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HercuLine 2000 Series Actuator

1. Xn VAL Yn Val Order Quick Opening Valve Characteristic of of Range Range 0 0 0 1 5 10 2 10 20 100 3 15 30 95 4 20 40 a 85 5 25 50 80 6 30 60 S 70 7 35 70 O e kl 8 40 77 P 60 9 45 82 g Se S 50 10 50 86 g 45 oO 11 55 88 40 35 12 60 90 gt 30 E 13 65 92 EE 20 14 70 94 15 15 75 95 10 5 16 80 96 0 17 85 97 5 10 20 30 40 50 60 70 80 90 100 18 90 98 5 Xn VAL Actual Input 19 95 99 5 20 100 100 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 43 3 13 Set Up and Calibration Procedures Relays Set Up Group Relays Set Up Group 44 ATTENTION The Relay set up group parameters are accessible only if relay PWAs are installed in the actuator HercuLine 2001 actuators can be equipped with one PWA for a total of two SPDT relays Using the Relay set up groups you can program the installed relays to operate in response to various operating conditions Table 13 lists the parameters and selections available when the SET RELAYn group is selected Table 13 Relay Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Seiting Prompt RTYPny NONE RELAY TYPE Selects the relay number and the relay n 1 2 3 0r4
2. Set Up Group Parameter Value SET RELAY1 RTYP11 DEV R11VAL 10 00 R11HL HI RTYP12 DEV R12VAL 10 00 R12HL LO RLY1HY 0 0 The resulting action is shown below Input Motor gt 0 50 Position 10 10 Closed Closed Open RELAY n Normally Open Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 3 13 47 Set Up and Calibration Procedures Relays Set Up Group Relay Type Upper Limit Travel with Hysteresis Selecting relay type ULim will cause the relay to energize when the motor position exceeds the upper limit trip point and can be set up as follows Note that relay hysteresis parameter RLY 1HY value is set to 10 which is 10 of range This means that when the relay is energized due to the motor position exceeding the upper limit value the relay will not de energize until the motor moves to 10 below the trip point Set Up Group Parameter Value SET RELAY2 RTYP21 ULim R21VAL 70 0 R21HL HI RTYP22 NONE RLY2HY 10 0 Motor _ gt 0 60 70 100 Position Closed Openi RELAY n Normally Open Motor 0 60 70 100 Position Closed H nHO fo TH lt I RELAY n Normally Open Relay Type Motor Starts Selecting relay type STRT will cause the relay to trip when the number of motor starts exceeds the selected l
3. Display Range of Setting PDA users The prompts are organized differently on your PDA s HercuLink Prompt software Grayed prompts are under Configuration Maintenance Non grayed prompts are under Maintenance TEMP nnnn F ACTUATOR TEMPERATURE Read Only Displays the current internal temperature of the actuator TEMPHI nnnn F HIGH TEMPERATURE LIMIT Displays the high temperature limit of the internal actuator temperature since it was last reset TEMPLO nnnn F LOW TEMPERATURE LIMIT Displays the low temperature limit of the internal actuator temperature since it was last reset hh mm ss t ACST t ACCUMULATED STALL TIME Displays the accumulated stall time of the actuator motor since it was last reset STARTS nnnn ACCUMULATED MOTOR STARTS Displays the accumulated motor starts since it was last reset Multiply displayed value times 10 to get actual value Range is 0 to 999 900 000 RLnCNT nannn RELAY CYCLE COUNTS Displays the accumulated cycle counts of a relay since it was last reset One relay cycle is n 1 2 30r4 when a relay is energized and deenergized Multiply displayed value times 10 to get actual value Range is 0 to 999 900 000 REGNn nnnn ACCUMULATED MOTOR STARTS Displays the accumulated motor starts in the 1 10 of motor span since n 0t09 it was last reset See Regions of Motor Travel page 62 Multiply displayed value times 10 to get actual value Range is 0 to 999 900 000 TOTDEG nnnn T
4. 38 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Input Set Up Group 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 Up group Press the FUNCTION key to scroll through the prompts listed in the set up group Press the A or W keys to view selections or change range settings Table 10 Input Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt INPUT ACTUATION TYPE This selection specifies the IN TYP signal type and range you are going to use for the actuator input Be sure that the values configured for the high and low Note If input range alarm setpoint etc are within the measuring range type from model for the selected signal range selection guide is 4 20 4 to 20 mA 0 4 20mA 0 1 0 20 0 to 20 mA 5Vdc 0 10Vdc 1 5V 1 to 5 Volts dc 0 5V 0 to 5 Volts dc 0 10 0 to 10 Volts dc R_SP Remote Setpoint via communications NOTE Changing the Input Actuation Type will restore the actuator calibration to its factory values IN TYP S 90 Series 90 0 to 135 ohms Note If input type from model selection guide is Series 90 control INP HI 10 0 to 100 INPUT HIGH RANGE VALUE in is displayed de
5. Digital Input The digital input closure Total Degrees The total degrees traveled Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 45 3 13 Set Up and Calibration Procedures Relays Set Up Group ah Relay connector 1 d Relay connector 2 Relay connector 3 Relay connector 4 Figure 22 Relay connectors Relay Examples Relay Type Position Range Selecting PosR relay type you can cause the relay to energize when the actuator motor travels below 20 of range and above 80 of range Note in the example below that Relay 1 is set up to provide two trip points The first trip point R11 VAL causes the relay to energize when the motor travels above 80 the second trip point R12VAL is set so the relay energizes when the motor travels below 20 Set Up Group Parameter Value SET RELAY1 RTYP11 PosR R11VAL 80 0 R11HL HI RTYP12 PosR R12VAL 20 0 R12HL LO RLY1HY 0 0 The figure below shows the resulting action Motor _ 0 20 80 100 Position Closed RELAY 1 Normally Open 46 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Relays Set Up Group 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 follows
6. Pot 1 K Double 150 Degree 6 32 Hex Nut N 6 Washer 6 Lock Washer Machine Screw Pan Hd Cross Rec MNINININJ Top Cover Gasket Kit Instruction 62 86 33 38 Qty Unit Part Number Description Figure ID 50018180 501 Upgrade to Non Contact Position Sensor HercuLine 2001 6 PCB Assembly Screws SEMS 4 40 x 310 Ig Gasket Cable Assembly RVI T Z Setup Gage Bracket Molding Stainless Steel Pin ee ee 1 sch Set Screw 3 32 x 4 40 Kit Instruction 62 86 33 46 Qty Unit Part Number Description Figure ID 51452342 501 10K Ohm Potentiometer Kit HercuLine 2001 9 Position Sensor SA2001 6 32 Hex Nut N 6 Washer 6 Lock Washer Machine Screw Pan Hd Cross Rec N NI N INJj Top Cover Gasket Kit Instruction 62 86 33 40 Qty Unit Part Number Description Figure ID 515000657 502 Rvit Z Ncs Replacement Kit 19 Ncs Rvit Z Pwa 0 150 Machnl 4 40 X 31 Pnslstl Top Cover Gasket Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 97 Replacement Upgrade Accessory Kits Replacement Kits Qty Unit Part Number Description Figure ID 51452174 501 Crank Arm Kit 6 Crank Arm Screw Hex Hd 1 3 4 X 1 4 20 Kllwss1 4sp a
7. 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Maintenance Replacement Procedures Replacement Procedures Fuse Replacement The motor drive circuit contains two fuses They are located on the power distribution PWA If it becomes necessary to replace these fuses follow the procedure in Table 36 and refer to Figure 36 for fuse location A WARNING Disconnect power before opening the actuator case to replace the fuse s A potentially lethal shock hazard exists inside the case if the unit is opened while powered Table 36 Motor Drive Fuse Replacment Procedure Step Action 1 Remove AC power from actuator 2 Remove the 6 screws and the extended cover of the actuator case See Figure 35 3 Lay assembly down on a flat surface 4 Remove connectors from CPU and power distribution PWA 5 Remove power distribution PWA 6 Locate the two fuses on the power distribution PWA See Figure 36 Carefully remove and replace fuse s with Wickmann T1 type 6A 250V or equivalent not available from Honeywell Reinstall power distribution PWA Reconnect connectors to CPU and power distribution PWA 9 Install a new gasket and replace extended cover Secure to actuator with screws F 8 oe Relay connector 1 J Power CPU Relay connector 2 retay PWA distribution connections Relay connector 3 PWA Relay connector 4 Retay PWA 2 Figure 35 Power Distribut
8. 3210 FPLB Floating Point Little Endian format with byte swapped 2301 default FP B 50 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Digital Input Set Up Group Digital Input Set Up Group Table 17 lists the parameters and selections availible for the SET DIGINP group Table 17 Digital Input Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Seiting Prompt DIGINP Digital Input State Selects the position of the actuator in response to a digital input signal contact closure NONE None No action by the actuator UP Up Actuator motor moves to full scale value DOWN Down Actuator motor moves to zero value USER User selected value Actuator motor moves to a customer selected value default UP Allows setting of End Position Value EndPos 0 100 END POSITION VALUE DIGINP USER only Selects the in percent motor position you want the actuator to go to when digital input signal present contact closure Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 51 Set Up and Calibration Procedures Display Set Up Group Display Set Up Group Table 18 lists the parameters and selections availible for the SET DISPLAY group Table 18 Display Set Up Group Parameters
9. 5 terminals will close The motor then rotates for 180 or until the opening switch breaks stops are adjustable factory set at 180 and stops in full open position A subsequent rise in temperature causes the controller to close the switch between the 4 and 6 terminals when the motor will start to rotate in the same direction for 180 or until the closing switch breaks The motor stops in the closed position and completes one cycle 20 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Installation Electrical Installation Power Connections Depending on which power supply selection is ordered for your actuator wire the power input MAINS POWER as described in the previous tables and figures Wiring must conform to national and local electrical codes CE Wiring When wiring the actuator power input for CE approved units you must also install a MOV and ferrite beads supplied with the CE unit You need the following tools e 5mm hex key e small flat blade screwdriver e small needle nose pliers A WARNING While the unit is powered a potentially lethal shock hazard exists inside the case Do not open the case while the unit is powered Do not access the terminals while the unit is powered Step Action 1 Remove AC power to actuator Loosen the 6 captive screws use 5mm hex key and remove the cover Locate the terminals TB
10. Installation Operation and Maintenance Manual Revision 8 3 13 Installation Mechanical Installation Mechanical Installation Linkage Set up Many applications require the use of a linkage assembly and often the final control element does not have a linear torque curve The actuator linkage can be set up to achieve an optimal delivered torque distribution for specific applications To assist with linkage design Honeywell offers a linkage analysis software application HAL The software can be ordered as P N 51197910 001 Constant Torque Linkage typical A constant torque linkage is employed when it is desired to provide a linear torque profile throughout the full range of final control element travel In this situation the actuator and driven crank arms will be set up proportionally with respect to each other Figure 4 shows a general linkage setup to achieve a linear torque profile Vertical Vertical Centerline Centerline RE 45 45 y Linkage Es Start Stop Close ASS Open Drive Unit Damper Crane Arm Horizontal Offset eran Ani aln 23199 Figure 4 Constant Torque Linkage Variable Torque Linkage A variable torque linkage is employed when it is desired to provide a non linear torque profile throughout the full range of final control element travel In this general situation the actuator and driven crank arms will be set up to provide a higher torque for seating or unseating the final control ele
11. User configurable characterizer value 73 7 Y19 VAL User configurable characterizer value 86 2 Y20 VAL User configurable characterizer value 100 SET RELAY RTYP11 Relay Type NONE R11VAL Relay Value 0 R11 HL Relay High Low LO R11SCALE Relay Scale X1 RTYP12 Relay Type NONE R12VAL Relay Value 0 R12 HL Relay High Low LO R12SCALE Relay Scale X1 RLY1HY Relay Hysteresis 0 RTYP21 Relay Type NONE R21VAL Relay Value 0 R21 HL Relay High Low LO R21SCALE Relay Scale X1 RTYP22 Relay Type NONE R22VAL Relay Value 0 R22HL Relay High Low LO R22SCALE Relay Scale X1 RLY2HY Relay Hysteresis 0 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 113 3 13 Appendix A HercuLine 2001 2002 Configuration Record Sheet Set Up Group Parameter Setting Default Prompt RTYP31 Relay Type NONE R31VAL Relay Value 0 R31 HL Relay High Low LO R31SCALE Relay Scale A RTYP32 Relay Type NONE R32VAL Relay Value 0 R32HL Relay High Low LO R32SCALE Relay Scale A RLY3HY Relay Hysteresis 0 RTYP41 Relay Type NONE R41VAL Relay Value 0 R41 HL Relay High Low LO R41SCALE Relay Scale X1 RTYP42 Relay Type NONE R42VAL Relay Value 0 R42HL Relay High Low LO R42SCALE Relay Scale X1 RLY4HY Relay Hysteresis 0 SET CUROUT CUROUT Output Signal Range S
12. CPU assembly Check actuator Cycle power to calibration actuator If CALTST recalibrate fails again replace if necessary CPU assembly Do all LEDs and display ER segments ligh up Yes Replace display assembly Figure 43 Power Up Diagnostics Test Non Contact Sensor PWA See page 85 108 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Troubleshooting Troubleshooting Procedures Test Power Distribution PWA Remove top cover of actuator Check Fuses F1 and F2 on the power distribution PWA No W Replace fuses with same type and rating Are fuses good Is correct voltage present at test points See below Replace CPU assembly Figure 44 Test Power Distribution PWA Power Distribution PWA Test Points Replace Power Distribution PWA Connector Test Points Pins Voltage J2 Pin 1 to pin 7 5V J3 Pins 1 2 to pins 3 4 8 5V Pins 3 4 to pin 7 9V J1 Pins 5 6 to pins 7 8 24 V Pins 1 2 to pins 7 8 28 V or 3V Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 109 Troubleshooting Troubleshooting Procedures Test AUTO MANUAL DRIVE Switch Yes Turn switch to Manual CW setting Does motor drive in the CW direction Yes MANUAL AUTO
13. If it becomes necessary to do a calibrationin the field adjust the output using the procedure in Table 28 Refer to Figure 26 for a diagram to connect a signal source to the actuator input and a DVM to measure actuator output signal D ATTENTION For a slidewire emulation output calibration to be saved you must complete the procedure The calibration will not be saved if you exit without completing the steps of the procedure To exit calibration mode press DISPLAY or SETUP keys 72 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Calibration Table 28 Slidewire Emulation Calibration Procedure Step Operation Press Result 1 Enter Calibration SETUP Upper Display CAL Mode until you see Lower Display OUTPUT FUNCTION Upper Display DIS Lower Display CALOUT Aor key Upper Display BEGN Lower Display CALOUT 2 Calibrate Zero 0 FUNCTION Upper Display XXX Lower Display ZERO xxx arbitrary number assigned by software Aor V key Adjust actuator output voltage using down key until value on DVM ceases to change then press up key until value on DVM moves up one digit 3 Calibrate Span FUNCTION Upper Display XXXX 100 Lower Display SPAN xxx arbitrary number assigned by software Aor V key Adjust actuator output voltage using A key until value on DVM ceases to change then press W down key until val
14. 150 degree 6 lock washer Machine screw pan hd cross rec 6 32 hex nut N Stainless steel pin 3 32x4 40 setscrew sshxsocupsb Washer 6 Flat washer M4 zinc MMs Ms Hlel Ms MM He Ay_oyhy Resistor 158 ohms 1 1 2W Kit Instruction 62 86 33 39 Accessory Kits Part Number Description 51197910 001 HAL Linkage Analysis software 51452354 509 HercuLink software PC Palm 51452354 510 Battery powered Palm 485 converter w cables 51452174 501 Crank Arm Standard 51452791 001 Crank Arm 2003 Unit 51452352 501 Turk Cable for Communication Connection 104 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Troubleshooting Introduction Troubleshooting Introduction Troubleshooting procedures can be followed when inaccurate or faulty actuator operation is detected In this section troubleshooting procedures consist of a few simple flow charts to test for proper function of various actuator components Component replacement is at the PWA or assembly level Table 39 indicates some of the observable symptoms of failure that can be identified by noting the faulty actuator operation Table 39 Observable Symptoms of Failure Symptom No Actuator current output No Actuator slidewire output Local display does not light Actuator fails one or more power up di
15. Accessory Kits Replacement Kits See Figure 37 through Figure 41 for drawings of replacement kit contents Table 38 Replacement kits Qty Unit Part Number Description Figure ID 51450802 503 Relay Kit 1 Relay Pwa Plug 03 Position 1 Top Cover Gasket Qty Unit Part Number Description Figure ID 51451397 501 CPU Kit 2 1 HercuLine CPU Bd Assembly 1 Plug 10 Pos 1 Label Phonix Connector 1 To 10 1 Insulator 4 Pin Snap Lock 125 X 187 Lg 1 Top Cover Gasket Qty Unit Part Number Description Figure ID 1 51452302 501 PROM Kit 2 Qty Unit Part Number Description Figure ID 51451424 501 Backplane Kit 3 1 HercuLine Backplane Assy 1 Card Guide Assy 1 Card Guide 4 Split Washer 4 Machine Screw Pan Head Slotted 4 Screw Trilob Philph 4 20x 38 1 Top Cover Gasket Qty Unit Part Number Description Figure ID 51451656 505 1000 Ohm Potentiometer Kit 90 Degrees 4 HercuLine 2000 1 Pot 1 K Double 90 Degree 2 6 32 Hex Nut N 2 6 Washer 2 6 Lock Washer 2 Machine Screw Pan Hd Cross Rec 1 Top Cover Gasket Kit Instruction 62 86 33 38 96 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Replacement Upgrade Accessory Kits Replacement Kits Qty Unit Part Number Description Figure ID 51451656 506 1000 Ohm Potentiometer Kit 150 Degrees HercuLine 2000 5
16. Auto Manual Switch 6 Local Display 8 31 Description 31 LEDs description 32 Operating displays 84 Set up 52 LOCK parameter 33 36 Lubrication 5 Main Worm gear 87 Spur gear 87 Main Gear Lubrication 87 Mains Supply 6 Mechanical Installation 15 Mechanical Stops 5 Modbus communications 50 85 Model distinctions 1 Motor 6 Motor Calibration 70 Motor Current 6 Motor Speed 56 Motor Stall 84 Motor Starts 45 Relay type 48 Mounting 13 N Non Contact Sensor 87 Checking 108 Operation 85 Non Contact Sensor Output Calibration 72 73 O Operating Temperature 7 Index Output Calibration 71 Output Shaft 5 Output Torque 5 Output Type 49 Outputs 49 P Password 60 LOCKID 53 Change 54 PDA 9 Position Range Relay type 46 Position sensing 7 POSITION SENSOR OUTPUT 63 Power Supply PWA Checking 109 Product Description 1 Programmable Functions 8 Pushbuttons Description 32 R Regions of Motor Travel 62 REGN parameter 59 Relative Humidity 5 Relay Function Testing 111 Relay PWA Replacement 90 Relay Type 44 45 Remote Setpoint Operation 85 Repeatability 7 Restore Factory Calibration Values 60 61 Rotation 5 S Scale 5 Scrolling through Set Up Groups 33 Self test Diagnostics 55 83 108 Sensitivity 7 Set Up and Calibration Procedures 31 Set Up Groups Communications 50 Current out 49 Digital input 51 Display 52 Drive 56 Input 39 L
17. HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures CAL POSOUT Group CAL POSOUT Group The CAL POSOUT group is used to verify that the position sensor is operating and adjusted properly This group allows the local display to indicate the output voltage of the position sensor This display is used when verifying the POS sensor is operating and that it is properly calibrated Table 23 shows the selections available for the CAL POSOUT group Table 23 CAL POSOUT Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt CALPOS n nnn POSITION SENSOR OUTPUT Read Only Displays the output voltage of the position sensor To access the display Press Result SETUP Upper Display CAL until you see Lower Display POSOUT FUNCTION Upper Display DIS Lower Display CALPOS A org key Upper Display BEGN Lower Display CALPOS FUNCTION Upper Display n nnn sensor output in volts Lower Display POSOUT Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 63 3 13 Set Up and Calibration Procedures Auto Manual Drive Switch Auto Manual Drive Switch The Auto Manual switch is located on the side of the actuator case below the handwheel The switch allows manual mode control of the actuator motor for set
18. MANUAL DRIVE Turn switch to Manual CCW setting No Does motor drive in the CCW No direction y Possible trouble spots a Auto Manual switch b Power Supply PWA See D c Limit switches d Motor e R C networks f etc Others Figure 45 Test AUTO MANUAL Switch 110 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Test Relay Function Press SET UP button on keypad to enter Set up mode Set suspect Relay type to MAN Place ohmmeter across associated relay contacts at Actuator terminal block See below po Set AUTO MANUAL switch to MAN Troubleshooting Troubleshooting Procedures Does Relay Replace Relay PWA or Wire harness from Relay PWA to terminal block See Relay replacement in Maintenance Section 7 Figure 46 Test Relay Function Relay Associated Contacts RELAY 1 NC COM NO RELAY2 NC COM NO RELAY3 NC COM NO RELAY4 NC COM NO Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 111 Appendix A HercuLine 2001 2002 Configuration Record Sheet 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 actua
19. RA Wel ek Sh Rh led 96 Table 39 Observable Symptoms of Failure cc ceesesssesecseeseceeeeecsaeeeessecaeesecneesecsaesecsaeceeesecseeseenaseeeeaeneeereeaees 105 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual vii 3 13 Contents Figures Figure 1 HercuLine 2000 Series Actuator Figure 2 HercuLine 2002 Actuator Internal View Figure 3 Outline and Dimensions of HercuLine 2000 Series Actuators Figure 4 Constant Torque Linkage Figure 5 Variable Torque Linkage Figure 6 Standard crank arm Figure 7 Crank arm with optional ball joint and push rod Figure 8 HercuLine 2000 connections Figure 9 HercuLine 2001 2002 connections Figure 10 HercuLine 2003 connections Figure 11 CE wiring part 1 Figure 12 CE Wiring part 2 Figure 13 Burner Control Flame Safety Wiring Figure 14 Series 90 connections Figure 15 T775 Controller connections Figure 16 Flow Diagram Figure 17 Interconnection Diagram Figure 18 Proportional Flow Using Multiple Actuators Figure 19 Multiple Actuator Interconnection Diagrams Figure 20 Interconnection Diagrams Figure 21 HercuLine 2000 Display and Keypad Figure 22 Relay connectors Figure 23 Regions of Motor Travel Figure 24 Auto Manual Switch Figure 25 Calibration Wiring Connections non slidewire emulation Figure 26 Calibration Wiring Connections slidewire emulation Figure 27 Jumper Location on CPU PWA Figure 28 Location of NCS Assembly F
20. Remove relay cards if present Reapply AC power to the actuator Press SET UP key to access the INPUT set up group Press FUNCTION key until the lower display reads Direct Press the A or W keys to set Actuator Rotation direction to CCW NOTE Actuator direction must be set to CCW for this procedure Direction can be changed after calibration is complete Drive the actuator to the 50 position this refers to the position on the actuator scale for CCW rotation This should be done manually with the handwheel or with the AUTO MANUAL switch Press SET UP key until the display reads CAL POSOUT Press the FUNCTION key until the dispaly reads DIS CALPOS Press the A or W keys until the lower display reads BEGN CALPOS Press FUNCTION key The upper display now shows the output of the position sensor in Volts Loosen the allen screw in the hub of the NCS spoiler just enough to be able to rotate the spoiler See Figure 28 Adjust the NCS spoiler so that the voltage in the local display is 2 500 0 010 volts dc The allen screw should be almost in a vertical position The bottom edge of the spoiler should almost be horizontal in relation to the NCS PWA See Figure 28 Tighten NCS spoiler set screw with an allen wrench holding spoilers located on each side of the NCS PWA in position IMPORTANT Spoilers need to be held in position both rotationally and longitudinally along the drive shaft extension An air gap must
21. SPEED SELECTION speed per 150 degree rotation Torque Ib in N M 50 6 0 100 11 5 200 22 5 400 45 0 400 45 0 TABLE Il ROTATION Travel 90 degrees 150 degrees 360 degrees TABLE Ill POWER SUPPLY Single Phase 100 130 Vac 60 Hz 100 130 Vac 50 Hz 200 240 Vac 60 Hz 200 240 Vac 50 Hz TABLE IV ANALOG INPUT OUTPUT SIGNALS Note 1 Note 1 TABLE V SWITCH AND RELAY OUTPUTS 2 end of travel switches are standard Auxiliary Outputs Relay Outputs 3 Wire Drive up down 0 4 20 mA 0 1 5 Vdc 0 10 Vdc 0 4 20 mA 0 1 5 Vdc 0 10 Vdc 0 to 135 ohm input Series 90 control Contact Input for 2003 None Dual 1000 Ohm 1000 ohms over 150 degrees Dual 1000 Ohm 1000 ohms over 90 degrees Slidewire Emulation Slidewire Emulation 0 4 20mAdc 0 1 5 Vdc 0 16 Vdc 0 4 20mAdc 0 1 5 Vdc 0 16 Vdc No Auxiliary Switches 2 Auxilliary Switches 4 Auxilliary Switches No Relays 2 Programmable Relay Outputs 2 Programmable Relay Outputs 4 Programmable Relay Outputs Selection Availability continued HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Specifications Model Selection Guide 2000 2001 2002 2003 TABLE VI OPTIONS Selection A A No local display interface supplied Note 2 display Integrally mounted local display keypad interface Local Auto No auto manual switch manual switch Auto manual
22. activation type See Table 14 Relay Type Descriptions y 1or2 InPR Input Range Upper lower limits of input signal exceeded PosR Position Range Upper lower limits of motor position exceeded DEV Deviation Deviation from input exceeded ULim Upper Limit Travel Same as PosR for upper limit LLim Lower Limit Travel Same as PosR for lower limit T Hi Temperature High High temperature limit exceeded TLo Temperature Low Low temperature limit exceeded STRT Starts Motor starts limit exceeded Allows setting of multiplier value STAL Stalled Motor position does not follow input MAN Manual Actuator is set to manual mode PWRF Power Up Test Failure Failure of any power up diagnostic FsFA Failsafe Alarm Failsafe condition detected PosF Position Sensor Signal Failure position output out of valid range DiGI Digital Input Digital input closure TDEG Total Degrees total degrees traveled Allows setting of default InPR and multiplier value NONE RnyE X1 MULTIPLIER Relay Types STRT and TDEG only X10k Selects the multiplier for the number limit of motor starts and default X1 total degrees traveled before the relay is activated Multiplier specifies the value on display as times one X1 or times ten thousand X10k RnyVAL 0 0 to 100 0 RELAY VALUE Sets numerical value of limit where relay n 1 2 3 or4 trips energizes Units are determined by the relay type y 1or2 selection See Table 14 Relay Type Descriptions
23. be maintained between the surface of the PWA and each spoiler Any plastic or paper insulating material may be used to create this gap while positioning the spoilers Make sure that neither spoiler is touching the sensor PWA when the adjustment is complete 10 Press DISPLAY key to exit calibration mode 11 Remove AC power to the actuator Reinstall relay cards If present 12 Install a new gasket and replace extended cover Secure to actuator with screws 13 Continue with calibration procedure in Table 31 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Calibration ke LNW Set oi NCS set pE y NCS PWA Relay PWA card guides relay PWAs removed NCS Spoiler Shown at full 150 degree travel CCW Figure 28 Location of NCS Assembly Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 75 3 13 Set Up and Calibration Procedures Calibration Table 30 Potentiometer Position Sensor Calibration Procedure Step Action 1 Remove AC power to the actuator 2 Remove the six screws and the top cover from the actuator case See Figure 2 Lay extended cover assembly on a flat surface Remove relay cards if present 3 Reapply AC power to the actuator 4 Press SET UP key to access the INPUT set up group Press
24. determines the CW direction of rotation of the actuator shaft Counterclockwise rotation Clockwise rotation NOTE Actuator rotation is the direction of the output shaft when facing the end of the shaft and refers to the direction of default CCW rotation on increasing signal Dband 0 2 to 5 0 INPUT DEADBAND Specifies an adjustable gap that is the in percent of difference between the setpoint value and the value at which span the motor energizes Deadband is set in percent of full span default 0 5 FSFTYPH FAILSAFEHI TYPE Selects the motor position you want the actuator to go to when input signal is above the high end range value NOTE Failsafe condition occurs when the input exceeds its high end range value by 3 LAST Last Position Actuator motor remains at last position UP Up Actuator motor moves to full scale value DOWN Down Actuator motor moves to zero value USER User selected value Actuator motor moves to a customer defined value default UP Allows setting of failsafehi input value 0 to 100 FAILSAFEHI INPUT VALUE FailsafeH Type USER only FsFVALH Selects the motor position you want the actuator to go to default 100 when input signal is above the high end range value Range is from 0 to 100 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Input Set Up Group Actuator Lower Display Promp
25. in degrees of rotation or percent of span See Relay Examples for setting upper limit with hysteresis Lower Limit Travel The motor position has exceeded the lower limit of travel Same as Position Range Relay value parameter defines limits and units are in degrees of rotation or percent of span Temperature High The high temperature limit of the actuator has been exceeded Relay value parameter defines temperature limits and units are in either degrees C or degrees F Temperature units are defined in the UNITS setting of the DISPLA set up group Temperature Low The low temperature limit of the actuator has been exceeded Relay value parameter defines temperature limits and units are in either degrees C or degrees F Temperature units are defined in the UNITS setting of the DISPLA set up group Starts The accumulated motor starts have exceeded the limit Relay value parameter defines the limit See Relay Examples for setting motor starts limit Range is from 10 to 99 990 000 Stall The motor is in a stall condition Manual Mode The actuator is in manual mode Power Up Test Failure A failure of any one of the power up test diagnostics See READ STATUS set up group Failsafe The actuator is in failsafe input signal loss or input signal out of valid range Position Sensor Failure The potentiometer or non contact sensor output is out of range or has failed
26. of internal parts and to provide access to the handwheel Actuator Mounting Firmly bolt the actuator to a mounting surface that will not distort when subjected to the torque stresses generated by the actuator The output shaft of the actuator should be parallel to the output shaft of the driven device The output shaft crank arm is fully adjustable through 360 Mounting holes bottom and side and location of shaft crank arm duplicate mounting for Honeywell Actionators M640A 740A 940A for drop in replacement Optional adaptor plates available for replacing Landis and Staefa SQM53 56 and Barber Coleman series MP495 models Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 13 3 13 Installation Actuator Mounting CLEARANCE FOR TOP REMOVAL 289 101 6 11 379 40 Sooo es i Fh AN WITH Viel 187 42 7 eit H 119 Eh j 63 5 WITHOUT WANDWHEEL Na im it s 2500 614 WITHOUT H 1 250 EIB e a Deel ns Ax 11 18 Eege 45 12 25 4 2 800 1 800 1 00 3 18 125 73 66 50 8 2 900 2 000 298 45 11 750 ee 2 HM ne 13 630 1 4 20 UNC batt MOUNTING HOLES 8 PLACES ees Lei 187 26 7 372 oats y 6 1 WITE hone SWITCH 50 6 2 000 1 NPT CONDUIT HOLE 7 600 TH DISPLAY 119 7 047 WITHOUT 3 4 NPT CONDUIT HOLE mm inches Figure 3 Outline and Dimensions of HercuLine 2000 Series Actuators 14 HercuLine 2000 Series Actuator
27. or input limits which are programmable in the HercuLine 2001 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 25 3 13 Burner Control Flame Safety Split Range Split Range The HercuLine 2001 2002 actuators can be set up to operate within a narrow input range for example 4 to 12mA input in certain applications The procedure in Table 5 describes how to set up an actuator to operate as part of a split valve configuration Table 5 Split Range Set Up Procedure Step Action To Set Actuator span to operate from 4 to 12 mA input 1 Enter Set Up mode by pressing SET UP key Select SET INPUT group Press FUNCTION key until INP HI on lower display is selected Set INP HI value to 50 0 Press FUNCTION key to select INP LO and set value to 0 0 oO oa Gol DY Press DISPLAY key to exit Set Up mode To Set Actuator span to operate from 12 to 20 mA input 1 Enter Set Up mode by pressing SET UP key Select SET INPUT group Press FUNCTION key until INP HI on lower display is selected Set INP HI value to 100 0 Press FUNCTION key to select INP LO and set value to 50 0 2 3 4 5 6 Press DISPLAY key to exit Set Up mode ATTENTION Be sure to review failsafe strategy for your process application Master Slave Arrangement Introduction 26 With the motor positioner the controlling signal for
28. parameter See SET DISPLA set up group t Note that the upper display contains the parameter name and the lower display contains the value This is to allow for the display of hours minutes seconds Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 61 3 13 Set Up and Calibration Procedures Regions of Motor Travel Regions of Motor Travel The full span of motor travel can be 90 or 150 rotation The span is divided into 10 regions of motor travel as shown in Figure 23 regions are numbered 0 through 9 Maintenance statistics are accumulated on the total number of motor starts as well as the total number of motor starts that occur in each region of travel The statistics can be accessed in the maintenance set up group The counts can also be reset to zero if desired See the Maintenance Set Up Group for more information The regions of travel are determined by the full span motor travel 90 or 150 rotation If the actuator is set up to operate in a smaller range for example between 40 and 80 of full span the maintenance statistics will show motor starts only in regions 4 through 7 Percent of Span 0 20 40 60 80 100 Region of Travel 0 1 2 3 4 5 6 7 8 9 0 30 60 90 Degrees of Rotation Percent of Span 0 20 4 0 60 8 0 100 Regio nof Trave 0 1 2 3 4 5 6 7 8 9 0 30 60 150 Degrees of Rotation Figure 23 Regions of Motor Travel 62
29. position sensor does not require maintenance Main Gear Lubrication Under normal operating conditions the main worm gear should not require maintenance Spur Gear Lubrication Honeywell recommends that during major shutdown periods the spur gears should be inspected and lubricated Follow the steps in Table 35 to access the spur gear compartment and lubricate the gears if necessary A WARNING Disconnect power before opening the actuator case to inspect the actuator gears A potentially dangerous pinch hazard exists inside the case if the unit is open while powered Table 35 Spur Gear Lubrication Procedure Step Action 1 Remove AC power from actuator 2 Remove the six screws and the bottom cover of the actuator case See Figure 34 3 Inspect the final spur gear the idler gear and motor pinion for excessive wear and adequate lubrication See Figure 34 4 If needed use Texaco Starplex 2 EP grease or equivalent and apply lubricant to assure that the gears are adequately protected 5 Install a new gasket and replace side cover Secure to actuator with screws 6 Restore actuator to service Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 87 3 13 Maintenance Basic Maintenance Bottom cover Gears 88 Idler spur gear Final output spur gear _ Motor pinion gear Figure 34 Spur Gear Location HercuLine
30. precision engineered for exceptional reliability accurate positioning and low maintenance Figure 1 Designed for very precise positioning of dampers and quarter turn valves the HercuLine 2000 series actuators perform especially well in extremely demanding environments requiring continuous duty high reliability and low maintenance Model distinctions HercuLine 2000 series actuators are used in applications requiring on off or power to open close position proportional with 135 or 1000 ohm feedback HercuLine 2001 and 2002 are smart actuators used in applications requiring current proportional control or digital control They offer digital electronics providing for precision positioning control easy set up and configuration on board health monitoring and network communications Programming access is provided through our HercuLink Palm PDA software connected to the actuator via a 232 485 converter via HART communications or through the optional local keypad and display HercuLine 2002 smart actuators offer features and functions similar to the HercuLine 2001 and are used for more severe service applications requiring features such as non contact position sensing HercuLine 2003 actuators are unidirectional 360 degree rotation special purpose actuators The keypad and display are available on the HercuLine 2001 and HercuLine 2002 products at additional charge HercuLink Software HercuLink Computer software enable
31. signal source output at zero and switch power on 5 Connect a 250 ohm resistor across the Output terminals of the actuator and connect the DVM leads to the terminals Calibrated Signal Source 4 g Output 1 Terminal Block Digital Voltmeter at Internal 250 ohm resistor settable through Jumper W2 resistor supplied Current Voltage K Figure 25 Calibration Wiring Connections non slidewire emulation 66 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Calibration E Actuator Digital Voltmeter Calibrated Signal Source 4 Terminal Block i Input Output 4 3 9 SFB Internal 250 ohm resistor settable through Jumper W2 Current Voltage e Figure 26 Calibration Wiring Connections slidewire emulation Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 67 3 13 Set Up and Calibration Procedures Calibration Jumper W2 ACTOR HUEL SE Figure 27 Jumper Location on CPU PWA Calibrate Input The HercuLine 2001 2002 actuator accepts a variety of signal inputs 1 Oto 20 mA or 4 to 20 mA 2 Oto5 Volts 1 to 5 Volts or O to 10 Volts The input type is selected through the Input set up group using the local keypad Refer to Figure 25 for the wiring connections and follow the procedure in Table 25 to calibrate the input
32. ssc honeywell com or ssc honeywell com or FAX 61 7 3840 6481 OF TAC hts tac TAC hfs tac Toll Free 1300 36 39 36 TAC hfs tac support honeywell com support honeywell com Toll Free Fax support honeywell com 1300 36 04 70 China PRC Shanghai Honeywell China Inc Phone 86 21 5257 4568 Fax 86 21 6237 2826 Singapore Honeywell Pte Ltd Phone 65 6580 3278 Fax 65 6445 3033 South Korea Honeywell Korea Co Ltd Phone 822 799 6114 Fax 822 792 9015 Honeywell Honeywell Process Solutions 1860 West Rose Garden Lane 62 86 25 10 Rev 8 Phoenix Arizona 85027 March 2013 www honeywellprocess com 2013 Honeywell International Inc
33. the actuator is a 4 to 20mA from a current output controller as shown in the flow diagram in Figure 16 Unlike the position output controller the current output controller must produce a continuous analog signal or the actuator will revert to one of its failsafe states Signal failure is not a problem since the available failsafe settings allow you to set the actuator position on signal loss HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Burner Control Flame Safety Master Slave Arrangement Basic Flow Control When the process variable signal is below set point the controller increases current 4 to 20mA to the actuator input and opens the valve Controller set point governs valve position to obtain desired flow rate Orifice Plate PV l Positioner amp Actuator Controller Valve Linkage vd 4to 20 mA Position mA Figure 16 Flow Diagram Current Output Controller Actuator See Figure 27 for jumper location Jumper W2 Hot Current Neutral 120 240 4 to 20 mA Ground VAC Figure 17 Interconnection Diagram Proportional Flow using Multiple Actuators Refer to flow diagram in Figure 18 and interconnection diagrams in Figure 19 The controller governs flow rate in one burner Only that flow is measured Since 2 and 3 motor positions receive the same signal as 1 motor positioned valves 2 and 3 will deliver the same amount
34. 0 or 150 degrees Switches respectively Auxiliary Switches Relays Optional Up to 4 additional SPDT switches rated at 10 A at 125 Vac 5 A at 250 Vac Certifications Approvals CSA UL Standard CE Compliant optional Enclosure Rating Type 4 NEMA 4 IP66 standard Torque Settings of Crank Arm Bolts Clamp Bolt 88 Ib in 10 N m Electrical and Performance Specifications Wel HercuLine 2002 HercuLine 2001 HercuLine 2000 2003 Input Signals Analog Analog 0 4 to 20 mA With CPU 0 4 to 20 mA With CPU 120 vac drive open 120 vac PWA jumper in current PWA jumper in current drive close position position 240 vac drive oper 240 vac 0 1 to 5 Vdc 0 1 to 5 Vdc drive close Oto 10 Vdc Oto 10 Vdc Digital Series 90 control e Modbus RTU RS485 Digital e Modbus RTU RS485 Isolation Input signal output signal and power are isolated from each other Load Requirement 4 20 Current Out 0 to 1000 ohms NA Input Impedance 0 4 to 20 mA 250 ohms 0 1 to 5 Vdc 10 K ohms 0 10 vdc Feedback 0 to 20 mA 4 to 20 mA Dual output 1000 ohms Oto 5 Vdc amp 1 to 5 Vdc with 250 ohm resistor 0 to 16 Vdc with g00 Over 90 degrees 135 ohms ohm resistor with 158 resistor Dual output 1000 ohms over 150 degrees 135 ohms with with 158 resistor 6 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Specifications Technical and Operating Specifications _ j Herc
35. 00 F 0 to 99 R H non condensing over the full operating temperature range 0 to 100 corresponding to full crank arm travel Adjustable radii 1 0 in 25 4mm to a maximum of 2 8 in 71 1mm Position adjustable through 360 rotation 0 625 005 in 15 88 13mm diameter 90 or 150 degrees between 0 and 100 on scale limited by mechanical stops Provides a means of positioning the actuator in the event of a power failure or set up Lubrication Texaco Starplex 2 EP Grease Output Torque Full Torque Ib in N 50 Hz 90 1 50 60 Hz 90 1 50 Travel Stroking Time M 4 5 7 5 4 6 50 6 0 9 15 7 12 100 11 5 18 30 15 25 200 22 5 SS SS 30 50 400 45 0 45 75 400 45 0 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 5 3 13 Specifications Technical and Operating Specifications 100 130 Vac single phase 50 Hz or 60 Hz 200 240 Vac single phase 50 Hz or 60 Hz Instant start stop non coasting non burnout continuous duty permanent magnet synchronous induction motor Can be stalled up to 100 hours without damage Motor Current No load full load locked rotor 0 4 amp for 120Vac 0 2 amp for 240 Vac Loss of Power Stays in place on loss of power Local Auto Manual Switch Optional Allows local and automatic operation of the actuator End of travel Limit Standard adjustable to limit actuator travel to less than 9
36. 1 1 TB1 2 and ground screw Loosen the screws at terminals TB1 1 and TB1 2 Remove screw used for ground Install the appropriate MOV assembly as shown in Figure 11 All ferrites require 1 loop of wire per ferrite Connect as shown in following steps zl 1 OO oO AJOIN e Current input and output slidewire emulation connection e Communications and digital input connection Ground screw Current input and output slidewire TB1 2 emulation TB1 1 Communications and digital input e Figure 11 CE wiring part 1 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 21 3 13 Installation Electrical Installation Step Action 8 e AC power connection e Auxiliary switches connection e Relay contact connection Aux switches 1 and 2 SW3 and SW4 Aux switches 3 and 4 SW5 and SW6 Relays 1 and 2 Relays 3 and 4 AC power connection Figure 12 CE Wiring part 2 9 Install new gasket and top cover Secure top cover with 6 captive screws 10 Reapply AC power to the actuator 11 Actuator is ready for use Input Signal Connections ATTENTION Shielded and grounded cables are recommended 0 4 20 mA Input Signals For current signal input ensure jumper W2 on the CPU PWA is in the Current position See Figure 27 on page 68 Observing polarity connect the signal input wires TB3 4 and TB3 5 o
37. 2 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual v 3 13 Contents Lock Set Up Groups Eed ite a ee ads 53 Read Status Set Up Group 55 Drive Set Up Groups 41 0 tivdina i ani awd eh aida eile 56 Maintenance Set Up Group 59 Regions of Motor Travel 62 GALE POSOUT GUD siea aana ege ed Ed cestueenpeecdenendstedungutes 63 Auto Manual Drive Switch cccceeccceeeeeeeeeeceeeeeceaeeeeaeeeeeeeeesaaeeseeeeseeeeesaeeeenaeeeenees 64 G72 o Li 0 EE 65 Setting End of Travel Limit Switches 0 cccceeeeeeeeeeeeeeeeceeeesaeeeeaeeseeeeeseaeeeeeaeseenees 78 Setting Auxiliary SWitCheS AAA 81 Slant p OBSKA ON EE 83 INTRODUCTION tess cite cen Avice eee Aue ded ee Ain wen Ave a es ER 83 POWer UP Diagnostiese raiar anns EEO TA E EEN AO EAE 83 Operations Checklist AA 83 Operating DisplayString aa aa a dee tet gh HA ai aia 84 Mot r Stallin raa NA 84 Position Sensor Operation cccccceceeeeeeeeeeeeeeeeeeeeeeeaaeceeeeeseaeeesaaeeeeaeeseeeeessaeeeseaeeseaes 85 Remote Setpoint Operation 85 Maintenance ENEE 87 atelier E 87 Basic Maintenance seiniin raae iania a UAA ANNASA E 87 Replacem nt Procedures E 89 Replacement Upgrade Accessory Kits cccccccccccecceccceceeeeeeeeeeeeeeeees 91 Replacement KUS mAr hii ate ea int ie 91 Upgrade KITS ccevcentceves ct geeks cheek a E Eeer D eg et e ee 102 Accessory EC 104 dee enn reece ke A Netcast he Nee Nene he he fee ee
38. 3 Connections Output 23 Slidewire emulation 23 Crank Arm 5 Crank Arms 16 Customer Connections 17 CW and CCW Direction See Actuator Rotation Index D Deadband 7 40 Decimal Point Location 52 Deviation 45 Relay type 47 Device Address 50 Direction of Rotation 7 Duty Cycle 7 E Electrical and Performance Specifications 6 Electrical Installation 17 Enclosure 5 Enclosure Rating 6 End of travel Limit Switches 6 Exiting Set Up mode 33 F Failsafe 40 41 Failsafe Input Value 40 41 Failsafe operation 7 Feedback 6 Flame Safety Module wiring diagram 23 Fuses Replacement 89 G Gear Train 5 H Handwheel 5 HercuLine 2000 Terminal Connections 18 HercuLine 2001 2002 with Auto Manual Terminal Connections 19 HerculLine 2003 Wiring Connections and Operation 20 Hysteresis 7 44 Input Calibration 68 Input Characterization 41 Input Filters 7 40 Input High Range 39 Input Impedance 6 Input Low Range 39 Input Set Up Group 39 Input Signal Connections 22 Input Signals 6 116 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 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 Variable torque 15 Load Requirement 6 Local
39. 35 ohm available by parallelling 1K potentiometer with 158 Ohm resistor supplied 2 HercuLink software pn 51452354 509 RS232 485 converter pn 51452354 510 customer supplied Palm PDA running OS3 5 or higher and Palm serial cable are required for the 2001 and 2002 actuators if no display is selected 3 Requires PDA manufacturer s serial interface cable 4 CSA approval is good for 75 C and a maximum relay load of 3 5 amps or 70 C with a relay load of 5 amps Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 11 3 13 Installation Installation Overview Installation Installation Overview The procedures to install the HercuLine 2000 Series actuator and place it in service require that you Select a suitable location for installation See Installation Considerations below Mount the actuator securely Install mechanical connections or linkage between control arm and final control element Use HAL software application to aid in mechanical installation Make all electrical connections for actuator according to local and national electrical codes Power up actuator Enter verify and adjust set up parameters for proper operation Adjust control arm linkage for accurate operation of final control element This section provides you with mechanical and electrical installation information required to mount and connect the HercuLine 2000 Series Actuator to your specific a
40. Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Seiting Prompt DECMAL DECIMAL POINT LOCATION This selection determines where the decimal point appears in the display 8888 None 888 8 One Place Note Be sure the selection agrees with the value to be displayed If display value requires 4 whole digits the default 8888 decimal will not show EUNITS UNITS DISPLAY Selects the units of the position display PCNT Percent Shows actuator position as a percentage of span 0 to 100 DEG Degrees Shows the actuator position in degrees of rotation 0 to 150 90 default PCNT UNITS DISPLAY UNITS Selects standard for unit values for the local display SI SI Display will show unit values in international metric units Temperature in degrees C Date format ddmmyy ENGL English Display will show unit values in U S units Temperature in degrees F Date format mmddyy default ENGL e j 52 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Lock Set Up Group 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 Setting Parameter Definition PDA HercuLink Prompt LOCKID 0 to 4095 default 0 PAS
41. FUNCTION key until the lower display reads Direct Press the A or W keys to set Actuator Rotation direction to CCW NOTE Actuator direction must be set to CCW for this procedure Direction can be changed after calibration is complete 5 Drive the actuator to the 50 position this refers to the position on the actuator scale for CCW rotation This should be done manually with the handwheel or with the AUTO MANUAL switch 6 Press SET UP key until the display reads CAL POSOUT Press the FUNCTION key until the dispaly reads DIS CALPOS Press the A or W keys until the lower display reads BEGN CALPOS Press FUNCTION key The upper display now shows the output of the position sensor in Volts 7 Loosen the set screw at the end of the switch camshaft where the potentiometer connects to the shaft 8 Using pliers adjust the white plastic knob on the back side of the potentiometer so the voltage in the local display is 2 500 0 010 volts dc 9 Tighten set screw with an allen wrench 10 Press DISPLAY key to exit calibration mode 11 Remove AC power to the actuator Reinstall relay cards If present 12 Install a new gasket and replace extended cover Secure to actuator with screws 13 Continue with calibration procedure in Table 31 76 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Calibration Potentiometer position sensor Mounting bracket Figu
42. Honeywell HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Doc No 62 86 25 10 Revision 8 Date March 2013 Honeywell Field Solutions Notices and Trademarks Copyright 2013 by Honeywell Revision 8 March 2013 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 CE Conformity This product conforms with the protection requirements of the following European Council Directive 89 336 EEC the EMC directive and 73 23 EEC the Low Voltage Directive Conformance of this product with any other CE Mark Directive s shall not be assumed Attention The emission limits of EN 50081 2 ar
43. Ne ee eee 105 aikaa Tee TEE 105 Troubleshooting Procedures cecceeeeeeeeeeeeeeeeeeeeeeaeeeseeaaeeeseeaaeeeeeeaaeeeenenaeeeeeneaaes 106 Appendix A HercuLine 2001 2002 Configuration Record Sheet 112 d E 116 vi HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Contents Table 1 Specifications E 5 Table 2 Recommended Minimum Wire Size 17 Table 3 Terminal Connections HercuLine 2000 18 Table 4 Terminal Connections HercuLine 2001 2002 with auto manual cc cccsscsscsssesssssessesssesseessesseesseeees 19 Table 5 Split Range Set Up Procedure diie onr e eane eet ae e E EE eE E Ee Eea E oa Sea TESE E EEES 26 Table 6 Keypad Deseriptron se en e oen E re ci e E SEE E e E AE EE 32 Table 7 Set UP Taps an ee Een 33 Table 8 Set UP Groups res Eae erae erore pEr AEE E nE E EEE E O E E A E EE EE E E e oE 34 Table 9 Set Up Procedure Using Display and Keypad cececsecssesssesecseeseceesecaeeecesecaeesecneeacesesnesecsaeseeeneeats 36 Table 10 Input Set Up Group Parameters 0 eee eceesceescesecesecesecsecsaecaeecaeeeaeeeseseaeeeaseseseaeeeeseuecsaecsaessaesaeeeas 39 Table 11 Equal Percentage Valve Characteristics cccescssescesssecesecseesecseesecseeecsaececeecsasenessecseeseeneeaeeaseaeeneeats 42 Table 12 Quick Opening Valve Characteristic cceeseesscsceescsseeecesecseesecaeesecneesccsaeceeaecaeesecsavscesaeeeesaecaseaeeaeeats 43 Table 13 Rela
44. OTAL DEGREES OF MOTOR TRAVEL Displays the total number of degrees of motor travel since it was last reset Multiply displayed value times 10 to get actual value Range is 0 to 999 900 000 Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 59 Set Up and Calibration Procedures Maintenance Set Up Group 60 DATSAV MAINTENANCE DATA FORCED SAVE Allows you to manually force a save of the current maintenance data DIS values ENAB DISABLE Forced data save is disabled ENABLE Forced data save is enabled PASSWRD nannn PASSWORD If a password has been activated then a 4 digit password is required to enable any of the functions below NOTE Password is set or changed from the Lock set up group MANRST MAINTENANCE STATISTIC RESET Allows reset of the following maintenance statistics NONE None No reset of maintenance statisitics STAL Stall Resets accumulated stall time to zero STRT Motor Starts Resets the accumulated motor start counter to zero REGNn Motor Starts in the Region Resets the selected motor n 0to9 span region counter to zero TEMP Temperature Statistics Resets the high low temperature limit statistics TDEG Total Degrees Resets the total degrees of motor travel to zero RELn Relay Counts Resets the selected accumulated relay n 1 2 30r4 cycle counter to zero ALL All Resets all maintenance statis
45. SWORD LOCK 4 digit password can be selected to provide security access to calibration information set up parameters and supervisory functions Password can be a number from 0 to 4095 LOCK NONE CAL CONF FULL default NONE LOCK OUT FEATURE Selects lockout security for calibration and supervisory functions and set up groups None No lockout of any calibration or set up groups You select and change set up group values and perform field calibration Calibration Lockout for calibration groups SET CALINP SET CALMTR SET CALOUT and CAL POSOUT only You can select and change set up group values Configuration Lockout for calibration groups and set up group configuration You can only scroll through and view set up group values Full Lockout for calibration and all set up group values Only SET LOCK and READ STATUS groups are accessible MAENAB DIS ENAB default ENAB Manual Auto Allows the ability to lockout mode changes from the front panel Disabled Disables the front panel auto manual switch functionality Enabled Enables the front panel auto manual switch functionality Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 53 Set Up and Calibration Procedures Lock Set Up Group Set Change Password A password is required to disable the ability to readily change features of the actuator L
46. Split Washer Machine Screw Pan Hd Cross Rec Pp rpo Top Cover Gasket Qty Unit Part Number Description Figure ID 51500581 503 Auto Manual Switch upgrade for SA2000 17 Auto Manual Label Nut Sealing 3 8 32 Thrd Knob A M Switch Wire Assy Label Customer Wiring k H sch ee 1 sch ee ee Top Cover Gasket Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 101 3 13 Replacement Upgrade Accessory Kits Upgrade Kits Qty Unit Part Number Description Figure ID 51500581 504 Auto Manual Switch upgrade for SA2001 amp SA2002 18 1 Auto Manual Label 1 Nut Sealing 3 8 32 Thrd 1 Knob 1 A M Switch Wire Assy 1 Label Customer Wiring 1 Top Cover Gasket Upgrade Kits Qty Unit Part Number Description 51452444 502 Cover with Display no Handwheel 1 Display gasket 1 Overlay display 1 Lens display 1 Gasket adhesive die cut 1 Display mtg collar machining 1 Keypad 6 position 1 Support plate keypad 1 Display PWA 1 Top cover w display no hndwhl 9 Sems 4 40 x 310lg pnphstl 4 Screw metric panhd cross rec 4 Split washer 6 Sleeve keypad 1 Display keybd cable HercuLine 2001 2002 1 Top cover gasket 102 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Replacement Up
47. ade Accessory Kits Replacement Kits Qty Unit Part Number Description Figure ID Spur Gear Kit 10 51452443 501 51452443 507 51452443 508 51452443 509 51452443 510 51452443 511 1 Spur Gear 24p 18t 1 Spur Gear 24p 18t 1 Spur Gear 24p 36t 1 Spur Gear 24p 72t 1 Gear Assembly 1 Gear Assembly 1 Spur Gear 24p 36t 1 Bottom Cover Gasket 1 Intermediate Shaft all except 7 5 seconds 1 Intermediate Shaft 7 5 seconds Kit Instructions 62 86 33 35 Qty Unit Part Number Description Figure ID 51452443 502 Auxiliary Switch Kit Replacement and Upgrade 11 1 Cam Assembly 4 Aux switches 2 end of travel switches 1 Switch and Mounting Plate assembly 6 Kit Instruction 62 86 33 45 Qty Unit Part Number Description Figure ID 51452443 503 Gasket Set Kit 12 1 Bottom Cover Gasket 1 Shaft Seal 1 O Ring 2 144 Id X 0 070 Buna N 1 Top Cover Gasket 1 O Ring Buna N 1 Display Gasket Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 99 3 13 Replacement Upgrade Accessory Kits Replacement Kits Qty Unit Part Number Description Figure ID 51452443 504 Display and Keypad Kit 13 Display Gasket Overlay Display Lens Display Gasket Adhesive Die Cut Display Mtg Collar Machining Keypad 6 Position Support Plate Keypad Display Pwa Se
48. age 39 configure the parameter FSTYPL to Down In the Digital Input Set Up group Page 51 configure the parameter DIG INP to Up Wiring Figure 13 Burner Control Flame Safety Wiring shows a Typical Flame Safety Module wiring diagram HercuLine TB3 jit 2 sia s ol7 s 9 fiol Add Jumper 4 to 20 Output from Controller Modulate H 4 to 20 Output from Controller Typical Flame Safety Module Figure 13 Burner Control Flame Safety Wiring Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 23 3 13 Burner Control Flame Safety Series 90 Control HercuLine 2001 model only Series 90 Control HercuLine 2001 model only Series 90 Controls are commonly used in building environmental systems and flame safeguard systems to provide modulating control The control is affected by balancing a 135 ohm potentiometer The HercuLine 2001 provides an emulation of this system as follows The current output is used to excite the potentiometer in the controller To do this it is set permanently at 11 ma This produces a 1 5 volt span The wiper is then connected to the HercuLine 2001 input which is operating in voltage mode The returns from both the input and the output are tied together Series 90 terminals are typically color coded white red and blue Conventionally red is the wiper and white and blue are the two ends of the potentiometer On a drop in temperature the wiper moves towa
49. agnostics Actuator motor does not drive in response to input signal Actuator motor does not drive to proper position Actuator Motor is Hunting Motor does not drive to a position and stop Position sensor position is not correct Auto Manual Switch does not operate correctly Relay s does not operate Procedure Replace CPU Assembly Replace CPU Assembly See Figure 42 See Figure 43 Perform input calibration See Figure 42 Perform motor calibration Process control loop is not tuned correctly Refer to the Instruction Manual for your controller on how to tune a loop Increase the Deadband in the Actuator and or in the control loop See page 85 See Figure 45 See Figure 46 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 105 3 13 Troubleshooting Troubleshooting Procedures Troubleshooting Procedures Overview Follow the procedure or flow chart to test for and determine actuator component operation When using the flow charts for troubleshooting you may be instructed to go to another flow chart in order to identify the faulty component Instruction for replacing actuator components can be found either in Maintenance page 87 or in the kit with the replacement components Equipment needed You will need the following equipment in order to troubleshoot the symptoms listed in the tables that follow DC Milliammeter mA DC Calibratio
50. and Calibration Procedures Communications Set Up Group Communications Set Up Group Table 16 lists the parameters and selections available for the SET COMM group Table 16 Communications Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt COMM COMMUNICATONS PARAMETERS Disables or enables parameter displays for Modbus communciations set up DIS Disabled Locks out access to communications displays and parameters MODB Modbus Allows access to the communication displays and settings for the parameters listed below HART HART selects HART as the communications protocol ADDRES 1 to 99 DEVICE ADDRESS Selects device address when used in a Modbus communications loop Select an address that is default 1 unique to other devices on the communications link BAUD 2400 BAUD RATE Selects the speed of data transfer All 4800 equipment on the link must be set to match the host setting 9600 19 2k default 19 2k XmtDLY NONE RESPONSE DELAY Selects the time delay in 10ms milliseconds before a response to a query is transmitted 20ms 30ms 40ms 50ms default 20ms DBLBYT FLOATING POINT DATA FORMAT Selects the format for transferring floating point data Byte Order FP B Floating Point Big Endian format 0123 FPBB Floating Point Big Endian format with byte swapped 1032 FP L Floating Point Little Endian format
51. ation HART must be configured for Multi drop operation Current Output Controller Actuator 1 Jumper W2 Hot at Current Neutral 120 240 4 to 20 mA i Ground VAC Actuator 2 See Figure 27 for jumper location Jumper W2 Voltage Alternate Ground Ko Wiring Figure 20 Interconnection Diagrams NOTE If using HART communications for this application HART must be configured for Multi drop operation 30 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Overview Set Up and Calibration Procedures Overview Once you have installed the actuator you can verify set or change certain operating parameters Set up is accomplished through use of the local display and keypad interface through your PDA with HercuLink software see HercuLink manual 62 86 25 11 or via the HART communication option Please keep in mind that the unit is calibrated at the factory for your application and can be placed into service right out of the box Changing operating parameters may require recalibration of the actuator This section details the various operating parameters and functions of the actuator available using the local display and keypad interface and calibration procedures Local Display and Keypad The alphanumeric display and keys on the keypad are the local operator interface for control monitoring and configuration of the act
52. ay Wiring Keypad Label PWA gt ms Sg Stops TB3 a A df Ge A Connector e Gams and for customer Wa limit input and switches output connection on CPU PWA TB1 customer power connection Non contact External Relay PWAs sensor k auto manual switch Figure 2 HercuLine 2002 Actuator Internal View Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 3 3 13 Introduction Product Description 4 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Specifications Technical and Operating Specifications Specifications This section provides you with the technical specifications and the model selection guide for the HercuLine 2000 Series Actuators Technical and Operating Specifications Weight Enclosure Gear Train Mechanical Stops Storage Temperature Relative Humidity Scale Crank Arm Output Shaft Rotation Manual Handwheel Table 1 Specifications General Physical 2000 25 Ib 11 36 kg 20012002 27 Ibs 12 27 kg Precision machined die cast aluminum housing finished in light gray powder coat epoxy Alloy steel high efficiency steel spur gear primary train Precision ground self locking self releasing worm gear final mesh Factory set at 90 or 150 5 Attention Do not adjust the mechanical Stops Adjusting the stops will void the warranty 40 C to 93 C 40 C to 2
53. ays date or of last repair ddmmyy LCAL mmddyy DATE OF LAST FACTORY CALIBRATION Factory set or only Displays date of last factory calibration ddmmyy REPTYP REPAIR TYPE Factory set only Displays a repair code to identify the type of repair service previously performed NONE None 01 Future 02 Non contact Sensor 03 Main CPU PWA repair 04 Motor service 05 Power Distribution PWA service 06 Switch repair 07 Relay service 08 Gear service 09 Service to repair water damage 10 Service to repair damage caused by heat 11 Service to repair due to over voltage damage 12 Actuator reconfigured 13 Warranty Repair NOTE Date format is set by the UNITS parameter See SET DISPLA set up group Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 57 3 13 Set Up and Calibration Procedures Drive Set Up Group Set Tag Name 58 The actuator tag name can be an alphanumeric name up to six characters The tag name is set by using the keys on the keypad and the local display Follow the steps below to set the tag name Step Action 1 Press SET UP key until the display reads SET DRVINF 2 Press the FUNCTION key until the upper display reads TAG 3 The lower display contains six digits A decimal point will be flashing at the leftmost digit for approximately three seconds Then the decimal point shifts to the right and flashes for three seconds before sh
54. ch 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 32 for auxiliary switch settings 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 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 Double check limit switch actuation by first manually driving the actua
55. ch 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 Setting Auxiliary Switches page 81 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 Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 79 Set Up and Calibration Procedures Setting End of Travel Limit Switches ATTENTION Make sure you do not to set the switches too close to the hard stop Relay PWAs Relay 1 Relay 2 Aux switch 1 End of travel switch 1 Relay 3 Aux switch 2 stops CW rotation Relay 4 Aux switch 3 End of travel switch 2 Aux switch 4 stops CCW rotation Figure 31 Location of End of Travel Limit and Auxiliary Switches 80 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Setting Auxiliary Switches Setting Auxiliary Switches D ATTENTION Referring to Figure 31 The first two cams starting from the front are for the 0 and 100 end of travel limi
56. circuit of the HercuLine 2001 2002 actuator ATTENTION For an input calibration to be saved you must complete the procedure The calibration will not be saved if you exit without completing the steps of the procedure To exit calibation mode press DISPLAY or SETUP keys 68 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Calibration Table 25 Input Calibration Procedure Step Operation Press Result 1 Enter Calibration SETUP Upper Display CAL Mode until you see Lower Display INPUT FUNCTION Upper Display DIS Lower Display CAL IN Aor key Upper Display BEGN Lower Display CAL IN 2 Calibrate Zero 0 FUNCTION Upper Display APLY Lower Display INZERO e Adjust the signal source to an output value equal to 0 range value e Wait 5 seconds then go to step 3 3 Calibrate Span FUNCTION Upper Display APLY 100 Lower Display INSPAN e Adjust the signal source to an output value equal to 100 range value e Wait 5 seconds then go to step 4 4 FUNCTION Calibration for zero and span input values are now saved Input calibration is complete NOTE The display will automatically go to the CAL MOTOR set up display See Table 26 You may also exit calibation mode by pressing the DISPLAY or SETUP keys ATTENTION When calibrating the motor to a short stroke range you must reset the end of travel limi
57. ckwise rotation is the direction of the output shaft when facing the end of the shaft As shown full clockwise rotation of the output shaft activates SW1 and CCW rotation activates SW2 Figure 30 End of Travel Limit Switch Settings Kai 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 See Figure 8 page 18 and Figure 9 page 19 An unactuated switch has its roller arm in the up position when adjacent to the reduced diameter portion of the cam If it becomes necessary to do adjust the limit switch cams in the field use the procedure given in Table 32 While the unit is powered a potentially lethal shock hazard exists inside the case A WARNING P p y 78 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Setting End of Travel Limit Switches Table 32 End of Travel Limit Switch Setting Procedure Step Action Remove AC power to the actuator Remove the six screws and the cover from the actuator case See Figure 2 Lay cover assembly on a flat surface 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 Figu
58. configuration CFGTST e Verification of valid calibration values CALTST e Test of the local display and LED indicators all display segments and LED indicators light simultaneously The local display shows the status of the diagnostics as they are completed during power up TEST DONE is shown on the display when diagnostics are complete and actuator should be in AUTO mode See Table 20 for more information on the power up diagnostics Operations Checklist To make sure that the actuator is properly installed and set up for your particular application you should check and verify the following e Verify that the configuration is correct for your application by stepping through all set up groups and checking the setting of all set up parameters e Verify operation of end of travel limit switches e Verify operation of auxiliary switches or relay function if installed e Check operation of AUTO MANUAL DRIVE switch if present by setting the knob to the CW and CCW MANUAL positions The output shaft should rotate in the direction indicated by the knob The LED indicator on the local display should also indicate the actuator is in manual mode Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 83 3 13 Start Up Operation Operating Displays Operating Displays Pressing the DISPLAY key cycles the display through a number of operating parameters Table 34 shows a number of sample dis
59. creasing signal Indicates the movement of the actuator arm in the clockwise direction ND NOTE Actuator rotation is the direction of the output shaft when facing the end of fei the shaft and refers to the direction of rotation on increasing signal lt 4 STALLED Indicates that the actuator has detected a motor stall condition x ALARM Indicates a programmed alarm condition exists x MANUAL Indicates actuator is in manual mode x AUTO Indicates actuator is in automatic mode 29 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Set Up Tips Set Up Tips Table 7 contains tips that will help you view verify and enter the operating parameters more quickly If you cannot change the parameters check the status of the SET LOCK parameter Also some parameters require that you enter a security password before you access or change the parameter value Table 7 Set Up Tips Function Tip Displaying Groups Use the SET UP key to display and scroll through the set up groups The group titles are listed in the order that they appear on the actuator display Displaying Functions Use the FUNCTION key to display the individual function parameters under each set up group The prompts are listed in the order of their appearance in each group See Tables 8 through 19 Scrolling Pressing and holding the SET UP key will scroll through th
60. e designed to provide reasonable protection against harmful interference when this equipment is operated in an industrial environment Operation of this equipment in a residential area may cause harmful interference This equipment generates uses and can radiate radio frequency energy and may cause interference to radio and television reception when the equipment is used closer than 30 m to the antenna e In special cases when highly susceptible apparatus is used in close proximity the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment Honeywell Process Solutions 512 Virginia Drive Fort Washington PA 19034 HercuLink and HercuLine are trademarks of Honeywell Palm is a trademark of Palm Inc Other brand or product names are trademarks of their respective owners ii HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 About This Document Abstract This manual describes the installation set up operation maintenance and troubleshooting of the HercuLine 2000 series actuators References The following list identifies all documents that may be sources of reference for material discussed in this publication Document Title Doc ID HercuLine 2000 Series Actuator Specification 61 86 03 14 HercuLine 2000 Series Actuator Model Selection Guide 62 86 16 21 Modbus RTU Serial Communications User Manual 51 52 25 66 M
61. e set up groups However when any set up group is displayed you can scroll through the set up groups twice as fast using the A or W key When in any set up group hold the FUNCTION key in to scroll through the prompts within that group Changing values quickly When changing the value of a parameter you can adjust a more significant digit in the upper display by holding in one key A or W and pressing the other A or W at the same time e The adjustment will move one digit to the left e Press the key again and you will move one more digit to the left Exiting Set Up mode To exit Set Up mode press the DISPLAY key This returns the display to the same state it was in immediately preceding entry into the Set Up mode Timing out from If you are in Set Up configuration mode and do not press any keys for Set Up mode thirty seconds the actuator display will time out and revert to the mode and display that was being used prior to entry into Set Up mode Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 33 3 13 Set Up and Calibration Procedures Set Up Groups Set Up Groups Pressing the SET UP key on the keypad provides access to the various set up groups and allows you to set up operating parameters such as input types and alarms calibrate the actuator s inputs and outputs set communications and check actuator status Table 8 on the next page lists the set up g
62. ect the individual functions of a selected configuration set up group Used during field calibration procedure MAN AUTO Alternately selects MAN Actuator is in Manual mode AUTO Actuator is in Automatic mode NOTE When in Manual mode the POS display is automatically selected so you can use the up and down arrow keys to drive actuator motor manually NOTE This button is disabled if MAENAB is set to DIS See Table 19 page 53 DISPLAY Pressing this key repeatedly cycles through the operating parameters that can be shown on the lower display INP Input Shows the value of the actuator input OP Output Shows the value of the actuator output DE Deviation Shows deviation between input value and actuator position POS Position Shows current actuator position INCREMENT Increases the configuration values shown on the display Also shown as In manual mode and POSition display selected pressing this key will drive actuator motor in direction of increasing signal input DECREMENT Decreases the configuration values shown on the display Also shown as V In manual mode and POSition display selected pressing this key will drive actuator motor in direction of decreasing signal input Y Indicates the movement of the actuator arm in the counterclockwise direction NOTE Actuator rotation is the direction of the output shaft when facing the end of xt the shaft and refers to the direction of rotation on in
63. ee Note 1 SET COMM COMM Communications Parameters MODBUS ADDRES Device Address 1 BAUD Baud Rate 19 2K XmtDLY Response Delay 20MS DBLBYT Floating Point Data Format FP B SET DIGINP DIGINP Digital Input State UP Endpos End Position Value 0 SET DISPLA DECMAL Decimal Point Location 8888 EUNITS Units Display Pent UNITS Display Units ENG SET LOCK LOCKID Password Lock 0 MAENAB Enabled ENAB LOCK Lock Out NONE READ STATUS FAILSF Failsafe Read Only RAMTST RAM Test Diagnostic Read Only SEETST Serial EEPROM Test Diagnostic Read Only CFGTST Configuration Test Diagnostic Read Only CALTST Calibration Test Diagnostic Read Only 114 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Appendix A HercuLine 2001 2002 Configuration Record Sheet Set Up Group Parameter Setting Default Prompt SET DRVINF VERSON Firmware Version Read Only SPEED Stroke Speed Factory Set POWER Power Input Voltage Line Frequency Factory Set TAG Tag Name MFGDAT Manufacturing Date Factory Set LREP Date of Last Repair Factory Set LCAL Date of Last Field Calibration Factory Set REPTYP Repair Type Factory Set SET MAIN TEMP Actuator Temperature Read Only TEMPHI High Temperature Limit Read Only TEMPLO Low Temperature Limit Read Only ACST Accumulated Stall Time Read Only STARTS Accum
64. ep Operation Press Result 1 Enter Calibration SETUP Upper Display CAL Mode until you see Lower Display CUR OUT FUNCTION Upper Display DIS Lower Display CALOUT A or W key Upper Display BEGN Lower Display CALOUT Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 71 3 13 Set Up and Calibration Procedures Calibration Step Operation 2 Calibrate Zero 0 Press FUNCTION A or V key Result Upper Display XXX Lower Display ZERO e Read meter connected to actuator output e Adjust actuator output to a value equal to 0 output as read from the DVM NOTE Typically for a 4 mA output the display will show a value of approximately 382 A lower limit value is imposed on the zero output If the value is 357 or lower the actuator will not allow you to calibrate the zero output The value must be larger than 357 for a valid calibration 3 Calibrate Span 100 FUNCTION Upper Display XXXX Lower Display SPAN e Read meter connected to actuator output A or V key e Adjust actuator output to a value equal to 100 output as read from the DVM e NOTE Typically for a 20 mA output the display will show a value of approximately 1887 FUNCTION Calibration for zero and span output values are now stored Output calibration is complete Slidewire Emulation The HercuLine 2001 2002 Actuator comes already calibrated from the factory
65. es a potentially hazardous situation which if CAUTION not avoided may result in property damage A H F D WARNING PERSONAL INJURY Risk of electrical shock This symbol warns the user of a potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 Vdc may be accessible Failure to comply with these instructions could result in death or serious injury ATTENTION Electrostatic Discharge ESD hazards Observe precautions for handling electrostatic sensitive devices Protective Earth PE terminal Provided for connection of the protective earth green or green yellow supply system conductor Functional earth terminal Used for non safety purposes such as noise immunity improvement NOTE This connection shall be bonded to protective earth at the source of supply in accordance with national local electrical code requirements Earth Ground Functional earth connection NOTE This connection shall be bonded to Protective earth at the source of supply in accordance with national and local electrical code requirements Chassis Ground Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements iv HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Contents Contents KEENT EE take v INrod CtON EE 1 Prod
66. esesbvasoapuendeshaonssausendeanes 71 Table 28 Slidewire Emulation Calibration Procedure 0 0 0 cceccssesecssecsseseceesccseesecsaeeecsecseesccneeseceecnesseeeaeeseeneaes 73 Table 29 NCS Position Sensor Calibration Drocedure eecssseccsseeseesecseeeeceeeeecaseecesecaeesecnasecsaeeeeaecaeeseeneeats 74 Table 30 Potentiometer Position Sensor Calibration Procedure ececeeeceseecessecseeeeceeeeeceseseeecsaeeecaecateseeneeets 76 Table 31 Load Position Sensor Factory Calibration ccceeecsssecssecscesecseeeecseeeecaeeecsecsaeeeessecaesseeneesuecateaeeneeats 77 Table 32 End of Travel Limit Switch Setting Procedure s esesesseeseesesestsesresrsrsrststetteretsssststerreretssesesrerrerseeees 79 Table 33 Auxiliary Switch Setting Procedure ic eeseesecseessceseeeceseceeesecseesecneesccsaeneeecsaeeeessecaeeseseeesaecsteaeeneeats 82 Table 34 Typical Operating Displays cc eeesecssesecseeseceseescsecseesecseeseesecseesecsaeseesaseeeaecaeesecnavseeseseeesaecateaeeneaes 84 Table 35 Spur Gear Lubrication Procedure eeeecesecsseeecssecseeecseeecsseeecsaecacesecsesseeneesecsaeeeeaecateseceeesaecateaeeneeaes 87 Table 36 Motor Drive Fuse Replacment Procedure seeceeccssseecsseeseesecseesccseeeecsaseeeesecaeesecnessccsaeenesaecateaeeneeats 89 Table 37 Relay PWA Replacement Procedure 0 eee cecceeceseceseceseceecaeecaeeeaeeeseseeeeseeseseeeesaeeseceeenseecsaesaaeeas 90 Table 38 Replacement Kits gek ege AAS RA A el SS
67. etected The motor drive for the indicated direction is shut off approximately 3 minutes after the stall alarm is indicated Also the appropriate CW CCW LED direction indicator is turned OFF The maintenance statistic for accumulated stall time gets updated during the stalled condition To reactivate the drive in the stalled direction change the position of the drive to the opposite direction and set at a point below where the stall originally occurred then start the drive in the stalled direction Note A stall condition is not detected if a limit end of travel limit switch is activated while the motor is moving toward the setpoint or if the motor position is within 0 5 of calibrated motor 0 and 100 end points HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Start Up Operation Position Sensor Operation Position Sensor Operation On HercuLine 2000 and HercuLine 2001 the potentiometer position sensor is a sealed film pot that is directly coupled to the output shaft On HercuLine 2002 the non contact sensor NCS is inductively coupled to the output shaft of the actuator so that the sensor detects shaft position The sensor is adjusted at the factory and under normal conditions and requires no adjustment A simple check can verify that the sensor working properly and that it is in adjustment Verification of the output is performed by setting the drive motor to its zero midpo
68. fault 100 NOTE When Input Type R_SP or S_90 is selected Input Hi is not configurable INP LO 0 0 to 90 0 INPUT LOW RANGE VALUE in is displayed default 0 0 NOTE When Input Type R_SP or S_90 is selected Input Hi is not configurable Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 39 Set Up and Calibration Procedures Input Set Up Group 40 Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt NONE INPUT FILTER TYPE Allows the selection of a software FILTYP digital input filter to smooth the input signal SPIK Spike Selects spike filter to remove transients in the input signal when actuator is installed in noisy environments S LP Spike plus Low Pass Selects spike and low pass filtering Allows setting of lag time constant for low pass filter LPAS Low Pass Selects low pass filter Allows setting of lag time constant default LPAS NOTE When Input Type R_SP or S_90 is selected Input Filter Type NONE LPFILT 0 to 50 00 LAG TIME CONSTANT Filter Type S LP or LPAS only in seconds Allows you to set the first order lag time constant of the low pass filter when selected Range is from 0 to 50 seconds NOTE When Input Type R_SP or S_90 is selected Low default 0 5 Pass Filter Value is not configurable Direct CCW ACTUATOR ROTATION This selection
69. for units Rny HL H RELAY HIGH LOW Sets relay trip point to high or low n 1 2 3 or4 LO limit y 1or2 RLYnHY 0 0 to 100 0 RELAY HYSTERESIS 0 0 to 100 0 of span or full output n 1 2 3 or4 in percent NOTE Relay Hysteresis parameter is accessible only if appropriate relay type is selected nis the relay number y is the relay contact HercuLine 2000 Series Actuator Revision 8 3 13 Installation Operation and Maintenance Manual Set Up and Calibration Procedures Relays Set Up Group Table 14 Relay Type Descriptions When this Relay Type is selected The Relay can be set up to indicate RTYP Input Range The upper lower limits of the input signal have been exceeded Relay value parameter defines range limits and units are in percent of full span Position Range Upper lower limits of motor position have been exceeded Relay value parameter defines range limits and units are in either percent of span or degrees of rotation See Relay Examples for setting range limits Deviation Motor position has exceeded deviation limit from input Deviation is defined as setpoint motor position Deviation Relay value parameter defines limits and units are in percent of span See Relay Examples for setting deviation limit Upper Limit Travel The motor position has exceeded the upper limit of travel Same as Position Range Relay value parameter defines limits and units are
70. grade Accessory Kits Upgrade Kits Qty Unit Part Number Description 51452444 503 Cover with Display and Handwheel 1 Display gasket 1 Overlay display 1 Lens display 1 Gasket adhesive die cut 1 Display mtg collar machining 1 Keypad 6 position 1 Support plate keypad 1 Display PWA 1 Top cover w display amp hndwheel 9 Sems 4 40 x 310lg pnphstl 4 Screw metric panhd cross rec 1 Hand wheel 1 O ring buna n 4 Split washer 6 Sleeve keypad 1 Display keybd cable HercuLine 2001 2002 1 Retaining ring 1 Shim 1 Top cover gasket Qty Unit Part Number Description 51452444 504 Blank Cover with Handwheel Qty Unit Part Number Description 51451656 510 1000 ohms 90 degrees upgrade kit 2 Machine screw pan hd cross rec 1 Knob 1 Bracket molding 1 Pot 1K double 90 degree 2 6 lock washer 2 Machine screw pan hd cross rec 2 6 32 hex nut N 1 Stainless steel pin 1 3 32x4 40 setscrew sshxsocupsb 2 Washer 6 2 Flat washer M4 zinc 2 Resistor 158 ohms 1 1 2W Kit Instruction 62 86 33 39 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 103 3 13 Replacement Upgrade Accessory Kits Accessory Kits Qty Unit Part Number Description 51451656 511 1000 ohms 150 degrees upgrade kit Machine screw pan hd cross rec Knob Bracket molding Pot 1K double
71. ifting again to the right This pattern repeats continuously 4 Set the digit to the left of the flashing decimal point Use the A or W keys to scroll through the character set of 0 through 9 the letters a through z and the letters A through Z Scroll through until the desired character is displayed 5 Wait for the decimal point to shift to the right and then scroll through using the A or W keys until the next character is displayed 6 Repeat for each character of the tag until the complete tag name is displayed 7 Press the FUNCTION key to go to the next parameter or press DISPLAY to exit set up mode HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Maintenance Set Up Group Maintenance Set Up Group The Maintenance set up group consists of information about actuator operation accumulated through time This information or maintenance statistics can be used to evaluate actuator operation and determine predicted or scheduled maintenance periods Table 22 lists the parameters and selections available for the SET MAINTENANCE group Please note that maintenance statistics are written to the EEPROM every 8 hours Therefore the statistics are saved in the event of a power interruption Table 22 Maintenance Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt
72. igure 29 Location of potentiometer position sensor Figure 30 End of Travel Limit Switch Settings Figure 31 Location of End of Travel Limit and Auxiliary Switches Figure 32 Auxiliary Switch Settings Figure 33 Terminal Block Connections for Modbus Communications Figure 34 Spur Gear Location Figure 35 Power Distribution PWA and Relay PWA Locations Figure 36 Motor Drive Circuit Fuses Figure 37 Replacement Kits 6 7 8 11 12 14 Figure 38 Replacement Kit 10 Figure 39 Replacement Kits 1 2 3 4 5 9 15 16 19 Figure 40 Replacement Kit 13 Figure 41 Replacement Kits 17 18 Figure 42 Test for Actuator Operation Figure 43 Power Up Diagnostics Figure 44 Test Power Distribution PWA Figure 45 Test AUTO MANUAL Switch Figure 46 Test Relay Function viii HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Introduction Product Description Introduction Product Description Honeywell s HercuLine 2000 series actuators are available in four versions HercuLine 2000 HercuLine 2001 HercuLine 2002 and HercuLine 2003 Al are low torque precision electric rotary actuators incorporating all of the high quality and reliable features of the traditional HercuLine series actuators These precision control and high reliability actuators ensure processes operate at maximum efficiency with minimal downtime and lowest lifetime cost Honeywell s HercuLine 2000 series actuators are
73. imit The motor starts value is stored as one of the maintenance group statistics This example sets the motor starts limit at 200 000 for Relay 1 Set Up Group Parameter Value SET RELAY1 RTYP11 STRT R11 E X10K R11VAL 20 R11HL HI RTYP12 NONE The resulting action is that Relay 1 will trip when the number of accumulated motor starts in the maintenance group exceeds 200 000 48 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Current Out Set Up Group 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 Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Seiting Prompt CUROUT OUTPUT SIGNAL RANGE Selects the signal output range Note If output type from model 4 20 4to 20 mA selection guide 0 20 0 to 20 mA is 1 5V 1 to 5 Volts 250 ohm resistor required 0 4 20mA 0 1 0 5V 0 to 5 Volts 250 ohm resistor required 5Vdc CUROUT SWE Slidewire Emulation Note If output type from model selection guide is Slidewire Emulation CUROUT NONE No current output configured Note If output type from model selection guide is None Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 49 3 13 Set Up
74. ing displayed in the lower display Lower Display INPUT This is the first set up group you see when you press SET UP 2 Select any Set Up SET UP Successive presses of the SET UP key will display the other set Group up group titles as listed in Table 8Error Reference source not found You can also use the A or W keys to scroll through the set up groups in both directions Stop at the set up group title that describes the group of parameters you want to configure Then proceed to the next step 3 Select a Function FUNCTION Upper Display Parameter S b Shows the current value or selection for the function prompt in the selected set up group Lower Display Shows the first function prompt within the selected set up group Example display shows Input group function prompt IN TYP and the selection 4 Select other FUNCTION Successive presses of the FUNCTION key will sequentially function parameters display the other function prompts of the selected set up group Stop at the function prompt that you want to change and then proceed to the next step 36 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Set Up Procedure Step Operation Press Result 5 Change the Value A These keys increase or decrease the value or display the next or Selection available selection for the selected function prompt or See Table 7 Set U
75. int and 100 positions and observing the output voltage of the sensor The actuator has a feature that the sensor output voltage can be read from the local display Step Action 1 Drive the motor to 50 position 2 Press SET UP key on the keyboard until the display reads CAL POSOUT Press FUNCTION key until the display reads DIS CALPOS Press the A or W keys until the display reads BEGN CALPOS Press the FUNCTION key Upper Display n nnn Output voltage of the sensor Lower Display POSOUT 3 The display should read 2 500 0 012 Volts for both 90 and 150 operation 4 Press DISPLAY key and then drive the motor to zero position Repeat Step 2 The display should read 1 600 0 060 Volts for 90 operation 1 000 0 060 volts for 150 operation 5 Press DISPLAY key and then drive the motor to 100 position Repeat Step 2 The display should read 3 400 0 060 Volts for 90 operation 4 000 0 060 volts for 150 operation 6 If the sensor needs adjustment refer to the Calibrate Non Contact Sensor procedure in Table 29 page 74 Remote Setpoint Operation The HercuLine 2001 2002 actuator can be set up to receive a digital input from a remote source The actuator uses RS485 communications that supports digital Modbus RTU protocol Press the SET UP key to select the Input set up group Change the Input Type to Remote Setpoint R_SP Make the necessary connections to termi
76. ion PWA and Relay PWA Locations Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 89 3 13 Maintenance Replacement Procedures Fuses for O O a LJ Motor Drive Circuit Figure 36 Motor Drive Circuit Fuses Relay PWA Replacement If a relay PWA needs to be replaced follow the procedure in Table 37 to access and replace the PWA A WARNING Disconnect power before opening the actuator case A potentially lethal shock hazard exists inside the case if the unit is opened while powered Table 37 Relay PWA Replacement Procedure Step Action 1 Remove AC power from actuator 2 Remove the six screws and the cover of the actuator case See Figure 35 3 Lay assembly down on a flat surface 4 Disconnect the wire connector from the relay PWA 5 Carefully remove the relay PWA Pry the locking tabs of the card guides away to unlock the PWA and slide it out from the card guides 6 Install the replacement relay PWA by sliding it into the card guides until it mates with the backplane board Locking tabs on the card guides will engage to secure the PWA in place 7 Plug in wire connector to relay PWA 8 Install a new gasket if needed and replace cover Secure to actuator with screws 90 Herculine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Replacement Upgrade Accessory Kits Replacement Ki
77. ision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 7 3 13 Specifications Technical and Operating Specifications JEE HercuLine 2002 HercuLine 2001 HercuLine 2000 2003 Programmable Selectable and configurable operating parameters NA Functions e Input range e Input filtering e Input characterization e Security e Digital Input action e Deadband e Failsafe on loss of input signal e Failsafe on loss of position sensor e Direction of rotation e Relay closure action e Communication parameters e Split range operation e Output range e Alarms Specifications Local Display and Keypad Display Display Design Multi segment LED displays that provides up to ten alphanumeric characters Display arrangement consists of two rows 1 row Upper display four characters d row Lower display six characters LED indicators Six single LEDs provide actuator status and alarm indications Display Operating 30 C to 50 C 20 F to 122 F Temperature Automatically shuts off when operating temperature exceeds 50 C Storage Temperature 40 C to 93 C 40 F to 200 F Keypad Keys Six single pushbutton keys allow access to all status displays and set up group parameters See Set Up and Calibration Procedures page 31 for detailed information on display and keypad functions 8 HercuLine 2000 Series Actuator Installation Operati
78. ment Figure 5 shows a general linkage setup to achieve a non linear torque profile Note that this linkage can be characterized in many different ways by varying start angles and rotation requirements of both the Actuator Crank Arm and the Driven Arm Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 15 3 13 Installation Mechanical Installation Vertical Vertical Centerline Centerline 45 RE VA Open Actuator Linkage Crank Arm 5 o a n 23200 Crank Arm Horizontal Offset o Damper Figure 5 Variable Torque Linkage Actuator Crank Arms The HercuLine 2000 Series Actuator comes standard with a crank arm with adjustable radius of 1 0 in 25 4mm to 2 80 in 71 12mm See Figure 6 Figure 7 Crank arm with optional ball joint and push rod 16 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Installation Electrical Installation Electrical Installation General Wiring Recommendations A WARNING Only qualified personnel should perform wiring Wiring must conform to national and local electrical codes In general copper wire used Unless locally applicable codes dictate otherwise the recommended minimum wire sizes in Table 2 should be observed Table 2 Recommended Minimum Wire Size AWG Description 14 Earth ground wire to common power supply 18 Earth ground wire to single actua
79. ms 4 40 X 310lg Pnphstl Screw Metric Panhd Cross Rec Split Washer Sleeve Keypad Display Keybd Cable hl ch IO Pl ALO sch l sch sch schl schl sch hl sch Top Cover Gasket Qty Unit Part Number Description Figure ID 51452443 505 R C Kit Motor date codes prior to 8 5 2005 14 Capacitor 2 25 Mfd Resistor 200 Ohm 25w Capacitor 75 Mfd 400vac Resistor 500 Ohm 25w Top Cover Gasket a 1 sch ee 1 sch ee 1 sch Bottom Cover Gasket Kit Instruction 62 86 33 44 100 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 3 13 Replacement Upgrade Accessory Kits Replacement Kits Qty Unit Part Number Description Figure ID 51452443 506 R C Kit Motor date codes after to 8 5 2005 Capacitor 4 0 Mfd Cable plus Resistor 4000hm Capacitor 3 Mfd 400vac Cable plus Resistor 600 Ohm Capacitor 0 75 Mfd 400vac Cable plus Resistor 1100 Ohm Top Cover Gasket 1 k a oa oa e re sch re Ce ee 1 sch Bottom Cover Gasket 1 Kit Instruction 62 86 33 44 Qty Unit Part Number Description Figure ID 51500166 503 Power Distribution Pwa Kit 15 Power Dist Pwa Insulator Pin Snap Lock 125 X 187 Lg Top Cover Gasket po Qty Unit Part Number Description Figure ID 51500457 502 Transformer Kit 16 Transformer
80. n CPU terminal board 0 1 5 Vdc and 0 to 10 Vdc Input Signals For voltage signal input ensure jumper W2 on the CPU PWA is in the Voltage position See Figure 27 on page 68 Observing polarity connect the signal input wires to terminals TB3 4 and TB3 5 of the terminal block 22 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Burner Control Flame Safety Electrical Installation Output Signal Connections 0 4 20 mA 0 1 5 Vdc Feedback Signal Connections ATTENTION Shielded and grounded cables are recommended Actuator output is a 4 to 20 mA analog signal If a voltage input is required for customer devices a range resistor is needed at the device input Refer to page 19 for more information Slidewire Emulator Connections ATTENTION Shielded and grounded cables are recommended If you ordered the Slidewire output option for your actuator it is set at the factory to provide an output that emulates 100 to 1000 ohm slidewires Refer to page 19 for more information Burner Control Flame Safety Introduction Often Gas Fired control applications use a Flame Safety System that drives the gas valve to full closed and full open during the start up sequencefor the burner HercuLine 2000 Series actuators have been designed to be compatible with the Flame Safety Systems and to perform the required operations Configuration In the Input Set Up Group P
81. n source Volt mA etc Digital Voltmeter Safety precautions Exercise appropriate safety precautions when troubleshooting the actuator operation A WARNING While the unit is powered a potentially lethal shock hazard exists inside the case Do not open the case while the unit is powered Do not access the terminals while the unit is powered 106 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Troubleshooting Troubleshooting Procedures Test for Actuator Operation Cycle power to actuator Does display light up Move handwheel on actuator 2 or 3 turns Observe self test Does motor reposition Do all diagnostics pass Yes RAMTST PASS No itself SEETST PASS Yes CALTST PASS CFGTST PASS All LEDs and Replace display display segments assembly light Replace display assembly Figure 42 Test for Actuator Operation Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 107 3 13 Troubleshooting Troubleshooting Procedures Power Up Self Test Diagnostics Cycle power to actuator Does display light up Observe self test Yes No RAMTST PASS Replace CPU Assembly Check actuator Cycle power to Yes configuration actuator If CFGTST setup reconfigure fails again replace if necessary
82. nals 6 7 8 on the actuator terminal block See Figure 33 Communicaton parameters should be set to the same values as the host device The actuator communication parameters are accessed in the Communications Set Up group There are some restrictions to actuator operation when remote setpoint input is active In order to provide a bumpless transfer when switching from one input signal type to remote setpoint the actuator will use the last known analog input value as its setpoint when switching to remote setpoint input operation No input filtering is active on the input signal to the actuator Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 85 3 13 Start Up Operation Remote Setpoint Operation Actuator Terminal Block 6 7 8 9 10 5 2 2 B 2 S SHIELD COM INP COMMUNICATION DIGITAL INPUT Figure 33 Terminal Block Connections for Modbus Communications 86 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Maintenance Introduction Maintenance Introduction There is some basic maintenance that is recommended for the HercuLine 2000 Series Actuators The electronic PWAs within the actuator require no maintenance or servicing under normal conditions If there is a problem refer to information in this section or to Troubleshooting page 105 Basic Maintenance Position Sensor Under normal conditions the
83. ne 2000 connections Revision 8 Installation Electrical Installation HercuLine 2001 2002 with Auto Manual Terminal Connections Table 4 Terminal Connections HercuLine 2001 2002 with auto manual Connection Terminal Numbers Descriptions and LABEL See Figure 9 TB1 Hot 1 Hot wire for 120 240VAC mains supply Neutral 2 Neutral wire for 120 240VAC mains supply Protective Ground 3 Ground wire connection for mains supply Auto Manual Switch 4 Switch contact to indicate setting of actuator AUTO MANUAL Contact 5 switch Switch is closed when actuator is NOT IN AUTO 6 TB3 4 to 20mA Output 1 Analog signal output 2 Feedback 3 Feedback signal used in conjunction with 4 to 20mA OUTPUT voltage when using Slidewire Emulation 4 to 20mA Input 4 Analog signal input 5 Modbus 6 Connection for RS485 Modbus loop wires Communication 7 8 Shield HART Communications 4 HART Communication is 4 20 mA only 5 Digital Input 9 Com Customer s contact closure 10 Input HART SLIDEWIRE Communications USE COPPER CONDUCTORS ONLY EMULATION Connection TB1 f e 4 TO 20mA 4TO 20mA DIGITAL 420 240V HART connection using OUTPUT INPUT COMMUNICATION ae HOTI 50 60Hz external Turck connector SUPPLY PRO ARTH Auxiliary PE GRSENIYELLOW Connector RW AMSMTCH A NC UT OF AUT We Ee CONTACT S AEA E E swe eS eS No o NOV JNO o No
84. oa ja o Nut Nmsndc 1 4 20 Qty Unit Part Number Description Figure ID 50011455 501 120vac 60HZ Motor Kit 7 Motor 120v 50 60 Hz Capacitor 3 ufd 400Vac Cable plus Resistor assembly 600 Ohm Resistor Bracket Split Washer M5 M3 X 5mm lg screw w ext tooth lock washer Socket head cap screw M5 x 12 Al PI Pl PI sch sch LI sch 1 sch Top Cover Gasket Kit Instruction 62 86 33 36 Qty Unit Part Number Description Figure ID 50011455 502 120vac 50HZ Motor Kit 7 Motor 120v 50 60 Hz Capacitor 4 0 ufd 400Vac Cable plus Resistor assembly 400 Ohm Resistor Bracket Split Washer M5 M3 X 5mm lg screw w ext tooth lock washer Socket head cap screw M5 x 12 e Pl hl sch LI sch 1 sch Top Cover Gasket Kit Instruction 62 86 33 36 Qty Unit Part Number Description Figure ID 50011455 503 240VAC 50 60HZ Motor Kit 7 Motor 240v 50 60 Hz Capacitor 75 Mfd 400Vac Cable plus Resistor assembly 1100 Ohm Resistor Bracket Split Washer M5 M3 X 5mm lg screw w ext tooth lock washer Butt Splice SA2000 Socket head cap screw M5 x 12 Al P bhM l Pl LRJAalasyaja Top Cover Gasket Kit Instruction 62 86 33 36 98 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Replacement Upgr
85. ock 53 Maintenance 59 Read status 55 Relays 44 Slidewire Emulation 23 Solid State Motor Control 7 specifications 5 Split Range 26 Spur Gear Lubrication 87 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 117 3 13 Index Stall 84 Start Up Checklist 83 Storage Temperature 5 Stroke Speed 56 T Tag Name 58 TAG parameter 56 Technical and Operating Specifications 5 Temperature Coefficient 7 Terminal Connections 18 19 Total Degrees of Motor Travel TOTDEG parameter 59 Troubleshooting 105 118 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Equipment 106 V Voltage Supply Stability 7 W Weight 5 Z Zero Suppression 7 Revision 8 3 13 Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 119 Sales and Service For application assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below ASIA PACIFIC EMEA NORTH AMERICA SOUTH AMERICA TAC hfs tac Phone 80012026455 or 44 Honeywell Process Solutions Honeywell do Brazil amp Cia suppori honeywell com 0 1202645583 Phone 1 800 423 9883 Phone 55 11 7266 1900 eet EE Or 1 800 343 0228 FAX 55 11 7266 1905 Honeywell Limited Email Sales sc B Email Sales ask Email Sales ask Phone 61 7 3846 1255 GES ege eem
86. ock out of calibration capability and other supervisory functions can be controlled by using a password The password can be any number from 0 to 4095 The password is set and or changed by using the keys on the kepad and the local display Follow the steps below to change the password NOTE The LOCK parameter must be set to NONE in order to change the password Step Action 1 Press SET UP key until the display reads SET LOCK 2 Press the FUNCTION key until the lower display reads LOCK If the prompt in the upper display is flashing a password is required to change the LOCK type proceed to step 3 If the upper display is not flashing and you want to change the LOCK type proceed to step 5 If the upper display is not flashing and you want to change the password proceed to step 3 3 Press the FUNCTION key until the lower display reads LOCKID 4 The upper display will show 0 zero Use the A or W keys to increment the number to the correct password See NOTE below on use of keys Note If the password can not be recovered to allow user access a universal password can be obtained by calling the Honeywell Tactical Assistance center 5 Press the FUNCTION key the lower display should read LOCK The upper display should not be flashing If it is repeat steps 3 amp 4 6 Use the A or W keys to change the LOCK type to the desired selection If your not changing the password proceed to step 9 If your changing the pa
87. odbus RTU Serial Communications User Manual 51 52 25 103 Configuration Remote Calibration Interfaces for HercuLine Actuators HercuLink User Manual 62 86 25 11 HART Communications Installation and Operations Manual 62 86 25 12 Contacts World Wide Web The following lists Honeywell s World Wide Web sites that will be of interest to our customers Honeywell Organization WWW Address URL Corporate http www honeywell com Honeywell Process Solutions http www honeywell com ps Telephone Contact us by telephone at the numbers listed below Organization Phone Number United States and Canada Honeywell 1 800 423 9883 Tech Support 1 800 525 7439 Service Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual iii 3 13 Symbol Definitions The following table lists those symbols that may be used in this document to denote certain conditions Symbol Definition This DANGER symbol indicates an imminently hazardous situation which Ay DANGER if not avoided will result in death or serious injury This WARNING symbol indicates a potentially hazardous situation which if WARNING not avoided could result in death or serious injury This CAUTION symbol may be present on Control Product instrumentation A CAUTION and literature If present on a product the user must consult the appropriate part of the accompanying product literature for more information This CAUTION symbol indicat
88. of fuel This is true when the span and zero adjustment are all set the same as in curve 2 of the graph Other relationships between units exist if the span adjustment 3 for ratio or if the zero adjustment is changed 1 for bias Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 27 3 13 Burner Control Flame Safety Master Slave Arrangement PV Orifice Plate Controller 4 to 20 mA Proportional Positioner amp Actuator Linkage with Bias 1 Position mA Figure 18 Proportional Flow Using Multiple Actuators Current Output Controller 4 to 20 mA Note Controller must be capable of sourcing the impedance See Figure 27 for jumper location Preferred Wiring MP Linkage Valve 2 Linkage Valve Actuator 1 ucuvuo OUCIICS ALLUALUI HI Jumper W2 Current Hot f Neutral 120 240 T 1 WUY N Lef bei Ground VAC Actuator Jumper W2 Hot o Current Neutral 120 240 Ground VAC Actuator 3 Jumper W2 Hot Current Neutral 120 240 Ground VAC NOTE If using HART communications for this application HART must be configured for Multi drop operation g Revision 8 28 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 3 13 Burner Control Flame Safety Master Slave Arrangement Current Output Controller 1 Actuator 1 d
89. on and Maintenance Manual Revision 8 3 13 Specifications Technical and Operating Specifications Specifications Communications Communications Communications RS 485 Serial Communication Modbus RTU Protocol Option Connection Twisted pair cable with shield Maximum loop length 600 meters 2000 feet Communication Mode Half duplex Baud Rate 300 600 1200 2400 4800 9600 19 2K Required Specifications PDA customer provided Operating System Palm OS version 3 5 or greater Communications Serial port with RS232 compatible levels to drive external converter Note As of this writing only Palm devices have this feature Honeywell has qualified the M105 M125 M130 and M505 devices with the HercuLink application Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 9 3 13 Specifications Model Selection Guide Model Selection Guide 10 Instructions e Select the desired key number The arrow to the right marks the selection available e Make the desired selections from Tables thru VIII using the column below the arrow A dot e denotes unrestricted availability Key Number i Rese ssl il IV Vil vill IX EE KEY NUMBER Motor Selection Basic Motor Unit no electronics Basic Motor Unit plus Digital Electronics Enhanced Performance Motor Unit with Non contact Position Sensing Unidirectional Motor M640D Replacement TABLE TORQUE amp
90. onnections Table 3 Terminal Connections HercuLine 2000 Connection Terminal Numbers Descriptions and LABEL See Figure 8 Hot 1 Hot wire for 120 240VAC mains supply Use only if Auto Manual switch is present Neutral 2 Neutral wire for 120 240VAC mains supply Auto Manual Switch 3 Switch contact to indicate setting of actuator AUTO MANUAL Contact 4 switch Switch is closed when actuator is NOT IN AUTO CW from Controller 5 CW motor drive CCW from Controller 6 CCW motor drive Potentiometer 1 7 Clockwise End 8 Slider 9 Counterclockwise End Potentiometer 2 10 Clockwise End 11 Slider 12 Counterclockwise End Protective Ground Ground wire connection for mains supply 158 ohm 158 ohm lt Install resistors to convert 1000 ohm POTENTIOMETER POTENTIOMETER 2 1 CONTROLLER OUT OF AUTO 50 60Hz S 3 3 51452161001 18 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual zo lt a lt gt Teo FROM AIM SWITCH 120 240V potentiometer to 135 ohms pua CONDUCTORS ONLY O AUTO MANUAL SWITCH OUT OF AUTO CONTACT IS RATED FOR A MAXIMUM CURRENT RATING OF 2 5 AMPS HOT AT 120VAC NON INDUCTIVE A REQUIRED ONLY IF AUTO MANUAL CONTACT SWITCH IS PRESENT SUPPLY ogg Ogg s OBE SWITCHES SW3 SW4 SW5 AND SW6 ARE RATED FOR A MAXIMUM CURRENT OF 10 AMPS AT 120VAC OR 5 AMPS AT 240VAC l Sw Sw5 Sw4 SW3 AUXILIARY SWITCHES Figure 8 HercuLi
91. ot 4 to 20 mA See Figure 27 for jumper location Alternate Wiring Jumper W2 L Current 1 Neutral 120 240 around VAC Actuator 2 lot Jumper W2 leutral 120 240 Voltage mound VAC 102605 Series Actuator 3 Actuator 3 Hot leutral 120 240 Jumper W2 round VAC Voltage Figure 19 Multiple Actuator Interconnection Diagrams NOTE If using HART communications for this application HART must be configured for Multi drop operation Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 29 Burner Control Flame Safety Master Slave Arrangement Split Valve Configuration A common heat or cool type process requires two valves In this case the controller has only one output The two motor positioners are calibrated differently one responds to 4 to 12mA and the other responds to 12 to20mA At 12mA both valves are closed one opening below 12mA and the other above 12mA Refer to Figure 20 for an interconnection diagram for split valve operation using two actuators Current Output Controller 1 Actuator 1 Jumper W2 Hot L Current Neutral 120 240 4 to 20 mA Ground VAC Note Controller must 1 Actuator 2 be capable of sourcing See Figure the impedance 27 for jumper location Jumper W2 Hot Current Neutral 120 240 Preferred enn VAC Wiring NOTE If using HART communications for this applic
92. p Tips for instructions to increase or decrease y a value quickly Change the value or selection to meet your needs NOTE If the display flashes you are trying to make an unacceptable entry or the value on the display is at its range limit The display may also show KEYERR Key error 6 Enter Value or FUNCTION This key selects another function prompt Selection or SET UP This key selects another set up group NOTE Pressing either key will cause the previously selected value or selection to be entered into memory 7 Exit Set Up mode DISPLAY Exits set up mode and returns actuator to the same state it was in immediately preceding entry into the set up mode Any changes you have made are stored in memory If you do not press any keys for 30 seconds the display times out and reverts to the mode and display shown prior to entering the set up mode Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 37 3 13 Set Up and Calibration Procedures Configuration Prompt Hierarchy Configuration Prompt Hierarchy Se Lovar RELAYn ee n 1 2 30r4 y lor2 CUROUT DIGINP DISPLA DECMAL EUNITS UNITS LOCK STATUS Lanser RamTst seersr CrGTsT CALTST DRVINF VERSON SPEED POWER ROTATE TAG MFGDAT p LREP LCAL REPTYP MAINT TEMP TEMPHI TEMPLO ACSTAL STARTS RLICNT F R DATSAV PASSWD MANRST LD CAL LD CFG RESTRT
93. parameters specific to the Table 21 DRVINF actuator 34 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Set Up Groups SET Display various operating statistics Reset Table 22 MAINT accumulated operating statistics CAL Use the display as an indicator in this case a Table 23 POSOUT voltmeter so you can verify that the position sensor is operating properly Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 35 Set Up and Calibration Procedures Set Up Procedure Set Up Procedure Each of the set up groups and their functions are either pre configured at the factory or set to their default values Tables 8 through 19 list and describe the options available in each set up group The following procedure shows you the key press sequence to access any set up group or any associated Function parameter Make sure lock set up group LOCK function is set to NONE or CAL Also some parameters require that you enter a security password before you access or change the parameter You can use this procedure to access the set up groups and select all parameters Table 9 Set Up Procedure Using Display and Keypad Step Operation Press Result 1 Enter Set Up Mode SET UP Upper Display SET Lets you know you are in the set up mode and a set up group title is be
94. plays that can be shown during operation Table 34 Typical Operating Displays Display Description Input Upper Display Shows input value 0 0 Lower Display prompt INP Output Upper Display Shows input value 00 Lower Display Shows output value OP 0 5 Deviation Upper Display Shows input value 100 0 Lower Display Shows value of deviation of DE 99 9 sensor from input Position Upper Display Shows value of position sensor 0 6 Lower Display prompt POS NOTE Position display will show negative values if appropriate NOTE When the AUTO MANUAL key is pressed placing the actuator in manual mode the local display mode is forced to the Position display POS The Manual L E D indicator should be lit When the AUTO MANUAL key is pressed again placing the actuator in auto mode the local display mode is forced to the Output display OP The Auto L E D indicator should be lit Set up parameters can still be accessed Motor Stall 84 The actuator is equipped with a low current motor that prevents against burnout if the motor becomes stalled A stall condition occurs when the motor position does not follow the input or if the motor does not reach setpoint within a given period of time When the stall condition occurs a stall alarm is indicated The actuator sets the STALLED LED indicator ON and also any other alarms or relay contacts that are programmed to close whenever a stall condition is d
95. pplication Unpacking instructions installation consisderations electrical and safety precautions also included in this section should be observed Mechanical Stops CAUTION Factory set at 90 or 150 5 See Figure 2 for location 12 Attention Do not adjust the mechanical stops Adjusting the stops will void the warranty HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Installation Before Starting Before Starting Unpacking If there are visible signs of damage to the shipping container notify the carrier and Honeywell immediately If there is no visible damage compare the contents with the packing list Notify the carrier and Honeywell immediately if there is equipment damage or shortage Please do not return goods without contacting Honeywell Applications Center in advance The contact number is 1 800 423 9883 Installation Considerations Mount the actuator in a location where it will be easily accessible for maintenance and for manual operation by means of the handwheel The exact location must be determined in accordance with the linkage used It is important that the actuator be mounted securely to a solid foundation commensurate with the maximum torque developed Use studs or bolts that are as large as the foot mounting holes Allocate sufficient clearance around the actuator for the removal of all covers to permit inspection
96. rd the blue terminal Connections TB3 Red 4 20mA output 4 20mA input Figure 14 Series 90 connections Considerations 1 This connection performs an emulation of a series 90 motor If the controller being used is also an emulation of a Series 90 the connections required may be different Shown in Figure 15 are the connections found necessary to connect a T775 controller through an S443A S90 Auto Manual Control If the controller has the capability to provide a 4 20 or voltage output it is easier to use that mode It will require only two wires and it will allow the independent use of the 4 20 output If help is required contact Honeywell 2 Due to variations in the definition of rotation directions it may be necessary to reverse the action of the actuator from CCW to CW or vice versa 24 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Burner Control Flame Safety Series 90 Control HercuLine 2001 model only rR T775 W1 out from HercuLine2001 gt Signal to HercuLine2001 E BE D Man GND to HercuLine2001 2 In the T775 controller manual there are several examples of using resistances or potentiometers as high and Figure 15 T775 Controller connections 3 low limit controls Because of the mode of emulation of Series 90 it is likely that these connections will not work as intended Instead use the output
97. re 29 Location of potentiometer position sensor Table 31 Load Position Sensor Factory Calibration Step Action Reapply AC power to the actuator Press SET UP key to access the MAINT set up group Press the FUNCTION key until the display reads LD CAL Press the A or W keys until the display reads POS Perform the Calibrate Motor procedure exactly as in Table 26 Motor calibration must be performed for the factory configured full soan range 0 100 ATTENTION When calibrating the motor to a short stroke range you must reset the end of travel limit switches See Setting End of Travel Limit Switches When motor calibration is complete the calibration is now stored as the factory calibration of the actuator motor Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 77 Set Up and Calibration Procedures Setting End of Travel Limit Switches Setting End of Travel Limit Switches D ATTENTION Referring to Figure 31 The first two cams starting from the front are for the 0 and 100 limit switches Switch 1 and Switch 2 and should not need any adjustments as they are factory set to stop the drive at 0 and 100 See Figure 30 for limit switch settings END OF TRAVEL LIMIT SWITCH SETTINGS FACTORY SET AT 0 AND 100 0 100 sw1com SW2 COM SW 1 Clockwise Rotation Counterclockwise Rotation Clockwise and counterclo
98. re 31 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 swit
99. roubleshooting page 105 SEETST SERIAL EEPROM TEST DIAGNOSTIC Read Only Shows status of serial electrically eraseable PROM test diagnostic PASS Pass Test passed no errors FAIL Fail Test failed see Troubleshooting page 105 CFGTST CONFIGURATION TEST DIAGNOSTIC Read Only Shows status of Configuration test diagnostic PASS Pass Test passed no errors FAIL Fail Test failed see Troubleshooting page 105 CALTST CALIBRATION TEST DIAGNOSTIC Read Only Shows status of Calibration test diagnostic PASS Pass Test passed no errors FAIL Fail Test failed see Troubleshooting page 105 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 55 3 13 Set Up and Calibration Procedures Drive Set Up Group 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 Selections or Parameter Definition PDA HercuLink Prompt Display Range of Seiting Prompt VERSON nnnn FIRMWARE VERSION Read Only Displays the firmware version currently in use by the actuator s CPU SPEED 6S STROKE SPEED Read Only The speed is the number of 12S seconds it takes for the actuator shaft to move its full range 150 60hz 25S of travel 50S 75S SPEED 3 2S STROKE SPEED Read Only The speed is the number of 7 2S seconds it takes for
100. roups that are available by using the SET UP and FUNCTION keys on the keypad Table 8 Set Up Groups Set Up Group Title Pressing the FUNCTION Key Allows You to For Details See SET Select and set various parameters associated with the Table 10 INPUT input signal to the actuator SET Select relay functions NOTE Set Relay groups will Table 13 RELAYn show on display only if relays are installed in the n 1 2 3 or4 actuator SET Select the output signal type of the actuator Table 15 CUROUT SET Select communication parameters for remote control of Table 16 COMM actuator when connected to a SCADA system SET Select the parameters for external digital input states Table 17 DIGINP SET Select and set parameters for the local display Table 18 DISPLA CAL Calibrate input zero and span values Calibration INPUT Procedure Table 25 CAL Calibrate zero and span values for motor operation Calibration MOTOR Procedure ATTENTION Table 26 When calibrating the motor to a short stroke range you must reset the end of travel limit switches See Setting End of Travel Limit Switches CAL Calibrate actuator output Calibration CURENT Procedure Table 27 SET Set or change security password Enable or disable Table 19 LOCK security access to set up parameters and calibration set up READ Display operating and alarm status Display self test Table 20 STATUS diagnostic results SET Display and or set various
101. s access to programming and communication functions available as standard with the HercuLine 2001 and 2002 actuators without the added expense of the keypad amp display HMI Using a Palm PDA laptop PC or desktop computer HercuLink software and a RS232 485 converter users may configure calibrate and access maintenance information locally or remotely to the actuator Using HercuLink software the computer may be used as a master device over a Modbus network to access information to from the actuators and to control the device Set up configurations may also be stored on the computer for download to other HercuLine devices Information may be stored on the users PC in CSV format for use in preventative maintenance programs e Certified on Palm m125 m130 and m505 e Compatible with Palm OS3 5 or higher e Compatible with Windows 2000 or XP operating systems e Minimum system requirements e Windows 2000 w service pack 2 Windows NT w service pack 5 Windows ME Windows XP e 200 MHz Pentium with 64 Megs Ram Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 1 3 13 Introduction Product Description Display and keypad Handwheel Shaft and position indicator switch Figure 1 HercuLine 2000 Series Actuator 2 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Introduction Product Description Displ
102. ssword set the LOCK type to NONE and proceed to step 7 7 Press the FUNCTION key until the lower display reads LOCKID 8 The upper display will show 0 zero Use the A or W keys to increment the number to the new password See NOTE below on use of keys 9 Press FUNCTION key to view next parameter Press DISPLAY to exit set up mode LOCK type has now been changed or Password is now set to new value NOTE When changing the value of the number you can adjust a more significant digit in the upper 54 display by holding in one key A or W and pressing the other A or W at the same time The adjustment will move one digit to the left Press the key again and you will move one more digit to the left HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Read Status Set Up Group 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 Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Seiting Prompt FAILSF FAILSAFE Read Only Shows whether actuator in failsafe NO No Actuator not in failsafe YES Yes Actuator in failsafe see Troubleshooting page 105 RAMTST RAM TEST DIAGNOSTIC Read Only Shows status of RAM test diagnostic PASS Pass Test passed no errors FAIL Fail Test failed see see T
103. switch with Out of Auto Contact Auto manual switch with Out of Auto Contact Approvals UL Type 4 IP66 CSA Note 4 ANHAR SR Clockwise shaft rotation on increasing signal TABLE VII COMMUNICATIONS PROTOCOL im ENNEN Modbus RTU RS485_ RS 485 Modbus compliant standard with EEU 1 JHARTS HART Communications Protocol JS Teil TABLE VIII MANUALS Standarda fEngish CT tele TABLE IX FACTORY OPTIONS Facto Options None Orr Restrictions ACCESSORIES Mounting Hardware Mounting plate adapter for Barber Colman Series MP495 51452354 501 Mounting plate adapter for Landis amp Staefa SQM53 56 51452354 502 Direct Couple Valve Hardware 51452354 503 North American Valve Retrofit Kit 51452354 511 Linkage Assembly Ball joint for 5 16 dia Pushrod 51452354 504 Pushrod 12 in 304 5 mm long 5 16 dia 51452354 505 Pushrod 18 in 457 2 mm long 5 16 dia 51452354 506 Pushrod 24 in 609 6 mm long 5 16 dia 51452354 507 Pushrod 48 in 1219 2 mm long 5 16 dia 51452354 508 HART Turk Cable for Handheld Connection Handheld Config HercuLink Palm Software Note 3 Battery powered 232 485 converter with cable 51452354 510 Remote Mount Remote 4 20 mA requires 135 ohm fdbk 120V 50 60Hz R7195A1031 Control Remote 4 20 mA requires 1000 ohm fdbk 120V 50 60Hz R7195A1056 Remote 4 20 mA requires 135 ohm fdbk 220V 50 60Hz R7195A1064 Remote 135 ohm input requires 135 ohm fdbk 120V 50 60Hz R7195B1021 Notes 1 1
104. t Selections or Range of Setting Parameter Definition PDA HercuLink Prompt FSFTYPL LAST UP DOWN USER default DOWN FAILSAFELO TYPE Selects the motor position you want the actuator to go to when input signal is below the low end range value or on loss of input signal NOTE Failsafe condition occurs when the input exceeds its low end range value by 3 or when the input signal goes to zero For input types 0 to 20mA 0 to 5 V and 0 to 10 V there is no failsafe condition at the zero value Last Position Actuator motor remains at last position Up Actuator motor moves to full scale value Down Actuator motor moves to zero value User selected value Actuator motor moves to a customer defined value Allows setting of failsafelo input value FsFVALL 0 to 100 default 0 FAILSAFELO INPUT VALUE FailsafeLO Type USER only Selects the motor position you want the actuator to go to when input signal is below the low end range value or on loss of input Range is from 0 to 100 CHAR LINR SQRT CUST default LINR INPUT CHARACTERIZATION Selects a characterization type that causes the actuator to characterize a linear input signal to represent a non linear input Linear Provides linear characterization of the input signal Square Root Provides square root characterizations of the input signal Custom Custom characterization Selecting custom allows you to create a
105. t switches See Setting End of Travel Limit Switches Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 69 3 13 Set Up and Calibration Procedures Calibration Calibrate Motor Use the procedure in Table 26 to calibrate the actuator motor for 0 and 100 input signal D ATTENTION For a motor calibration to be saved you must complete the procedure The calibration will not be saved if you exit without completing the steps of the procedure ATTENTION When calibrating the motor to a short stroke range you must reset the end of travel limit switches See Setting End of Travel Limit Switches Table 26 Motor Calibration Procedure Step Operation Press Result 1 Enter Calibration SETUP Upper Display CAL Mode until you see Lower Display MOTOR FUNCTION Upper Display DIS Lower Display CALMTR A org key Upper Display BEGN Lower Display CALMTR 2 Calibrate Zero 0 FUNCTION Upper Display APLY Lower Display MTR LO e Use the Handwheeel or AUTO MANUAL switch to manually drive the actuator motor to its low position e Wait 5 seconds then go to step 3 3 Calibrate Span FUNCTION Upper Display APLY 100 Lower Display MTR HI e Use the Handwheeel or AUTO MANUAL switch to manually drive the actuator motor to its high position e Wait 5 seconds then go to step 4 4 FUNCTION Calibration for zero and span motor positions are now sa
106. t switches Switches 1 and 2 and should not need any adjustments as they are factory set to stop the actuator precisely at 0 and 100 See Setting End of Travel Limit Switches page 78 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 32 for auxiliary switch settings 0 100 SW6 COM l SW3 COM SW5 COM SW4 COM sw 3 O2 SW 4 SW 5 SW 6 Figure 32 Auxiliary Switch Settings If it becomes necessary to do adjust the auxillary switch cams in the field use the procedure given in Table 33 While the unit is powered a potentially lethal shock hazard exists inside the case A WARNING p p y Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 81 3 13 Set Up and Calibration Procedures Setting Auxiliary Switches Table 33 Auxiliary Switch Setting Procedure Step Action Remove AC power to the actuator Remove the six screws and the cover from the actuator case See Figure 2 Lay cover assembly on a flat surface 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 31 The auxiliary switches should be set so switches 3 and 5 operate in synchronism with swit
107. the actuator shaft to move its full range 90 60hz 15S of travel 30S 45S SPEED 7 55 STROKE SPEED Read Only The speed is the number of 15S seconds it takes for the actuator shaft to move its full range 150 50hz 30S of travel 60S 90S SPEED 4 5S STROKE SPEED Read Only The speed is the number of 9S seconds it takes for the actuator shaft to move its full range 90 50hz 18S of travel 36S 54S POWER POWER INPUT VOLTAGE AND FREQUENCY Read Only Selects the power input voltage and line frequency of the actuator 1206 1206 120Volts 60Hz 1205 1205 120Volts 50Hz 2206 2206 220Volts 60Hz 2205 2205 220Volts 50Hz ROTATE ROTATION Indicates the factory calibrated degrees of rotation 90 90 Factory calibrated for 90 degrees of rotation 150 150 Factory calibrated for 150 degrees of rotation TAG nnnnnn TAG NAME Selects the tag name or identifier of the actuator Up to 6 alphanumeric characters See Set Tag Name on next page DMFG mmddyy MANUFACTURING DATE Read Only Displays date or code of manufacture for actuator ddmmyy 56 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Drive Set Up Group Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt LREP mmddyy DATE OF LAST REPAIR Factory set only Displ
108. tics to zero SYST SYST Enables the system restart function default NONE LD CAL NONE RESTORE CALIBRATION TYPE Allows you to restore a INP calbration value to its factory calibration Input Restores input calibration to the factory calibration MTR for the current configured input type COUT Motor Restores motor calibration to the factory calibration ALL Output Restores actuator output calibration to the factory POS calibration for the current configured output type default NONE All Restores input for the type configured motor and output for the type configured calibration to the factory calibration POS Allows a position sensor field calibration to be stored as a factory calibration This is to be used when a sensor is replaced in the field See Calibrate POS Output HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures LD CFG DIS RESTORE DEFAULT FACTORY CONFIGURATION Allows you to restore the factory default configuration ENAB DIS Restore disabled ENAB Restore enabled default DIS RESTRT DIS SYSTEM RESTART Allows you to force the system to restart ENAB DIS Restart disabled ENAB Restart enabled default DIS Note The MANRST function must be set to SYST Temperature units are displayed in degrees C or F and are set by the UNITS
109. tions are performed at the factory and may not be necessary Normally you may only need to perform Calibrate Motor Only qualified personnel should perform calibration A WARNING High voltages exist inside the actuator case Do not touch the powered wires inside Death or serious injury can occur Equipment Needed The table below lists the equipment you will need to calibrate the HercuLine 2000 input and output circuits Procedure Equipment Needed Input Calibration A calibrated signal source which can provide current 4 to 20 mA or voltage 0 to 10 V with an accuracy of 0 02 or better Two insulated copper leads for connecting the current source to the actuator Output Calibration A digital voltmeter with an accuracy of 0 01 or better A 250 ohm resistor 0 01 tolerance Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 65 Set Up and Calibration Procedures Calibration 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 current or voltage 2 Set jumper W2 on main CPU board according to type of signal source See Figure 27 on page 68 for jumper location 3 Connect the copper leads from the signal source to the input terminals of the actuator as shown in Figure 25 Place
110. tor 120 240 V ac line leads 24 V and common signal leads Common signal leads relays and aux switches Safety Precautions A WARNING An external disconnect switch must be installed to break all current carrying conductors connected to the actuator Turn off power before working on conductors Failure to observe this precaution may result in serious personal injury Actuator Connections D ATTENTION aE ON ground terminal must be connected to a reliable earth ground A WARNING While the unit is powered a potentially lethal shock hazard exists inside the case Do not open the case while the unit is powered Do not access the terminals while the unit is powered The actuator terminal connections for the field wiring are located behind the cover on the actuator case as shown in Figure 2 Power and field wiring is brought into the actuator through two access holes located on the side of the actuator case CAUTION Use both openings one for low level wiring control signal and the other for high level wiring 120Vac Do not run both the High Level and Low Level wiring through the same opening The screw terminals locations and descriptions for all customer connections are identified in the tables and figures that follow Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 17 3 13 Installation Electrical Installation HercuLine 2000 Terminal C
111. tor is configured Set Up Group Parameter Setting Default Prompt SET INPUT IN TYP Input Actuation Type See Note 1 INP HI Input High Range Value 100 INP LO Input Low Range Value 0 0 FILTYP Input Filter Type LPAS LPFILT Low Pass Filter Time Constant 0 Direct Actuator Rotation CCW Dband Input Deadband 0 5 FSTYPH Failsafehi Type UP FSVALH Failsafehi Input Value 100 FSTYPL Failsafelo Type DOWN FSVALL Failsafelo Input Value 0 CHAR Input Characterization type LINR CUSTOM Custom characterization type EQUL XO VAL User configurable characterizer value 0 0 X1 VAL User configurable characterizer value 5 0 X2 VAL User configurable characterizer value 10 0 X3 VAL User configurable characterizer value 15 0 X4 VAL User configurable characterizer value 20 0 X5 VAL User configurable characterizer value 25 0 X6 VAL User configurable characterizer value 30 0 X7 VAL User configurable characterizer value 35 0 X8 VAL User configurable characterizer value 40 0 X9 VAL User configurable characterizer value 45 0 X10 VAL User configurable characterizer value 50 0 X11 VAL User configurable characterizer value 55 0 X12 VAL User configurable characterizer value 60 0 X13 VAL User configurable characterizer value 65 0 X14 VAL User configurable characterizer value 70 0 X15 VAL User configurable characterizer value 75 0 X16 VAL User config
112. tor 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 82 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Start Up Operation Introduction 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 actuator and controlled device before placing it in service In other words operate the controlled device and check its direction of travel in response to an increase of the input signal and make sure it is correct for the process Actuators having the optional auto manual switch must have the knob set in the AUTO position This section provides a checklist that can be used to do a walk through with the actuator before it is actually used for control Other features which may be helpful in understanding actuator operation are also provided Power up Diagnostics When power is applied to the actuator the actuator electronics performs a diagnostic routine on various device components These tests include a e RAM diagnostic RAMTST e Check of the electrically eraseable PROM SEETST e Verification that valid parameter values are in the actuator
113. ts Replacement Upgrade Accessory Kits Replacement Kits This section provides you with a complete list of all the spare parts that may be needed for the HercuLine 2000 Series Actuators and optional equipment To determine which kit you need cross reference Figure 37 through Figure 41 with Table 38 on page 96 Each kit contains replacement parts accessories and instructions for component replacement Figure 37 Replacement Kits 6 7 8 11 12 14 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 91 3 13 Replacement Upgrade Accessory Kits Replacement Kits 92 Figure 38 Replacement Kit 10 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Replacement Upgrade Accessory Kits Replacement Kits Figure 39 Replacement Kits 1 2 3 4 5 9 15 16 19 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 93 3 13 Replacement Upgrade Accessory Kits Replacement Kits 94 Figure 40 Replacement Kit 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Replacement Upgrade Accessory Kits Replacement Kits O d d d 3 f Figure 41 Replacement Kits 17 18 Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 95 3 13 Replacement Upgrade
114. twentieth order characterization of input value x and associated shaft position y NOTE Selecting CUST input characterization causes the following prompt CUSTOM to be displayed CUSTOM EQUL QUIK USER default EQUL Equal percentage Sets the characterization as explained in Equal Percentage Valve Characteristic on page 42 Values are read only Quick opening Sets the characterization as explained in Quick Opening Valve Characteristic on page 43 Values are read only User configurable Lets you create your own characterization using the following Xn VAL and Yn VAL prompts Xn VAL n 1 20 0 to 100 Input Value as a percentage of input range Defaults are in increments of 5 Yn VAL n 1 20 0 to 100 Shaft Position Value as a percentage of position range Defaults are in increments of 5 Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 41 Set Up and Calibration Procedures Input Set Up Group Equal Percentage Valve Characteristic Table 11 contains values that approximate an equal percentage valve characteristic in the actuator When the EQUL custom characterization type is selected the values in Table 11 are automatically loaded into the actuator configuration to produce the characteristic as presented in the graph The Xn VAL is the input value as a percentage of range and Yn VAL is the characterized o
115. uLine 2002 HercuLine 2001 HercuLine 2000 2003 Feedback Slidewire emulation Provides output voltage ratiometric to shaft position and potentiometric to supply voltage 1 Vdc to 18 Vdc without a slidewire Emulates a 100 ohm to 1000 ohm slidewire 10 mA output maximum Modbus RTU or optional HART Operating Temperature 40 to 75 40F to 170 F 40T to 85 40 F to 185 F Position sensing Non contact position sensor 1000 ohm film potentiometer Dual 1000 ohm film potentiometers not on 2003 0 2 to 5 of 90 span proportional to deadband see Lepage ll 0 2 to 5 of 90 span programmable Shipped at 0 5 Repositions minimum 90 or 150 degree stroke Table 1 option 050 Table 1 option 100 Table 1 option 200 Table 1 option 400 Table 1 option 600 Voltage Supply 0 25 of span with 10 15 voltage change Stability Temperature Less than 0 030 of span per degree C for 0 C to 50 Coeffi ient Less than 0 05 of span per degree C for 40 to 75 C Zero Suppression 90 of span Input Filters Selectable spike and low pass filters Solid State Motor Two triac switches for clockwise or anti clockwise motor operation NA Control Transient voltage protection provided Failsafe operation If input signal exceeds configured input range Selectable and NA adjustable Direction of Rotation Field programmable Wire swap Duty Cycle Continuous Rev
116. uator The display consists of a four character upper display and a six character lower display Six LEDs of various colors indicate actuator operating status Directly below the display are six keys that allow you to setup monitor and control the actuator locally as well as call up various operating parameters and configuration values on the display Figure 21 shows the physical features of the display and keypad Table 6 summarizes the various functions you can perform using the keys as well as descriptions of the status indicators STALLED ALARM MANUAL AUTO Upper Display gt Four Characters Lower Display gt Six Characters SET UP FUNCTION MAN AUTO DISPLAY Figure 21 HercuLine 2000 Display and Keypad Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 31 3 13 Set Up and Calibration Procedures Local Display and Keypad Table 6 Keypad Description Key or Function LED Indicator SET UP Places the actuator in the set up group select mode Sequentially displays the set up groups and allows the FUNCTION key to display function parameters within the set up group See Set Up and Calibration Procedures page 31 Error Reference source not found for descriptions of the various options available in the set up groups FUNCTION Used in conjunction with the SET UP key to sel
117. uct D6scriptlonis sier Eao EEEE eters Bei A ETEF ATE AE 1 EE 5 Technical and Operating Specifications ceccceeeseeceeeeeeeeeeeeeeseeeeeeeeeeeaeeseneeseeeeees 5 Model Selection Guide s sess Weichert ins in adel Ao vee 10 ele RE 12 Installation OVErVieWw A 12 Mechanical Stops icici viva ege REENEN EE EEN 12 Before Starting BEE 13 Actuator MOuUntIAg d e deed ini Mace eee ice ae ee 13 Mechanical Installation ccccccccccessnececeesneeeeeesneeeeeeeeaeeeeeeaeeeseecaeeessenaeeseseeseeeeseaaes 15 Electrical Installation cc ccccccescceessceeeeeseeeeeesseeeeeeceeeeeeeseeeeeeeseeeeeeessseeaeeessesaeesseeeaess 17 Burner Control Flame Safety cccccccceeeeeeeeneeeeeeeeeeeeeeeenneeeeeeeeeeeeeeed 23 Series 90 Control HercuLine 2001 model om 24 Split RANGE EE aa le ha a iea 26 Master Slave Arrangement 26 Set Up and Calibration Procedures een 31 UNE 31 Local Display and Revpad eriari eiid ideias i A ai aE a a i 31 S t Up Tips EE 33 ABRE o A TE TA A E T 34 Set Yp Proce d EE 36 Configuration Prompt Hierarchy sssssssesssesssiessisssrssrissirssrrssrnssrnssrnnnrnnstnnsnnntnnnnsnnnt 38 Input Set Up GOUD i Ae le ee ee ee 39 Relays Set Up Group 44 Current Out Set Up Group 49 Communications Set Up Group 50 Digital Input Set Up Group cceeecececeeeeeeeeeeee sean eeeaaeeeceeeceaeeeseaeeseaaeseeaeeesaeeseaeeeeees 51 Display Set Up Group sesi2t 2sdevei rating paid said eee or a a e a aata Bioeth 5
118. ue on DVM moves down one digit FUNCTION Calibration for zero and span output values are now stored Calibrate Position Sensor Slidewire Emulation Output Calibration is complete Read meter connected to actuator output ATTENTION The Position Sensor is factory calibrated Under normal operation it does not require calibration Sensor calibration may be necessary due to any of the following conditions e The sensor output is incorrect e The position sensor in the actuator has been replaced e The position sensor adjustment has been disturbed When the position sensor has been replaced or serviced you should perform a calibration of the position sensor circuit and then store it as the motor factory calibration Please note that performing this procedure will destroy any previously stored motor factory calibration values Table 29 outlines the steps to perform a calibration to the position sensor circuit Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 73 3 13 Set Up and Calibration Procedures Calibration 74 While the unit is powered a potentially lethal shock hazard exists inside the case A WARNING p p y Table 29 NCS Position Sensor Calibration Procedure Step Action Remove AC power to the actuator Remove the six screws and the top cover from the actuator case See Figure 2 Lay extended cover assembly on a flat surface
119. ulated Motor Starts Read Only RLnCNTS Relay Cycle Counts Read Only n 1 2 3 or4 Read Only REGNy Accumulated Motor Starts for regions Read Only of motor travel y 0 through 9 DATSAV Forced maintenance data save DIS MANRST Maintenance Statistic Reset NONE LDCAL Restore Factory Calibration Type NONE LDCFG Restore Factory Default Configuration DIS RESTRT System Restart DIS CAL NCSOUT NCSOUT Non contact sensor circuit output Read Only Note 1 Type is set from model number Revision 8 3 13 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 115 Index A Actuator Rotation 40 64 Actuator Set Up 33 Set up groups 34 Set up procedure 36 Actuator Statistics Accumulated motor starts 59 Motor starts 59 Relay cycle counts 59 Reset 60 Temperature limits 59 Total degrees of motor travel 59 Applications Basic flow control 27 Proportional flow with multiple actuators 27 Split range 26 30 Approvals 6 Auto Manual Switch Testing 110 Auto Manual Switch 64 Auxiliary Switches 81 Setting 81 Auxiliary Switches Relays 6 Baud Rate 9 50 Burner Control Flame Safety 23 C Calibration 65 Set up 66 Calibration Values Restore 60 61 CE Wiring 21 Change Password LOCKID parameter 54 Clamp Bolt 6 Communications 7 9 Floating point data transfer 50 Configuration Prompt Hierarchy 38 Configuration Record Sheet 112 Configuration Tips 3
120. up calibration and troubleshooting Figure 24 shows an illustration of the Auto Manual switch and Table 24 describes the switch settings The Auto Manual Drive switch setting overrides all input signals analog signal and remote setpoint and local display mode settings When not in auto the manual LED will flash every second MANUAL AUTO MANUAL DRIVE Figure 24 Auto Manual Switch Table 24 Auto Manual Switch Functions Switch Setting Motor Drive Control AUTO Actuator moves according to signal input and set up configuration CCW Actuator moves to the fully counterclockwise position CW Actuator moves to the fully clockwise position OFF Actuator is idle 64 Herculine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Calibration Calibration Calibration of the HercuLine 2000 Series Actuator may consist of calibrating the motor circuit that positions the actuator with 0 4 20mA input signal calibrating the potentiometer or non contact sensor and calibrating the slidewire emulation output or the 0 4 20mA output signal Typically only a motor calibration is required for installation Calibration is performed by connecting test equipment to the input terminals or output terminals and then using the keypad and display to step through the calibration group functions D ATTENTION Input calibration and output calibra
121. urable characterizer value 80 0 X17 VAL User configurable characterizer value 85 0 X18 VAL User configurable characterizer value 90 0 mz HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Appendix A HercuLine 2001 2002 Configuration Record Sheet Set Up Group Parameter Setting Default Prompt X19 VAL User configurable characterizer value 95 0 X20 VAL User configurable characterizer value 100 0 YO VAL User configurable characterizer value 0 Y1 VAL User configurable characterizer value 0 8 Y2 VAL User configurable characterizer value 2 1 Y3 VAL User configurable characterizer value 3 2 Y4 VAL User configurable characterizer value 4 9 Y5 VAL User configurable characterizer value 6 5 Y6 VAL User configurable characterizer value 8 4 Y7 VAL User configurable characterizer value 10 7 Y8 VAL User configurable characterizer value 13 2 Y9 VAL User configurable characterizer value 15 7 Y10 VAL User configurable characterizer value 18 7 Y11 VAL User configurable characterizer value 22 6 Y12 VAL User configurable characterizer value 27 2 Y13 VAL User configurable characterizer value 33 4 Y14 VAL User configurable characterizer value 40 Y15 VAL User configurable characterizer value 46 Y16 VAL User configurable characterizer value 53 8 Y17 VAL User configurable characterizer value 63 2 Y18 VAL
122. utput actuator shaft position as a percentage of range Table 11 Equal Percentage Valve Characteristics 42 Xn VAL Yn Val Order of of Equal Percentage Valve Characterization Range Range 0 0 0 1 5 0 8 2 10 24 190 95 3 15 3 2 90 4 20 4 9 85 80 5 25 6 5 5 75 70 6 30 8 4 5 O 65 7 35 10 7 P 60 8 40 132 g 5 Q 50 9 45 157 amp 45 10 50 187 9 40 a 35 11 55 22 6 gt 30 EC 12 60 27 2 gt 2 20 13 65 33 4 15 14 70 40 10 5 15 75 46 0 16 80 53 8 10 20 30 40 50 60 70 80 90 100 17 85 63 2 Xn VAL Actual Input 18 90 73 7 19 95 86 2 20 100 100 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Input Set Up Group Quick Opening Valve Characteristic Table 12 contains values that approximate the characteristic of a quick opening control valve When the QUIK custom characterization type is selected the values in Table 12 are automatically loaded into the actuator configuration to produce the characteristic as presented in the graph The Xn VAL is the input value as a percentage of range and Yn VAL is the characterized output actuator shaft position as a percentage of range Table 12 Quick Opening Valve Characteristic
123. v A MAXIMUM CURRENT OF 10 AMPS AT 120VAC OR SW5 4 v No c nj c e c nj c eil SAMPS AT aa RELAY CONTACTS ARE RATED EE SW5 SW4 SW3 AUTO MANUAL SWITCH Black FOR AMAXIMUM CURRENT OUT OF AUTO CONTACT S RATED FOR A MAXIMUM OF 5 AMPS AT 120VAC OR 2 5 AMPS AT 240VAC eseou SWITCHES CURRENT RATING OF 2 5 AMPS Black Wire Not Used AT 120VAC NON INDUCTIVE 51452163 001 Figure 9 HercuLine 2001 2002 connections Revision 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 19 3 13 Installation Electrical Installation HercuLine 2003 Wiring Connections and Operation Actionator 640D Replacement Wiring CCW Motor windings Closing Opening switch switch PROTECTIVE EARTH GREEN OR GREENYELLOW 2 Position Controller Line Voltage Opening switch Opening Closing switch A AN switch breaks breaks stops stops motor motor full Y fully open y closed Closing switch A Direction of rotation as viewed from output end of motor Figure 10 HercuLine 2003 connections Operation The 2003 actuator is uni directional it does not reverse rotation with a reversal in control action Figure 10 illustrates the internal wiring and the external connections The smaller insert of the figure describes the limit switch action for one complete cycle When the two position controller detects a sufficient fall in temperature in a heating application the switch portion between the 4 and
124. ved Motor calibration is complete NOTE The display will automatically go to the CAL CURENT set up display See Table 27 You may also exit calibation mode by pressing the DISPLAY or SETUP keys 70 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Revision 8 3 13 Set Up and Calibration Procedures Calibration Calibrate Output HercuLine 2001 2002 actuator can be one of three output types 1 Oto 20 mA or 4 to 20 mA output 2 Oto 5 Volts or 1 to 5 Volts with 250 ohm range resistor 3 Slidewire emulation The output signal range is selected through the Current Out set up group using the keypad and local display 0 4 20 mA Output The HercuLine 2001 2002 Actuator comes already calibrated from the factory If it becomes necessary to do a calibration in the field adjust the output using the procedure in Table 27 Refer to Figure 25 for a diagram to connect a signal source to the actuator input and a DVM to measure actuator output signal This procedure provides the steps to calibrate the actuator for a 4 to 20mA output If you are using another output type change the procedure accordingly ATTENTION For an output calibration to be saved you must complete the procedure The calibration will not be saved if you exit without completing the steps of the procedure To exit calibation mode press DISPLAY or SETUP keys Table 27 Output Calibration Procedure St
125. y Set Up Group Parameter roose roerne eee teneant erens eeaeee ee ie E E E ONE ENE riie EE EEE 44 Table 14 Relay KK e e 45 Table 15 Current Out Set Up Group Parametere 49 Table 16 Communications Set Up Group Parameter 50 Table 17 Digital Input Set Up Group Parameter 51 Table 18 Display Set Up Group Parameters s sseseeseseseseseeseereseseststertesessstststerestsesseststtttstsesseseettetstsesestereernenes 52 Table 19 Lock Set Up Group Parameter Sier ye repne eer e o aaa oe aee E deele Ee EE EEEE EET 53 Table 20 Read Status Set Up Group Parameters esseeeseseseseeeseseeesesrerrsstsresesrestesrerrsrertstestrntesreeteseereneesresresreet 55 Table 21 Drive Set Up Group Parameters 2 00 0 ccseesssscssesecseesecsseeecssecaeesecseesccneescesseeecssecaeeseeaecaeeseeneesuseateneeneeees 56 Table 22 Maintenance Set Up Group Barameterg 59 Table 23 CAL POSOUT Group Parameters s sccccc s cssscisscessseissssnessasvsessssssenscassctestansesovtassseussasssevserseecysboscheneossesees 63 Table 24 Auto Manual Switch Functions 0 ccc ecesecssesecseeeeceseeecsseceeesecseescesecsecsecneseecsaeeeesaecaeeseeneesaecaeeaeeneeats 64 Table 25 Input Calibration Procedure iroitti arae e kaeaea iae aa EE EE AEAEE EE REEE Ria 69 Table 26 Motor Calibration Procedure sssini esisiini reires koea EEr aA era E oer E E iO PESEE SERER ESERE SEERE 70 Table 27 Output Calibration Procedure s c5sccss scisvessisstusteocspeschaseustcasssnsossscvebapssouseck

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