po ten tiometer position sensor is a sealed film pot that is directly coupled to the out put sha ft. On HercuLine ® 2002 the [...]

Start-Up/Operation Remote Setpoint Operation 86 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 9 8 67 COMM UNI CA TI O N SHIELD 10 IN P COM DI GI TAL I NPUT - + Act uat or Ter m i nal Bl oc k Figure 33 Terminal Block Connections for Modb u s Communications[...]

Maintenance Introduction Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 87 7/08 Maintenance Introduction There is som e basic maintenance that is recommended for t he HercuLine ® 2000 Series Actuators. The electronic PWAs within the actuator require no ma intenance or servicing under normal conditi[...]

Maintenance Basic Maintenance 88 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Bottom cover Gears Motor pi nion gear Final output spur gear Idler spur gear Figure 34 Spur Gear Location[...]

Maintenance Replacement Procedures Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 89 7/08 Replacement Procedures Fuse Replacement The motor drive circuit contains two fuses. They are locat ed on the power distribu tion PWA. If it becomes necessary to replace these fuse s, follow the procedure in Tab[...]

Maintenance Replacement Procedures 90 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Power D is tr i buti on PW A F u ses f or Moto r D r iv e Circ uit Figure 36 Motor Drive Circuit Fuses Relay PWA Replacem ent If a relay PWA needs t o be replaced, follow the procedure in Table 37 to a ccess and r[...]

Replacement/Upgrade/Accessor y Kits Replacement Kits Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 91 7/08 Replacement/Upgrade/Accessory Kits Replacement Kits This section provides you with a complete list of all th e sp are parts that may be needed for the HercuLine ® 2000 Series Actuators and op[...]

Replacement/Upgrade/Accessor y Kits Replacement Kits 92 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 10 Figure 38 Replacement Kit 10[...]

Replacement/Upgrade/Accessor y Kits Replacement Kits Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 93 7/08 4,5,9 15 1 3 19 16 2 Figure 39 Replacement Kits 1, 2, 3, 4, 5, 9, 15, 16, 19[...]

Replacement/Upgrade/Accessor y Kits Replacement Kits 94 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 13 Figure 40 Replacement Kit 13[...]

Replacement/Upgrade/Accessor y Kits Replacement Kits Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 95 7/08 17, 18 Figure 41 Replacement Kits 17, 18[...]

Replacement/Upgrade/Accessor y Kits Replacement Kits 96 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 See Figure 37 thro ug h Figure 41 for drawings of replacement kit contents. Table 38 Replacement kits Qty/Unit Part Number Description Figure ID # 51450802-503 Relay Kit 1 2 Relay Pwa 4 Plug 03 P[...]

Replacement/Upgrade/Accessor y Kits Replacement Kits Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 97 7/08 Qty/Unit Part Number Description Figure ID # 51451656-50 6 1000 Ohm Potentiometer Kit 150 Degr ees (HercuLine ® 2000) 5 1 Pot 1 K Double 150 Degree 2 #6-32 Hex Nut N 2 #6 Washer 2 #6 Lock Was[...]

Replacement/Upgrade/Accessor y Kits Replacement Kits 98 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Qty/Unit Part Number Description Figure ID # 51452174-501 Crank Arm Kit 6 1 Crank Arm 1 Screw,Hex Hd,1 3/4 X 1/4-20 1 Kllwss1/4sp 1 Nut Nmsndc 1/4-20 Qty/Unit Part Number Description Figure ID # [...]

Replacement/Upgrade/Accessor y Kits Replacement Kits Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 99 7/08 Qty/Unit Part Number Description Figure ID # 51452443-50 1 51452443-50 7 51452443-50 8 51452443-50 9 51452443-51 0 51452443-51 1 Spur Gear Kit 10 1 Spur Gear 24p, 18t 1 Spur Gear 24p, 18t 1 Sp[...]

Replacement/Upgrade/Accessor y Kits Replacement Kits 100 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Qty/Unit Part Number Description Figure ID # 51452443-504 Display and Ke ypad Kit 13 1 Display Gasket 1 Overlay, Display 1 Lens, Display 1 Gasket,Adhesive Die Cut 1 Display Mtg Collar Machining [...]

Replacement/Upgrade/Accessor y Kits Replacement Kits Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 101 7/08 Qty/Unit Part Number Description Figure ID # 51452443-506 R/C Kit (Motor date codes after to 8/5/2005) 1 Capacitor, 4.0 Mfd 1 1 Cable plus Resistor, 400Ohm 1 1 Capacitor, 3 Mfd, 400vac 1 1 Ca[...]

Replacement/Upgrade/Accessor y Kits Upgrade Kits 102 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Qty/Unit Part Number Description Figure ID # 51500581-504 Auto/Manual Switch (upg rade for SA2001 & SA2002) 18 1 Auto/Manual Label 1 Nut, Sealing 3/8-32 Thrd 1 Knob 1 A/M Switch/Wire Assy 1 Labe[...]

Replacement/Upgrade/Accessor y Kits Upgrade Kits Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 103 7/08 Qty/Unit Part Number Description 51452444-503 Co ver with Display and Han dw heel 1 Display gasket 1 Overlay, display 1 Lens, display 1 Gasket,adhesive die cut 1 Display mtg collar machining 1 Ke[...]

Replacement/Upgrade/Accessor y Kits Accessory Kits 104 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Qty/Unit Part Number Description 51451656-511 1000 ohms 150 degrees upgrade kit 2 Machine screw-pan hd-cross rec 1 Knob 1 Bracket molding 1 Pot 1K double 150 degr ee 2 #6 lock washer 2 Machine scr[...]

Troubleshooting Introduction Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 105 7/08 Troubleshooting Introduction Troubleshooti ng procedures can be followed when inaccura te or faulty actuato r operation is detected . In this section, troublesho o ting procedures consist of a few sim ple flo w char[...]

Troubleshooting Troubleshooting Proced ures 106 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Troubleshooting Procedures Overvie w Follow the p rocedure or flow chart to test for an d determine actuator c omponent operat ion. When using the flow charts for troub leshooting, you may be instruct ed[...]

Troubleshooting Troubleshooting Proced ures Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 107 7/08 Test for Actuator Operation Do al l di agnosti cs pass? RAMTST PAS S SEETST P AS S CALTST PASS CFGT ST PASS Replace display assembly Doe s motor reposition itse lf ? Ye s Ye s No No All LEDs and dis p[...]

Troubleshootin g Troubleshootin g Procedures 108 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Power Up Self Test Diagnostics Replace di s play assembly . Cycl e pow er to actuator. I f CALTST fai ls again, replace CPU assembly . Cyc le power to act ua to r . If CFGTST fai ls again, replac e CPU [...]

Troubleshootin g Troubleshootin g Procedures Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 109 7/08 Test Power Distribution PWA Replace CPU assembly. Is cor rect voltage pres ent at test points? See be low . Remove top cover of act uator. A re fuses good ? Replace fuses wit h same type and rating Y[...]

Troubleshootin g Troubleshootin g Procedures 110 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Test AUTO - MANUAL DRIVE Switch Possible troubl e spots a. Auto/Manua l swit ch b. Power Supply PW A. (S ee D) c. Limi t s w itch es d. M otor e. R/ C netw orks f. etc. ,Oth ers? Doe s motor drive in t [...]

Troubleshootin g Troubleshootin g Procedures Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 111 7/08 Test Relay Function Set suspe ct Relay type to MAN. Replace Relay PW A or W ire ha rness from Relay PW A to te rmina l block. See Relay replacement in Ma i n te na n ce , S e c tio n 7 . Set AU TO - [...]

Appendix A - HercuLine® 2001/2002 Co nfiguration Record Sheet 112 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Appendix A - HercuLine ® 2001/2002 Configuration Record Sheet Enter the value or selection for each set up parameter on this sheet so you will have a record of how your actuator is co[...]

Appendix A - HercuLine® 2001/2002 Co nfiguration Record Sheet Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 113 7/08 Set Up Group Prompt Parameter Setting Default X19 VAL - User configur able characterizer v alue X20 VAL - User configur able characterizer v alue Y0 VAL -- User configurabl e charac[...]

Appendix A - HercuLine® 2001/2002 Co nfiguration Record Sheet 114 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Set Up Group Prompt Parameter Setting Default RTYP31 – Relay Type R31VAL – Relay Value R31 HL – Relay Hi gh/Lo w R31SCALE– Relay Sca le RTYP32 – Relay T ype R32VAL – Relay [...]

Appendix A - HercuLine® 2001/2002 Co nfiguration Record Sheet Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 115 7/08 Set Up Group Prompt Parameter Setting Default SET DRVINF VERSON – Firmware Version SPEED – Stroke Speed POWER – Power Input Voltage Li ne Frequenc y TAG – Tag Name MFGDAT ?[...]

Index 116 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Index A Actuator Rotation, 40, 64 Actuator Set Up, 33 Set up groups, 34 Set up procedure, 36 Actuator Statistics Accumulated motor star ts, 59 Motor starts, 59 Relay cycle co unt s, 59 Reset, 60 Temperature limits, 59 Total degrees of motor [...]

Index Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 117 7/08 Inputs, 39 Installation, 12 Installation Considerations, 13 Isolation, 6 K Keypad, 8, 31 Description, 32 L LEDs on Local Display, 32 Limit Switches, 78 Setting, 78 Linkage Kits, 96 Linkage Set-up, 15 Constant torque, 15 Crank arms, 16 Var[...]

Index 118 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Stall, 84 Start Up Checklis t, 83 Storage Temperature, 5 Stroke Speed, 56 T Tag Name, 58 TAG parameter, 56 Technical and O perating Specifications, 5 Temperature Coeffic ient, 7 Terminal Connections, 18, 19 Total Degrees of M otor Travel TOT[...]

Revision 7 HercuLine™ 2000 Seri es Actuator - Installation, O per ation and Maintenance Manual 119 7/08[...]

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