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Beck, R&J ELECTRIC ACTUATORS FOR INDUSTRIAL PROCESSCONTROL 11-1_9 User's Manual

1. ETT FUSE _ EBE 1 L E B B E T U nan E DEMAND TI CAUBRATE POSITION E SETPOS EXER OJ m STALL a o sms TEMP FB OPEN ra semet In aowe E Ie mx n amp zs Location of DCM 2 Test Points and Resistor APPENDIX SPARE PARTS RECOMMENDED SPARE PARTS HOW TO ORDER SPARE PARTS It is recommended that certain replacement Select the needed parts from the spare parts parts be stocked for quick availability in the event list given below Specify the drive s model serial that service of your Beck control drive is required number e g 11 309 031891 01 02 given on the The types of parts are listed in Table 4 below nameplate to allow the factory to verify the part selection Parts may be ordered by mail telephone or fax with the confirming order sent to the factory see back cover TABLE 4 RECOMMENDED SPARE PARTS DESCRIPTION PART NO DESCRIPTION PART NO Limit switch assembly 20 3202 10 Control motor See Table 5 below Auxiliary switch assembly Motor resistor S
2. RS 232 CONNECTOR 000000 _ U Hyperterminal is a product of Hilgraeve Inc DCM 2 SERIAL INTERFACE COMMANDS AND ARGUMENTS Commands can be used for a variety of functions including changing the operating configuration of the drive verifying operation settings calibration and accessing diagnostic information There are essentially four different types of commands 1 Dual purpose commands These commands can be used to either modify drive configuration settings or display the settings already set in the drive In order to set or make a change to the settings the command requires an argument n If the command is used for display purposes only the argument is omitted Examples of these commands include dead band and demlos 2 Display only commands These commands are used to display diagnostic or operating information like present sign
3. v Check the voltage Check the voltage Is the torque sensing NO Connect across test points across test points cable connected the TP2 amp TP3 R11 TP1 amp TP4 to the cable YES Is the signal 9 side the expected YES Is the TRQ THRUST greater than the E load from 2 LOS threshold calibration range by cranicam LED still on gt 5 of span 5 NO Appl Recalibrate Repl tth pene PPY SPa Is the TRQ THRUST NO the correct demand drive the LED still on over torque DCM signal see p 24 DCM C condition Repl Is the DEMAND Is the POSITION jo LED still on LED still on sull on sull on DCM YES YES Is the TRQ THRUST LED still on Consult Factory Note Choose the side of the slash corresponding with the direction of travel in which the drive is not working i e CW CCW or green red Does Handwheel turn freely without repositioning drive Check SLM for damage rebuild or replace as necessary Consult Factory Is the STALL LED lit Place Handswitch in STOP check linkage and driven element Is binding or an obstruction present YES NO I Move Hand
4. 57 Torque 0000 0 00 58 Maintenance ACIE cpm arent 59 amp PERI 62 DCM 2 Serial Interface Sr p ME 66 67 Command Error 8 73 Maintenance iet X HRRE 74 Component Replacement 75 Spare PAM a MO 79 EE 80 Index 86 ot cee ga 87 HART is a registered trademark of the Hart Communication Foundation PRODUCT DESCRIPTION Beck control drives are engineered for precise reliable operation of dampers quarter turn valves and fluid drives The cool stable operation of Beck s control motors coupled with the powerful gear train provide the tight responsive control required by modern control loops to optimize output while keeping operating costs low The unique all spur gear construction used in the Beck cont
5. ud c OES THE DISPLAY REMOVE CHECK FOR MESSAGE ED DEMAND IN MERE 5 SOURCES OF REPLACE CORRESPOND TO A SIGNAL NOISE SLM EXPECTED VALUE MS MED AND CORRECT VIEW IS POWE LED REPLACE DCM BOARD PUT CON TROLLER IN MANUAL MODE AND CHECK THE HART COMMUNICATOR PER FIG P 35 WILL DCM BOARD YES COMMUNICATE NO v CALL FACTORY REPLACE DCM 64 REMOVE DCM COMPART MENT COVER TO LEDs R PWR LIT CHECK REPAIR CON4 TROLLER OR SIGNALI SOURCE amp WIRING DOES LOOP DEM TO THE EXPECTED DRIVE DEMAND INPUT SIGNAL IS PROPER DC SIG SENT ACROSS TER MINAL BB FROM CHECK VOLTAGE AT PAGE 65 TEST POINTS TP2 amp 1 SEE FIG 78 VOLTAGE PRESENT NECESSARY IS PROPER DC CHECK DRIVE DE MAND CALIBRATION amp RECALIBRATE IF DOES THE DISPLA ED POSITION IN CORRESPOND TO POSITION IN 96 GO TO THE DETAILED STATUS MENU UNDER DIAG NOSTICS AND VIEW THE RAW POS CONSULT FACTORY PARAMETER DOES THE RAW POS VOLTAGE CORRESPOND TO THE DRIVE POS CHECK POSITION CALIBRATION AND RECALIBRATE IF NECESSARY GO TO THE DETAILED STATUS MENU AND VIEW
6. 21 Torque protection and information 21 Unpacking 2 rre 15 87 WIM 17 SERVICES PRODUCT DEMONSTRATIONS Each of Beck s Sales Engineers has access to a complete set of drive models so that he can demonstrate virtually any of their features at your location In order to arrange to see a Beck drive in your plant or office contact Beck s Sales Department SITE SURVEYS Beck Sales Engineers are available to discuss your process control requirements Often a visit This review will yield a better understanding of the versatility of Beck drives for your installations as well as complete details on options and accessories to make the process as effective as possible SPECIFICATION WRITING Beck provides specification writing assistance in order to help you specify and order the right drives for your applications Beck Sales Engineers will work with you to make it easier for you to obtain the proper equipment and give you to your location is the best way to gain a thorough confidence that no details are overlooked understanding of your needs in order to meet them most accurately and completely Mounting hardware torque requirements linkage control signal information and optional equipment can be analyzed most effectively at the work site Beck s analysis at the job site can help ensure that specifications are
7. y THIS MESSAGE INDI CATES THE DRIVE HAS SHUT DOWN AS A RESULT OF A STALL CONDITION OF DURATION LONGER THAN THE SET STALL TIME PARAMETER IF A STALLING PROBLEM EXISTS IT SHOULD HAVE BEEN FOUND ON CHART 1 GO TO PAGE 62 CALL FACTORY IF DRIVE STILL DOES NOT OPERATE CORRECTLY 65 66 DCM 2 SERIAL INTERFACE setup COMMUNICATIONS The Beck Digital Control Module DCM 2 is equipped with a serial interface which allows for direct communication with a computer Using a communication cable connect the DCM 2 to the computer using the DCM 2 s RS 232 J20 connector see illustration on this page and the computer s COM port Ensure that the COM port on the computer is active and that the cable is plugged into the proper COM port if more than one is present e g COM1 2 etc Note that a plug end adapter may be necessary for connection to the computer s COM port Once connected communication can be established between the DCM 2 and the computer using a terminal emulation program such as HyperTerminal9 This method of communication will allow for configuration calibration and verification of drive DCM 2 settings without the use of custom software applications HyperTerminal Software HyperTerminal is the standard ASCII terminal emulation software provided with Microsoft Windows If using HyperTerminal the following instructions will assist in setup Note that some v
8. EE 864646 BECK DEMAND S CALIBRATE Status Indication 1014 m mj LEDs Er e m TEMP F seem 2 Fur ee d Q 1006 e STOPJLIMT ILI anomena Pushbutton Controls The five pushbuttons pictured below on the DCM 2 customer interface panel are used for calibration When pressing a pushbutton pressure should be maintained until the ACKNOWLEDGE LED lights this confirms receipt of the pushbutton command See the Calibration section beginning on page 25 for further explanation of the calibration procedures Pushbutton functions are as follows CALIBRATE A safety feature this button must be pressed and held while pressing the pushbuttons described below to set the Position and Demand signal limits CAUTION Pressing the following buttons may change calibration and cause the drive to reposition SET POS 100 Press to set the desired 100 position for drive movement this will correspond to 100 Demand signal SET POS 0 Press to set the desired 0 position for drive movement this will correspond to a 096 Demand signal SET DEM 100 Press to set the Demand input signal that corresponds to 100 Demand SET DEM 0 Press to set the Demand input signal that corresponds to 0 Demand Sees Hog H B BECK DEMAND POSITION TROTHRUST Pushbutton Control
9. Is the FB OPEN LED still on Does drive respond correctly and is STALL LED out Confirm proper operation of drive Is the STAT LED still on Check limit switch wiring amp setting see p 26 Is the STAT LED still on Replace the DCM DCM 2 HART INTERFACE communication BECK MK2 HART COMMUNICATOR MENUS FOR THE DCM 2 Online 1 1 rt Functions 2 Setup Checklist 1 Functions 1 Setup Checklist 1 Drive S N 2 Position 45 4 2 Device Information 2 Drive Dir CW Incr 3 Demand 45 4 3 Configuration 3 Feedback Enabled 4 Loop Dem 11 20 mA 4 Statistics 4 CPS 2 1 000 v gt General Setup 5 Trq Thrust 3 5 Manual Operation 5 PositionUnit deg 1 Drive Dir CW Incr 6 Temp 73 degF 6 Diagnostics 6 MaxTravel 100 deg 100 deg 7 Feedback 11 30 7 Calibration Trim 7 Travel 100 deg 100 deg 4 StepSize 0 100 8 DemRngLwr 4 00 mA 5 Stall Time 3005 2000 mA 6 StallProt Enabled 7 LimitSwitch Accept E 8 PositionUnit deg 9 Temperature Unit degF BLOCK REFERENCE NUMBERS APPEAR AT THE UPPER RIGHT CORNER OF EACH BLOCK THIS VALUE CAN BE EDITED INDICATES AN ACTION RATHER THAN THE VIEWING OR EDITING OF APARAMETER 1 THIS IS THE MENU DISPLAYED BY THE HART COMMUNICATOR AT POWER UP IF COMMUNICATION IS ESTABLISHED 2 THIS AND OTHER OFF
10. The limit switches are positioned to provide an electrical overtravel protection typically 91 If the drive is short stroked i e the full travel rotation from 0 100 is reduced to less than the standard 90 rotation see page 55 it may be desirable to reset the over travel limit switches see page 52 If the limit switches are not reset Handswitch operation of the drive CW CCW will still result in the original full range oftravel Because the over travel limit switches define the maximum electrical drive range if they are to be reset they should be adjusted before performing DCM 2 demand and position calibration procedures The auxiliary switches are also cam operated but have no affect on drive and DCM 2 operation Therefore the auxiliary switches can be adjusted at any time without affecting performance or calibration 51 DCM 2 HART INTERFACE Calibration Switches NOTE Your Beck drive was shipped from the factory ready for installation no electrical adjustments are required before placing it in operation Each drive is set up and calibrated to the specifications that were written into the equipment order Under normal operating conditions there is no need to recalibrate the control drive However if the application requirements change or are different than specified on the equipment order the drive should be recalibrated according to the following procedures OVER TRAVEL CCW LIMIT LIMIT SW
11. In drives equipped with optional torque measurement this message may not occur due to the pre emptive action of overtorque protection The FB Out Test diagnostic allows the user to set Feedback to a fixed value rather than the normal mode of having Feedback follow the Position value If the Feedback value is left in the fixed mode this error will be reported to alert the user that Feedback is not following the Position value 61 62 DCM 2 HART INTERFACE ELECTRO MECHANICAL CHART 1 YES CHECK SLM amp PINION 5 NECESSARY GO TO PAGE 63 DOES HAND WHEEL RUN FREELY BUT DRIVE WILL NOT REPOSITION NO GO TO PAGE 63 DOES HAND WHEEL SHUDDER NO ABOUT ONE POSITION YES CHECK LINKAGE amp DRIVEN ELEMENT B1 C1 CONNECT PROPER POWER INSTALL JUMPER Maintenance Troubleshooting START DOES DRIVE WORK PROPERLY YES WITH THE HANDSWITCH IS PROPER AC POWER VOLTAGE CONNECTED ACROSS TERMI NAL C AND B IS JUMPER FROM TERMINAL A TO C PRESENT AND INTACT YES READ NO DOES IT WORK PROPERLY CW ENERGIZE YES YES DOES DRIVE RUN ves CHECK DRIV RANDOMLY AND 2 OR ERRATICALLY Ae YES DOES IT WORK PROPERLY C
12. 2 Ovt Prot Enables or Disables over torque protection which will remove power from the motor if excessive torque is detected 3 AlarmLevel Sets the value that if exceeded will cause the Torque Alarm to activate 4 ShutDwnTrq Setsthe value that if exceeded will cause the power to be removed from the motor if Ovt Prot is enabled see above This will cause a shutdown alarm 5 Trq Null Sets the torque value that corresponds to 096 torque applied This number is represented in TK units and is noted on the label inside the DCM 2 cover also referred to as Torque Zero 6 Trq Const Sets the torque value that corresponds to 10096 torque applied This number is represented in TK units and is noted on the label inside the DCM 2 cover 39 40 DCM 2 HART INTERFACE communication Statistics Menu Block 3D This menu is where all the drive s stored operating statistics are available There are eight different statistics available 1 2 Starts Logs and displays the total number of starts the drive motor has made Reversals Logs and displays the total number of times the motor started in a direction opposite to the previous start Stalls Logs and displays the total number of stalled conditions the drive has experienced For the drive to register a stall the DCM 2 board must be unable to balance the drive position against the Demand input signal for a period exceeding the Stall Time set
13. 4 Turn the Handswitch to the STOP position 5 Disconnect power from the drive and switch terminals 6 Connect the continuity meter across the appropriate terminals See the diagram on page 26 or the drive wiring diagram Rotate the cam to operate the switch Tighten the cam locking screw to 5 Ib in 56 Nem torque 8 Disconnect the meter and reconnect power 9 Move the drive s output shaft in the desired direction to verify that the cam lobe moves away from the switch lever If not correct return to step 2 and reset the cam to the proper orientation 10 Replace covers and tighten cover bolts to 10 Ib ft 14 Nem torque 27 28 DCM 2 LOCAL INTERFACE calibration Demand DEMAND CALIBRATION DCM 2 boards are designed to accept a 4 20 mA or 1 5 V dc analog demand signal Narrower spans within this range can also be accommodated for split range operation see page 29 The input comes calibrated from the factory for the full range unless otherwise specified by the customer It is not necessary to calibrate the Demand input when the drive is installed however it can be easily accomplished using the DCM 2 pushbutton controls or HART or Serial interface and a signal source Following this procedure is only necessary to compensate for slight differences between the signal source calibration and the DCM 2 factory calibration or if reduced range calibration is desired for special operating scenarios
14. Next select the Torque Setup submenu Select the Trq Null parameter which will allow the 096 torque value to be edited Enter the number corresponding to the 096 torque value that is shown on the inside of the DCM 2 cover Next select the Trq Const parameter and enter the number corresponding to the 10096 torque value that is shown on the inside of the DCM 2 cover Online help is available through the communication device DCM 2 HART INTERFACE Maintenance Alarm Messages COMMON HART MESSAGES HART compatible monitoring systems These messages alert the user to various alarm conditions and make it much easier to diagnose problems Below is a table of typical Beck drive messages and message sequences It does not include all possible messages only the most common HART protocol maintains both standard and device specific informational messages that are displayed on the 275 375 Handheld Communicator when various conditions occur They can also be used to trigger alarms and messages in other Handswitch and Limit Switch Messages Message Description Motor power is blocked check switches This message will appear if a condition prevents current flow to the motor Some of the most common conditions are The drive Handswitch is put in the STOP position either of the drive over travel limit switches are open or the motor control triacs fail Demand Signal and Process Variable Messages Message Description Process a
15. Numerical entry sets the minute of the hour Calibration Trim Menu Block 3G This menu displays sets drive calibration values 1 PresCPS V Displays the present value of the internal Position Sensor voltage This value can also be measured at TP4 and TP1 on the DCM 2 board This value can be edited to trim the Position Sensor Loop Dem Displays the Demand signal as measured at the field wiring terminals When the Demand control loop signal is being overridden by a special mode of operation the effective Demand will not correspond to the mA value This value can be edited to trim the Demand to ensure accurate measurement of the analog signal Demand can only be trimmed at 4 0 mA and 20 0 mA Feedback Displays the mA signal representing the output shaft position as measured at the field wiring terminals This value can be edited Trq Thrust Displays the load measured at the output shaft as a percentage This value can be edited 43 44 DCM 2 HART INTERFACE Configuration and Setup All drives are shipped completely configured to the customer s specifications and are ready to be installed If the need arises to change the configuration of the drive i e change one or more of the setup parameters that define how the drive operates this may be accomplished utilizing the HART interface and a communications tool model 275 or 375 HART Communicator as described in the Communications se
16. Motor Bolts Gear Module Bolts Model 11 409 Linkage Part Numbers amp Model Information Crank Arm Assembly 14 8018 02 Crank Arm 14 8018 01 30 0308 07 30 0313 27 Washer 2 Ib ft Crank Pin 14 9882 01 Crank Pin Nut Plate 20 2641 01 NOTE All dimensions subject to change 30 0308 03 30 0309 24 12 2840 04 2 7 8 73 3 4 16 x 1 3 4 44 mm Crank Pin Bolt 2 Rod End Lock Nut Rod End Dim L Length Dim T Thread 2 3 4 70 mm 270 Ibs 122 kgs 9 000 Ibs 4 082 kgs Output Shaft Dia Approx Weight Max Overhung Load 13 OUTLINE DIMENSION DRAWINGS MODEL 11 469 SPECIFICATIONS COVER 12 9 16 TERMINAL BLOCK 319 mm EXTERNAL WIRING NAMEPLATE 6 25 32 T COVER DIGITAL 1 2 N P T gamm CONDUIT CONTROL SIGNAL MODULE T CONNECTION i HANDSWITCH dB fmm COVER 4 3 4 POSITION BI 121 mm SENSING i DEVICES TT i 540 mm 2 19 32 66 1 N P T CONDUIT eds POWER 159 mm CONNECTION 13 5 8 346 mm MAX ALLOW 6 152 mm FOR REMOVAL MOUNTING HOLES 5 8 11 UNC 2B x 1 63 41 4 mm DEEP 4 HOLES EQUALLY SPACED ON A 9 75 248 mm DIA B C HANDWHEEL N 5 13 16 1
17. See the illustration below for component identification STEEL BALLS 1 8 SPRING THRUS W BEARIN OR m PINION SPRING FRICTION LOCKING DISC MATERIAL TABLE 3 SLM PART NUMBERS Motor Part Number SLM Rebuild Kit Instruction Sheet 11 159 169 20 2700 20 12 8060 15 80 0016 05 20 2701 20 12 8060 16 80 0016 05 11 209 269 309 369 20 2704 21 12 8060 17 80 0016 07 20 2705 21 12 8060 18 80 0016 07 11 409 469 20 2201 21 22 23 12 8060 11 80 0016 01 20 2201 31 32 33 12 8060 13 80 0016 02 HANDSWITCH To replace the Handswitch remove the terminal cover and then remove the terminal plate 11 209 269 309 369 and 409 469 only Clip the five wires from the old Handswitch Remove the knob and the nut under the knob to remove the switch Install the new Handswitch as shown below Splice the wires color for color Inspect the terminal plate gasket and replace if necessary To ensure a watertight seal between the plate and the gasket coat the gasket with a thin film of grease before replacing the terminal plate Torque the screws to 3 Ib ft 4 Do not over torque Replace the terminal cover Torque bolts to 10 Ib ft 14 Nem NOTE When the Handswitch is turned fully clockwise AUTO should be indicated r WASHER FIBRE BUSHING THREADED O RING
18. the F2 function key should now be defined as the SEND key Push this key to execute the change WARNING Carefully follow the on screen warnings and messages when proceeding because changing this parameter online will cause the drive to reposition This can adversely affect the process and cause potentially dangerous conditions LOSS OF DEMAND INPUT SIGNAL The DCM 2 board has the capability of determining when the Demand input signal to the drive is lost and then responding in the method most appropriate for the application There are three setup parameters that must be configured in order to define this capability LOS Mode LOS Pos and DemLimLwr The LOS Mode parameter determines how the drive should respond to the loss of the Demand input signal It can be configured as STAY which means the drive holds its current position when the signal is lost or GO TO POSITION which means the drive moves to a predetermined position If the Go to Pos option is selected the LOS Pos parameter is used to determine what output shaft position the drive must achieve when the input is lost Finally a loss of signal is sensed by the DCM 2 when the signal drops below the value set by the DemLimLwr parameter This value is represented in mA of the Demand input signal range Therefore the standard 3 2 mA value normally used for this parameter suggests that when the Demand input signal drops 596 below t
19. the HART interface requires a HART compatible communicator Typically a universal model 275 375 HART communicator is used but any device computer or controller capable of communicating with HART devices and supporting the Beck DCM 2 device description can be used This instruction supports drives built after 12 1 06 equipped with a DCM 2 p n 22 5012 59 The DCM 2 is designed to interface using a new universal device description BECK MK2 but the firmware can be set to closely emulate older revisions thus allowing a HART communicator to interface with the new DCM 2 using an earlier revision device description This is an emergency feature for when HART communications are necessary but the user does not have a new DD To access all DCM 2 features and ensure that all engineering units are correctly displayed the user must load the BECK MK2 device description to the communicator See page 69 for the serial command required to set the firmware HART type Please contact the factory for instructions regarding setting the HART type using a handheld communicator HART INTERFACE Figure 1 page 34 displays the interface menu tree for communicating with a DCM 2 using the BECK MK2 Device Description This menu tree summarizes possible setup options features and available information HART COMMUNICATORS FOR BECK MK2 The BECK MK2 Device Description requires a HART Communicator that is fully HART 5 capable and has the ability to
20. 11 369 SPECIFICATIONS COVER 1 2 TERMINAL BLOCK CONDUIT 9 7 8 EXTERNAL WIRING SIGNAL 251 mm CONNECTION COVER 6 1 16 NAMEPLATE DIGITAL 154 mm CONTROL MODULE i 4 25 32 COVER 1 HANDSWITCH 121 mm POSITION a SENSING GROS DEVICES ram g mm g E i 1 N P T 1 CONDUIT POWER SS CONNECTION _12 1 8 308 mm 12 3 4 1 ALLOW 6 152 mm 324 mm FOR REMOVAL MOUNTING HOLES 1 2 13 UNC 2B x 3 4 19 mm DEEP 4 HOLES EQUALLY SPACED ON A 5 127 mm DIA B C HANDWHEEL DIMENSION 51 16 DEPENDENT 129 mm ON VALVE SIZE 8 203 mm MAX ALLOW 3 76 REMOVAL r p B SS a SO HECK s tm DIMENSION 738 113 DEPENDENT gt ON VALVE SIZE 187 mm x 7 GEAR MODULE i ASSEMBLY 2 1 8 54 mm H TYPICAL VALVE MOUNTING 94 1 956 50 mm 004 11 DIA 1 3 4 44 45 mm 001 03 pia a Recommended Bolt Torques BASIC CONTROL DRIVE q Cover Bolts 5 16 18 Gear Module Bolts 5 16 18 Motor Bolts 1 4 20 Model Information Body Bolts 3 8 16 Body Bolts 1 2 13 Approximate Weight 115 Ibs 52 kg T Maximum Overhung Load 4 500 Ibs
21. 2 38 mm 001 03 mm DIA BASIC CONTROL DRIVE Model Information Approximate Weight Maximum Overhung Load 56 Ibs 25 kg 750 Ibs 340 kg NOTE All dimensions subject to change 1 2 N P T CONDUIT SIGNAL CONNECTION GEAR MODULE MOTOR ASSEMBLY CONNECTION 47 16 113 mm TYPICAL VALVE MOUNTING Recommended Bolt Torques 5 16 18 1 4 20 5 16 18 3 8 16 5 16 18 3 8 24 3 8 16 Cover Bolts Motor Gear Module Bolts Body Bolts Body Bolts Control End Cover Bolts Coupling Bolts Mounting Bracket Screws Flat Head May vary per application Refer to valve mounting specification sheet shipped with your drive OUTLINE DIMENSION DRAWINGS MODEL 11 209 amp 11 309 SPECIFICATIONS COVER TERMINAL BLOCK EXTERNAL WIRING 1 67 32 425 32 1 2 N P T COVER CODUIT 158 mm 121 mm CONDUIT POWER SIGNAL DIGITAL BONTROL HANDSWITCH CONNECTION CONNECTION MODULE T NAMEPLATE COVER 8 POSITION GEAR MODULE ASSEMBLY MOTOR SENSING DEVICES q 11 16 17 mm DIA 9mm 4 HOLES 3 4 61 2 7 8 19 165mm 52 mm 12 1 8 308 mm ALLOW 6 152 mm 824 mm FOR REMOVAL 41 4 11 1 4 286 mm MAX 108 ALLOW
22. 2 041 kg Gonu o EndiG oven Bolts Coupling Bolts 5 8 18 Mounting Bracket Screws 1 2 13 May vary per application Refer to Valve Mounting Specification NOTE All dimensions subject to change sheet shipped with your drive 12 COVER TERMINAL BLOCK EXTERNAL WIRING COVER DIGITAL CONTROL MODULE COVER POSITION SENSING DEVICES MODEL 11 409 SPECIFICATIONS 6 25 32 172 mm ASSEMBLY 178 mm 172 mm 77 8 5 8 4 HOLES 200 194 13 5 8 346 ole 14 1 4 x ALLOW 6 152 mm 362 mm FOR REMOVAL GEAR MODULE z 0 13 16 21 mm DIA 1 N P T e 727 32 43 4 1 2 N P T CODUIT 199 mm CONDUIT POWER SIGNAL CONNECTION CONNECTION NAMEPLATE as _ 21 1 4 540 mm 18 13 16 478 mm HANDWHEEL 159 mm 206 mm 15 7 8 403 A 165 mm ALLOW 4 102 mm FOR REMOVAL Crank Arm WASHER 2 CRANK ARM BOLT 4 NUT PLATE XX CRANK PIN BOLT 2 CRANK PIN END LOCK NUT ADJUSTABLE RADIUS R 6 152 mm TO 12 305 mm Recommended Bolt Torques Crank Arm Bolt 4 Crank Arm Bolts Crank Pin Bolt Rod End Lock Nut Body Bolts Body Bolts Cover Bolts
23. 300 seconds the DCM 2 will shut off power to the motor feature be enabled disabled GENERAL SPECIFICATIONS ALL MODELS cont d Overtorque Protection Optional Alarm Annunciation Temperature Indication Over travel Limit Switches Auxiliary Switches Handswitch Handwheel Motor Gear Train Mechanical Stops Enclosure Mounting Orientation Standards If the output torque of the drive exceeds 150 adjustable from 70 to 150 of the drive rating the motor will shut off feature can be enabled disabled Available at terminal E Measures the internal temperature of the drive and triggers an alarm when the temperature exceeds the rating range Two SPDT CW and CCW provide over travel protection Up to four 6 A 120 V ac switches available Switches are labeled S1 to S4 and are cam operated field adjustable Unless otherwise specified auxiliary switches are factory set 51 54 are set to operate just before reaching the CCW travel limit S2 and S3 are set to operate just before reaching the CW travel limit Permits local electrical operation independent of controller signal Standard on all units An auxiliary contact is available for auto indication rated 2 5 A at 120 V ac Provides manual operation without electrical power 120 V ac single phase no burnout non coasting motor has instant magnetic braking Requires no contacts or moving parts High efficiency precision
24. Local Cal ON indicates that a Local Calibration button is pressed Bad Pos Sig Bad Dem Sig CCW Inhibitors Submenu Block 5G This menu displays the ON or OFF status of the contributing sources of extend movement inhibitors of motor operation Balance Supervisory Stall OverTrq Thr Switch Block Bad Pos Sig Bad Dem Sig Local Cal See table above Tests Submenu Block 41 This menu provides procedures that allow the user to test identify and reset the DCM 2 board They are as follows 1 FB out test This procedure allows the user to test the 4 20 mA position feedback output signal Following the prompts through this procedure allows the user to physically verify the output signal value at 4 mA 20 mA and anywhere in between 2 Board self test This procedure runs an automatic board test that verifies the health of the DCM 2 control board It runs a checksum memory test and checks for the proper installation of the position sensor CPS rotor Running the test causes the drive to reposition temporarily so it should only be run offline The CPS test runs automatically as part of some calibration and setup procedures This test should be implemented only if a DCM 2 problem is suspected 3 Identify Device This command will cause the Acknowledge LED to blink for two seconds Used to verify proper HART communications as well as an aid in identifying which drive is being addressed when configuring multiple dri
25. STOP OR LIMIT FEEDBACK DISCONNECTED Switch Status Submenu Block 5D This menu displays the ON or OFF status of the eight switch parameters LV Lim CCW LV Lim CW OvrRd CCW OvrRd CW OvrRd Stop HndSw CCW HndSw CW and HndSw AUTO The Switch Status menu displays the status of the CW CCW control override input the STOP control override or if the Handswitch is in the CW CCW or AUTO position Local Control Status Submenu Block 5E This menu displays the ON or OFF status of five local interface drive parameters Calibrate Set Pos 10095 Set Pos 096 Set Dem 10095 and Set Dem 096 The Local Control Status submenu indicates which buttons on the Local Control board are pressed 41 42 DCM 2 HART INTERFACE communication CW Inhibitors Submenu Block 5F This menu displays the ON or OFF status of the contributing sources of retract movement inhibitors of motor operation Balance Supervisory Stall OverTrq Thr Switch Block Bad Pos Sig Bad Dem Sig Local Cal See below CONDITION DESCRIPTION ON indicates that the Demand and Position are at balance ON indicates that the DCM is initializing ON indicates a Stall condition ON indicates that the motor is stopped due to excessive torque or thrust ON indicates that the Handswitch Override or Limit Switch is inhibiting movement ON indicates that the Position signal is out of range ON indicates that the Demand signal is out of range
26. Setup main menu STEP 4 Atthe bottom of the Demand Setup menu the F2 function key should now be defined as the SEND key Push this key to execute the change WARNING Carefully follow the on screen warnings and messages when proceeding because changing this parameter online could cause the drive to reposition This can adversely affect the process and cause potentially dangerous conditions TORQUE OPTIONS DCM 2 boards have the capability to measure the drive s torque output This in turn makes it possible to provide several torque related features The features include a live display of the torque output on the 275 375 HART Communicator display or any other device capable of communicating and displaying HART transmitted variables Included is the ability to store peak torque values within the DCM 2 and view them by accessing the device information menu To protect the drive gearing and related equipment the drive can be configured to shut off if the torque exceeds 150 of the drive torque rating And finally the DCM 2 will provide a high torque alarm via HART communications that alerts the user to a high torque condition when the torque output exceeds a set value normally set at 105 of the drive rating Enabling Torque Functions STEP 1 From the HART communicator Online menu move to the Torque Setup menu and select the Trq Thrust parameter This is accomplished by using the up and down a
27. TABBED WASHER OR LOCK WASHER ENS Y 9 4 KNOB quo E DCM 2 BOARD Field service of the DCM 2 board is not recommended The factory maintains a stock of replacement boards for immediate shipment To replace the DCM 2 board remove the Digital Control Module compartment cover 1 2 bolt heads If applicable disconnect the torque sensing wires from the bottom of the customer interface panel by gently pulling on the connector Loosen the four captive screws holding the board to its mounting pads Note the L shaped mounting bracket on the end of the board To remove the board pull the mounting bracket away from its mating surface See illustration below To install a DCM 2 board lightly press the board connector into its receptacle until the mounting bracket is flush with its mating surface Tighten the four captive screws to 8 9 Nem If applicable connect the torque sensing wires to the bottom of the customer interface panel by gently pressing the connector into its receptacle Replace the compartment cover Torque cover bolts to 10 Ib ft 14 Nem CPS 2 Field repair of the CPS 2 assembly is not recommended The factory maintains a stock of replacement assemblies for immediate shipment If it is necessary to replace the CPS 2 replace both the rotor and stator circuit board assembly When returning the CPS 2 to the factory for service include the rotor and stator circuit
28. accurate especially in the case of complex applications APPLICATION REVIEWS By sharing your needs with a Beck Sales Engineer you can take advantage of the best application advice for the type of control you need HOW TO OBTAIN SERVICE Factory repair of drives or subassemblies is available for both normal and emergency service To assure prompt processing contact the factory to receive a Returned Material Authorization RMA number If a repair estimation is desired please send the name and phone number of your contact for service authorization It is helpful to include a description of the work desired with the shipment or in the event of a problem the malfunction being experienced THREE YEAR LIMITED WARRANTY STATEMENT Harold Beck amp Sons Inc Beck warrants that our equipment shall conform to Beck s standard specifications Beck warrants said equipment to be free from defects in materials and workmanship This warranty applies to normal recommended use and service for three years from the date on which the equipment is shipped Improper installation misuse improper maintenance and normal wear and tear are not covered The Buyer must notify Beck of any warranty issues within 37 months of original shipment date and return the goods in question at Buyer s expense to Beck for evaluation If the product fails to conform to the warranty Beck s sole obligation and the Buyer s exclusive remedy will be 1 the repair or replac
29. and STALL LEDs will light The stall condition timing is factory configurable or configurable using the HART or Serial interface from 300 seconds to as low as 30 seconds andis initially set according to the specification at time of order A sensed stall condition is cleared by either reversing the Demand input signal from the controller such that the drive tries to run in the direction opposite the blocked direction performing a Reset Stall or Board Reset using the HART interface see page 42 or by switching the drive power off and on Alarm indication is available at terminal E TEMPERATURE DCM 2s are equipped with a temperature sensing circuit The STAT and TEMP F LEDs will light when the drive s ambient temperature exceeds the rating of the drive Specific temperature readings are available using the HART see page 40 or Serial see page 72 interface Alarm indication is available at terminal E FEEDBACK SIGNAL The feedback sourcing module provides a 4 20 mA analog output signal that represents the drive output shaft position in terms of 0 10096 of full rotational travel configurable via the HART see page 56 or Serial see page 75 interface This signal can be remotely monitored or used by a controller or indicator The STAT and FB OPEN LEDs will light if the function is enabled and there is no current in the loop The Feedback signal can be factory configured as disabled or disabled
30. as close to the mounting plate as possible Leave the clamp loose Position the clamp in the same general location as the one removed previously Slide the new CPS 2 assembly over the studs and rotor Replace the hex nuts but do not tighten Carefully slide the rotor back into the CPS 2 assembly Twist the rotor while sliding to prevent damage to the assembly Tighten hex nuts to 5 lb ft 7 Thread the wires through the wire holes in the CPS 2 and reconnect them to the transformer and terminal block Restore 120 V ac power to the drive and connect a meter to the output Insert a 0 031 80 mm feeler gauge between the rotor clamp and stator Position the clamp 0 031 80 mm from the stator Rotate the rotor only a minor adjustment should be necessary on the control shaft until the output voltage measured across TP4 and TP1 see illustration at right reads 50 approx 3 volts of the signal span Tighten clamp to 5 Ib in 6 Nem torque Perform a position calibration procedure as described on page 30 or page 54 FERRITE SENSOR STATOR TERMINAL FERRITE SENSOR ROTOR FERRITE ROTOR CLAMP TERMINALS CPS 2 Components
31. as the ENTER key at the bottom of the display Pushing this key enters the value and reverts the display back to the General Setup main menu STEP 4 At the bottom of the General Setup menu the F2 function key should now be defined as the SEND key Push this key to execute the change POSITION FEEDBACK SIGNAL DCM 2 boards are equipped with a Feedback Sourcing module that provides a 4 20 mA analog output signal that represents the drive output shaft position in terms of 0 100 of full directional travel This signal can be remotely monitored or used by a controller or indicator The user has the option of enabling or disabling the signal Normally the signal should be enabled but in a situation where the feedback is present but unused i e not wired to a load a HART alarm message will be present while communicating using the 275 375 Communicator This message is helpful in alerting the user to open feedback wiring but it is a nuisance when the feedback is purposely disconnected or unused Disabling the feedback signal turns off the output and eliminates the message Enabling Disabling Position Feedback Signal STEP 1 From the HART communicator Online menu move to the Setup Checklist menu and select the Feedback parameter This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figu
32. been randomly selected for the purpose of this example DCM 2 LOCAL INTERFACE caiibration Direction Change DIRECTION OF OUTPUT SHAFT ROTATION CW vs CCW Direction of output shaft rotation is determined by observing the end of the output shaft see illustrations below Direction of rotation is defined as the direction of output shaft rotation produced by an increasing Demand signal Unless otherwise specified at the time of order the output shaft is factory set to rotate clockwise in response to an increasing signal Changing the direction of output shaft rotation is easily accomplished using the DCM 2 customer interface panel see page 23 for location of pushbutton controls or the HART or Serial interface Follow the steps below 1 Remove the DCM 2 cover 1 2 bolt heads 2 Position the drive at the present 096 position 3 Press and hold the CALIBRATE pushbutton on the DCM 2 customer interface panel then press the SET POS 100 pushbutton until the ACKNOWLEDGE LED is lit OR 2 Position the drive at the present 10096 position 3 Press and hold the CALIBRATE pushbutton on the DCM 2 customer interface panel then press the POS 0 pushbutton until the ACKNOWLEDGE LED is lit 4 Ensure the drive operates as desired 5 Replace the DCM 2 cover and tighten the cover bolts to 10 Ib ft 14 torque Reset travel index If the ACKNOWLEDGE LED do
33. cut heat treated alloy steel and ductile iron spur gears Interchangeable gear modules permit field change of timing Prevent overtravel during automatic or manual operation Precision machined aluminum alloy castings painted with corrosion resistant polyurethane paint provide a rugged dust tight weatherproof enclosure Drives designed for hazardous classified locations are also available NEMA 68 3 meters 48 hours Internal water damage is not covered by warranty Any orientation no limitations UL Listed CSA Listed CE Compliant NOTE For standards not specifically listed please call Beck for more information at 215 968 4600 OUTLINE DIMENSION DRAWINGS MODEL 11 159 SPECIFICATIONS COVER DIGITAL CONTROL MODULE ALLOW 4 102 mm FOR REMOVAL COVER 1 TERMINAL BLOCK 67 8 CONDUIT EXTERNAL WIRING 175 mm POWER 41 4 4 2 108 mm CONDUIT 133 SIGNAL HANDSWITCH E _ COVER POSITION i SENSING DEVICES ee A A mm m HR 281 mm 39 1 816 GEAR MODULE MOTOR ASSEMBLY 178m 161 2 13 14 1 3 4 45 mm DIA 114 mm 2 1 4 57 mm 11 1 2 292 LINKAGE 11 3 4 298 mm MAX ALLOW 6 152 mm ALLOW 4 102 mm FOR REMOVAL FOR R
34. ft 169 20 18 20 2705 21 56 14 9730 04 250 Ib ft 339 40 36 _ 50 Hz motor currents do not exceed 110 of 60 Hz levels 50 Hz timing 1 2 x 60 Hz timing 83 NOTES 85 86 INDEX Application 87 Beck linkage 5 18 Components 225 eer ern 80 82 Component replacement 75 78 Contactless Position Sensor 21 Control 20 79 DCM 2 HART interface 34 65 Alarm 59 61 Calibration ie or prr aa 50 58 34 43 Communication menu Figure 1 34 Configuration and setup 44 49 Troubleshooting ie tiet 62 65 DCM 2 Local 23 33 Calibration 25 31 aes 23 24 Troubleshooting 32 33 DCM 2 Serial interface 66 73 Comimands 67 72 COdGSii ice rre E endete 73 Imm 66 Digital Control Module DCM 2 Introduction 22 Feedback signal 21 Gear m 20 Gears torque and timing optio
35. is unable to balance for a set period of time known as the stall time If the DCM 2 is unable to balance the drive for a period greater than the stall time it shuts off power to the motor and prevents the drive from continuing to operate against the stall Resetting the drive and restoring normal operation is achieved in several ways Reversing the Demand signal to the drive performing a stall reset procedure see Manual Operation Menu Figure 1 page 34 performing a board reset procedure see Diagnostics Menu Figure 1 page 34 or cycling the drive ac power Changing Stall Time STEP 1 From the HART communicator Online menu move to the General Setup menu and select the Stall Time parameter This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figure 1 page 34 to navigate STEP 2 With the Stall Time parameter selected again press the right arrow key to display the modifiable entry box and using the alphanumeric keypad type in the desired stall trigger time value It is normally set to maximum of 300 seconds but can be changed to a minimum of 30 seconds WARNING It is possible that the stall time can be set to a value less than the full travel time of some drives This could lead to false stall conditions when making very large changes Typically this would only occur during st
36. operation one or more of the drives will be interpreting the Demand input signal as out of range i e either above 100 Demand or below 0 Demand and will be against an over travel limit switch at any given time Since this is normal for split range operation the message will be a nuisance rather than informational Setting the Overtravel Annunciate feature to Ignore will eliminate the message but only when the Demand signal is above 100 or below Continued 45 46 DCM 2 HART INTERFACE Configuration and Setup OVERTRAVEL ANNUNCIATION CONT D 0 and an over travel limit switch is open This eliminates the nuisance message but does not eliminate the message for other scenarios like the Handswitch being in the STOP position Changing Overtravel Annunciation STEP 1 From the HART communicator Online menu move to the General Setup menu and select the LimitSwitch parameter This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figure 1 page 34 to navigate STEP 2 With the LimitSwitch parameter selected again press the right arrow key to display the modifiable entry box select either Accept to turn off the HART warning or Alert to ensure the HART warning is transmitted STEP 3 With the desired selection highlighted push the F4 function key which is defined
37. see Table 5 page 84 for part number Handwheel Terminal DCM compartment cover Gasket body Gasket control motor Gasket terminal cover Gasket DCM cover Gasket control end cover Control end cover Control end cover extension Terminal block Barrier insulator terminal compartment Index pointer 159 only Bracket 169 only Note To ensure exact replacement parts include all nameplate data of the Beck drive with the order _ 54 7 DRIVE COMPONENTS FOR MODEL 11 209 269 309 369 ITEM ITEM NO DESCRIPTION NO DESCRIPTION Body rear Body front Output shaft assembly and main gear Spring washer Ball bearing output shaft Seal output shaft Gear 3rd combination Pin 3rd combination gear Thrust washer Gear module assembly see Table 9 page 88 for part number Control motor see Table 5 page 84 for part number Handwheel 1 2 3 4 5 6 7 8 9 eas N Terminal DCM compartment cover Gasket body Gasket gear module Gasket control motor Gasket DCM amp terminal cover Gasket control end cover Control end cover Control end cover extension Terminal block Barrier insulator terminal compartment Barrier plate Gasket barrier plate Index 209 309 only Bracket 269 369 only Note To ensure exact replacement par
38. step size please follow the steps below Changing the Step Size STEP 1 From the HART communicator Online menu move to the General Setup menu and select the StepSize parameter This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figure 1 page 34 to navigate STEP 2 With the StepSize parameter selected press the right arrow key to display the modifiable entry box and using the alphanumeric keypad type in the desired dead band value Values between 0 1 and 2 5 are valid STEP 3 With the desired value correctly typed into the entry box push the F4 function key which is defined as the ENTER key at the bottom of the display Pushing this key enters the value and reverts the display back to the General Setup main menu STEP 4 At the bottom of the General Setup menu the F2 function key should now be defined as the SEND key Push this key to execute the change WARNING Carefully follow the on screen warnings and messages when proceeding because changing drive setup parameters can cause the drive to reposition This can adversely affect the process and cause potentially dangerous conditions STALL PROTECTION The DCM 2 board provides protection of the drive motor and gearing in the event of a stalled condition The board accomplishes this by sensing that the drive
39. such as split ranging Calibration Procedure 1 Remove the DCM 2 cover 1 2 bolt heads 2 Ensure the Handswitch is in the STOP position This will prevent the drive from repositioning during this procedure 3 Apply the desired 0 Demand input signal to the drive e g 4 mA for 4 20 mA input If the drive has not been wired the Demand input signal is connected at terminals AA and BB as shown in the diagram on page 17 4 Press and hold the CALIBRATE pushbutton on the DCM 2 customer interface panel then press the SET DEM 0 pushbutton until the ACKNOWLEDGE LED is lit 5 Apply the desired 100 Demand input signal to the drive e g 20 mA for 4 20 mA input 6 Press and hold the CALIBRATE pushbutton on the DCM 2 customer interface panel then press the SET DEM 100 pushbutton until the ACKNOWLEDGE LED is lit 7 Turn the Handswitch to the AUTO position NOTE The drive may reposition 8 Run the drive through its full operating range to ensure proper response to the Demand input signal 9 Replace the compartment covers and tighten the cover bolts to 10 Ib ft 14 Nem torque If the ACKNOWLEDGE LED does not light but the DEMAND LED does light the signal is out of acceptable range and was not accepted by the DCM 2 This is typically caused by trying to set 0 and 100 values too close together i e less than 4 mA difference Split Range Operatio
40. the drive in percent the drive temperature and the external position feedback signal in milliamps Select the first menu item Functions to gain access to the Functions menu Backing out of the Online menu using the left arrow key results in selection of the Offline menu Functions Menu Block 2 From the Functions menu any of the DCM 2 functional menus can be selected and accessed There are seven functional areas Setup Checklist Device Information Configuration Statistics Manual Operation Diagnostics and Calibration Trim The Setup Checklist Block 3A is a menu that allows the user to setup the most important items necessary for basic drive operation After completing the setup checklist further setup can be accomplished using the configuration menu The other six functional areas and menus are described in more detail as follows Device Information Menu Block 3B The Device Information menu is strictly an informational page By entering this menu a selection of useful information can be viewed and or edited There are a total of ten information entries 1 Tag This 8 character entry can be used as a unique label that correlates to a field device label 2 Descriptor This entry is a 16 digit field that can be used to provide any description desired 3 Message This entry is a 32 digit field that can be used to provide any message desired 10 Model This entry displays the model number of
41. to the 0 100 Demand input signal this allows full flexibility in arranging the drive s torque to be distributed for the best mechanical advantage relative to the driven load In certain applications as a last resort it may become necessary to reduce the full rotation of the drive In these applications the DCM 2 can be calibrated to accommodate reduced stroke The recommended minimum full stroke rotation is 60 although it is advisable to make the range as close to 100 or 90 as possible for the highest position resolution attainable with the CPS and to avoid reduction in torque linkage connected drives if the driven element stroke rotation is less than 100 where applicable a linkage can be used to allow the driven element to move the correct rotation while still allowing the drive to rotate 100 To reduce the full rotation of the drive short stroke use the customer interface panel and follow the position calibration instructions this page Short stroking can also be accomplished by using the HART see page 55 or Serial see page 71 interface The illustration below represents a Beck drive with linkage requiring an 80 full stroke rotation Please note that the crank arm may be adjusted to any start angle orientation ROTATION 80 0 POSITION FULLY CLOSED __ 100 POSITION FULLY OPENED NOTE Crank arm may be adjusted to any start angle orientation The orientation shown above has
42. up and down arrow keys to select the desired parameter Enabling this parameter will activate the over torque protection while disabling the parameter will turn it off STEP 3 With the desired choice selected push the F4 function key which is defined as the ENTER key at the bottom of the display Pushing this key enters the selected parameter and reverts the display back to the Torque Setup main menu STEP 4 At the bottom of the Torque Setup menu the F2 function key should now be defined as the SEND key Push this key to execute the change This change should not effect drive positioning but as with all configuration changes carefully follow the on screen warnings and messages when proceeding 49 50 DCM 2 HART INTERFACE caiibration Beck drives are shipped completely calibrated to the customer specifications and are ready to be installed If the need arises to change the drive calibration confirm that the drive is installed as specified and operating properly before proceeding with the change It is also helpful to verify the drive configuration This can be done by reviewing the settings in the Configuration menu With the exception of the settings for the over travel limit switches auxiliary limit switches and CPS all calibration is performed using the HART interface and a communications tool model 275 375 HART Communicator as described in the Communications section of this manual If unfamiliar with th
43. 0 07 29 3 4 756 mm 20 1750 06 31 3 4 806 mm 20 1760 06 35 889 mm 20 1730 07 21 3 4 552 mm 20 1740 08 30 1 2 775 mm 20 1750 07 32 1 2 826 mm 20 1760 07 35 3 4 908 mm Weight 5 Ibs 2 kg 9 Ibs 4 kg 5 Ibs 2 kg 9 Ibs 4 kg 13 Ibs 6 kg 22 Ibs 10 kg 5 Ibs 2 kg 9 Ibs 4 kg 13 Ibs 6 kg 22 Ibs 10 kg 5 Ibs 2 kg 9 Ibs 4 kg 13 Ibs 6 kg 22 Ibs 10 kg 19 20 OPERATION HOUSING Beck electronic control drives have individual cast aluminum compartments for each of the five main components The control motor wiring terminal block drive train digital control module and control end Gasketed covers and sealed shafts make the drives ideally suited to outdoor and high humidity environments Heavy cast mechanical stops built into the housing are designed to prevent accidental over travel damage during manual cycling and ensure that proper orientation is maintained between the output shaft and the feedback system Drive travel is centered between the mechanical stops unless otherwise specified at time of order CONTROL MOTOR The Beck control motor is a synchronous inductor motor which operates at a constant speed of 72 RPM or 120 RPM in synchronism with the line frequency Motors are able to reach full speed within 25 milliseconds and stop within 20 milliseconds actual starting and stopping times will vary with load Beck motors have double grease sealed bearings an
44. 0 ohm input resistor may be added or removed to obtain the proper match Consult the factory for details For maximum safety the Beck drive body should be grounded Use the grounding terminal in the wiring compartment of the drive INSTALLATION SIGNAL WIRING Each Beck drive is custom built to match the control requirements of your system specified at the time of order Each drive has a specific wiring diagram attached to the inside of the wiring terminal cover Typical wiring connections are described below A drive can be ordered with up to four optional auxiliary switches Wiring connections for these are described on page 26 To prevent Handswitch initiated motion remove the jumper between terminals A and C CAUTION AC power to the drive must be turned off before removing the jumper Typical Wiring Connections NEUTRAL HANDSWITCH TRAVEL LIMITS POSITION FEEDBACK 4 20 MA 800Q MAX POWER AND DEMAND INPUT CONNECTIONS Customer must supply 120 V ac to power the drive and control circuitry 120 V ac line connects to terminal C and neutral to terminal B Input signal wires connect to terminals and BB 17 18 INSTALLATION START UP LINKAGE REQUIREMENTS If Applicable In most applications the best control will result when the linkage is adjusted so that the full 100 angular travel of the Beck drive output shaft is used even thoug
45. 25 V dc and 5 35 V dc respectively In this case the LOS message above will also be present This is a Beck specific message that appears after the HART defined messages previously mentioned It specifically pinpoints the position signal to the DCM 2 as the problem source and indicates that the signal is outside the 0 25 5 35 V design range The LOS message above will also be present when this message is present Miscellaneous Messages Message The Feedback Signal is enabled but the loop is open Stall condition has been detected see Stall Time the General Setup menu Feedback is in fixed mode Description This is a Beck specific alarm message that alerts the user that external position feedback signal is installed and enabled but not wired to an external load If the signal is wired to an external load and this message appears it implies that a wiring failure somewhere between the drive and the monitoring device has occurred If the DCM 2 board is equipped with the feedback module but the signal is not being used this message can be eliminated by disabling the feedback in the configuration This is a Beck specific alarm message alerting the user that the drive is in a stalled condition and is no longer trying to fight the load This condition occurs if the drive cannot reach the demand position in the ime allotted by the stall time setting configurable from 30 300 seconds default 300 sec
46. 269 11 309 369 11 409 469 Operating Conditions Communication Interface Demand input Signal Options DCM 2 Adjustability for Split Range Operation Step Size Linearity Hysteresis Demand input Signal Characterization Position Feedback Signal for Remote Indication Isolation Action on Loss of Power Action on Loss of Input Signal Power On Stall Protection Optional 40 to 185 F 40 to 85 0 to 100 relative humidity HART protocol Rev 5 burst mode is not supported local pushbutton LED panel and RS 232 Serial commands 4 20 mA 1 5 V dc input is possible with the removal of the R11 resistor located on the DCM 2 board see diagram on page 78 0 0 1 V to4 V dc 10096 096 1 V min to 5 V max 0 15 typical configurable 1 of span max independent error 0 25 of span at any point Linear Drive output shaft moves proportionally to the input signal Square Drive output shaft moves proportionally to the square of the input signal Custom Drive output shaft moves according to the custom demand response curve 4 20 mA Demand input and position Feedback signals are isolated from ground and the ac power line Signal buffering provides 24 V dc isolation between the Demand and Feedback signals Stays in place Stays in place or drives to any preset position configurable If the motor tries to run in one direction for more than 300 seconds configurable from 30 to
47. 3 76 mm LINKAGE 43 4 FOR REMOVAL 121 mm Crank Arm CRANK ARM NUT PLATE BOLT 2 CRANK ARM BOLT 2 a gt 2 5 CLAMP PLATE L CRANICBINIBOLT w zz CRANK PIN STUD ROD END LOCK NUT ADJUSTABLE RADIUS R LS 3 1 2 89 mm TO 8 203 mm ROD END Model 11 209 309 Linkage Part Numbers amp Model Information Recommended Bolt Torques Crank Arm Assembly 14 7330 26 14 8010 34 14 8008 02 14 8008 01 30 0308 75 30 0308 75 Nem 14 9883 01 14 9883 01 Crank Arm Bolt 5 8 18 i 14 9920 06 14 9920 07 Crank Pin Bolt Stud 3 4 16 i 30 0308 61 30 0308 61 Crank Pin Bolt Stud 3 4 16 14 9883 02 14 9883 02 Rod End lock nut Rod End Lock Nut 30 0309 19 30 0309 23 11 209 1 2 20 Rod End 12 2840 02 12 2840 03 11 309 5 8 18 Dim L Length 21 8 54mm 21 2 64 Body Bolts 3 8 16 Dim T Thread 1 2 20 x 5 8 18 x 1 2 13 1 3 16 30 mm 1 1 2 38 mm 5 16 18 1 4 20 ia 1 1 2 38 mm 1 3 4 44 mm Gear Module Bolts 5 16 18 Wei 120 Ibs 54 kgs 125 Ibs 57 kgs Max Overhung Load 3 000 Ibs 4 500 Ibs NOTE All dimensions subject to change 1 361 kgs 2 041 kgs 10 MODEL 11 269 SPECIFICATIONS COVER 1 2 N P T TERMINAL BLOCK CONDUIT 9 7 8 EXTERNAL WIRING SIGNAL vGsimm CONNECTION
48. 48 mm 13 3 8 340 mm MAX ALLOW 4 102 mm FOR REMOVAL DIMENSION o DEPENDENT i ON VALVE SIZE i ees impen mn 1 1 1 197 GEAR MODULE DIMENSION ASSEMBLY I DEPENDENT gt ON VALVE SIZE 2 3 4 69 85 mm 001 03 mm DIA TYPICAL VALVE MOUNTING BASIC CONTROL DRIVE Recommended Bolt Torques Cover Bolts 5 16 18 Model Information Gear Module Bolts 5 16 18 Motor Bolts 3 8 16 216 Ibs 98 kg Body Bolts 3 8 16 Maximum Overhung Load 9 000 Ibs 4 082 kg Body Bolts 1 2 13 Control End Cover Bolts 5 16 18 Coupling Bolts 5 8 18 Mounting Bracket Bolts 5 8 11 NOTE All dimensions subject to change May vary per application Refer to Valve Mounting Specification sheet shipped with your drive 14 INSTALLATION SAFETY PRECAUTIONS WARNING Installation and service instructions are for use by qualified personnel only To avoid injury and electric shock do not perform any servicing other than that contained in this manual STORAGE INFORMATION The drive should be stored in its shipping carton in a clean dry area If itis necessary to store the drive outdoors for a long period of time it should be removed from its shipping carton and stored above ground A waterproof cover should be securely fastened over it Do not stack drives on top of one another Stored drives should be periodically checked to make sure no co
49. 80 1103 00 MODELS 11 Rev 01 1 11 11 BECK 11 4 INSTRUCTION MANUAL ELECTRIC ACTUATORS FOR INDUSTRIAL PROCESS CONTROL INTRODUCTION TO THE MANUAL This manual contains the information needed to install operate and maintain Beck Model Group 11 Electronic Control Drives equipped with the Digital Control Module DCM 2 manufactured by Harold Beck amp Sons Inc of Newtown Pennsylvania The Group 11 drive is a powerful control package designed to provide precise position control of dampers valves fluid couplings and other devices requiring up to 1 800 Ib ft 2 440 Nem of drive torque IMPORTANT This manual contains information that will make installation simple efficient and trouble free Please read and understand the appropriate sections in this manual before attempting to install or operate your drive This manual also applies to Group 11 amp 11E hazardous location drives and with such orders is provided along with Beck Manual Supplement 80 1100 14 The Beck Group 11 fills an industry need for a reliable electronic control drive Exceptionally stable and trouble free these rotary drives are in use throughout the world in valve and damper applications Group 22 digital control drives are designed for accurate reliable digital control in high torque applications The drive is ideal for use in large boiler applications such as ID FD fan dampers Group 14 linear drives are ideall
50. 956 Demand This requires that the drives have different Demand signal calibrations Split ranging is easily accomplished by determining the break points 12 mA in the example above and using a HART communication device First navigate to the Configuration menu Next select the Demand Setup submenu Change appropriate Demand range limit accordingly In the example above one drive s upper Demand range DemRngUpr would be changed from 20 00 mA to 12 00 mA and the other drive s lower Demand range DemRngL wr would be changed from 4 00 mA to 12 00 mA NOTE Ensure that the L O S Loss of Demand input signal settings of the drives are appropriate for the new configuration This would involve changing the appropriate Demand LOS limits DemLimLwr or DemLimUpr Typically these settings are 5 and 105 of the Demand range See page 21 for a description of the LOS function 57 58 DCM 2 HART INTERFACE caiibration Torque Measurement TORQUE MEASUREMENT CALIBRATION DCM 2 boards have the capability of measuring the drive output torque and providing several torque related features The torque measurement is calibrated to the drive s rated output at the factory There is normally no reason to recalibrate this feature in the field unless a new DCM 2 board has been installed In the event that calibration is required it is easily accomplished by using a HART communication device First navigate to the Configuration menu
51. COVER 61e NAMEPLATE DIGITAL 154 mm MODULE 4 25 32 POETON BECK L HANDSWITCH 121 mm t P e DEVICES d 17 7 8 r 454 mm 1 1 N P T CONDUIT POWER CONNECTION ud 12 1 8 308 mm MAX 12 3 4 ALLOW 6 152 324 FOR REMOVAL MOUNTING HOLES 3 8 16 UNC 2B x 3 4 19 mm DEEP 4 HOLES EQUALLY SPACED ON A 5 127 mm DIA B C HANDWHEEL 5 1 16 P 1229mm 4 7 16 MIN 1 113 mm 8 203 mm MAX ALLOW 3 76 mm d FOR REMOVAL e 4746 ni TYPICAL VALVE MOUNTING 7 3 8 113 187 7 GEAR MODULE 55 1 5 8 41 mm ASSEM A 7 1 056 60 mm 394 4 Recommended Bolt Torques 1 1 2 38 mm 001 03 pj BASIC CONTROL DRIVE Cover Bolts 5 16 18 Gear Module Bolts 5 16 18 Motor Bolts 1 4 20 Model Information Body Bolts 3 8 16 Body Bolts 1 2 13 Approximate Weight 115 Ibs 52 kg Control End Cover Bolts 5 16 18 Maximum Overhung Load 3 000 Ibs 1 361 kg Coupling Bolts 5 8 18 Mounting Bracket Screws 3 8 16 Flat Head May vary per application Refer to Valve Mounting Specification NOTE All dimensions subject to change sheet shipped with your drive 11 OUTLINE DIMENSION DRAWINGS MODEL
52. CW DOES OUTPUT SHAFT MOVE WITH COMBIEN ce HANDSWITCH IN CONSULT FACTORY CONNECTIONS OK YES REPLACE FACTORY FAULTY FOR Assis NENTS DANCE PAGE 65 IS BINDING OR GO BACK AN OBSTRUCTION TO PRESENT START NO CONSULT FACTORY FOR ASSISTANCE REPAIR OR REMOVE OBSTRUCTION CHECK SLM FOR WEAR REPLACE SLM AS NECESSARY INSTALL JUMPERS CONSULT FACTORY FOR ASSISTANCE ARE JUMPERS REMOVE DCM COMPART MENT COVER AND VIEW FWD amp REV LEDs SEE FIG 66 THESE LEDs LIT WITH POWER ON IS THE AC VOLTAGE ACROSS NO DCM H FUSE F1 ABOUT 0 V SEE FIG PG 78 IS PROPER AC VOLTAGE PRESENT FROM V TOB amp U TO B REPLACE HANDSWITCH CHECK WIRING INSTALLED FROM FTON amp DTOM TERMIN IS SUPPLY VOLT AGE ACROSS BETWEEN 102 amp 132 V AC PLACE HAND SWITCH IN AUTO amp MODULATE CONTROL SIGNAL TO DRIVE ALC amp B DOES DRIVE YES AT ALL I IS PRO CONSULT FACTORY FOR ASSISTANCE N AUTO NO VOLTAGE PRESENT FROM N TOB amp M TO B PER AC APPLY CORRECT POWER MOVE HANDSWITCH TO THE CW POSITION ACROSS TERMINAL A amp 07 GO TO CHART 2 PG 64 IS PROPER AC
53. E Operation OVERVIEW The DCM 2 customer interface panel pictured below allows the user to easily calibrate the drive and troubleshoot conditions The following information provides an overview of the DCM 2 customer interface panel features H S BECK DEMAND CAIBRATE POSITION T SETPOS Ol STALL Dno SETPOS TEMP F S 0 mul FB OPEN C sme 92 STOPILIMT d ILI AcwoMEDE O NOTE Beck drives are shipped from the factory set up and calibrated to customer specifications placed at the time of order and are ready for installation Overview LEDs The four LEDs as highlighted below indicate the present state of the drive FWD This LED is lit when the drive is receiving a Demand signal greater than its position A lt This LED is lit when the drive is receiving Demand signal smaller than its position STAT This LED is lit when additional status is available For details regarding possible conditions see Status Indication LEDs on page 24 PWR This LED is lit when power is applied to the drive This LED pulses from bright to dim indicating the DCM 2 is fully operational DEMAND CALIBRATE POSITION TRO
54. EATER THAN 150 OF THE DRIVE RATING AND OVERTORQUE PRO TECTION IS ENABLED CHECK FOR BIND ING OR EXCESSIVE LOADS CHECK LINKAGE SETUP CORRECT AS NECESSARY CHECK TORQUE CAL RECAL IF NEC CALL FACTORY IF DRIVE STILL DOES HAS ERROR BEEN NOT OPERATE ELIMINATED CORRECTLY _ CALL FACTORY OH PERFORM BOARD RESET OR REPLACE DCM NO DISPLAY PROCESS APPLIED TO THE PRIMARY VARIABLE 15 OUT SIDE THE OPER ATING LIMITS OF THE FIELD DEVICE THE NEXT KEY PAGE THROUGH ADDITIONAL MESSAGES A NUMBER OF ADDI TIONAL MESSAGES WILL BE PRESENT THAT INDICATE AN OUT OF RANGE OR ABSENT POSITION SIGNAL FROM THE CPS TO THE DCM THE LIKELY CAUSE IS A CPS FAILURE GO TO THE DETAILED STATUS MENU AND VIEW THE CW amp CCW MOVEMENT INHIBITORS IS BAD POS SIG PARAMETER REPLACE CPS 2 DISPLAY H S IN STOP OR DRIVE IS AT LIMIT NEXT v THIS MESSAGE INDI CATES THAT AN OPEN CIRCUIT IS PREVENTING CUR RENT FROM DRIVING THE MOTOR THE HANDSWITCH IN STOP OR AN OPEN LIMIT SWITCH WILL CAUSE THIS MSG BUT SO WILL AN DCM TRIAC FAIL URE VERIFY HAND SWITCH IN AUTO VERIFY LIMIT SWITCHES ARE CLOSED HAS ERROR BEEN YES ELMINATED NO y REPLACE BOARD GO TO PAGE 64 DISPLAY DRIVE IS IN STALL NEXT
55. EMOVAL Crank Arm CRANK ARM 6 BOLT 152 mm J R WASHERS 2 Lm WEDGE ROD END BOLT ROD END ADJUSTABLE RADIUS R 1 1 2 38 mm TO 5 1 8 130 mm ROD END LOCK NUT Model 11 159 Linkage Part Numbers amp Model Information Crank Arm Assembly Crank Arm Recommended Bolt Torques SUMA UE usu Rod End Bolt Rod End Lock Nut Rod End Dim L Length Dim T Thread Crank Arm Bolt Rod End Bolt Rod End Lock Nut Cover Bolts Motor Gear Module Bolts Body Bolts Body Bolts 1 2 20 x 1 1 Output Shaft Dia Approx Weight Max Overhung Load NOTE All dimensions subject to change 10 3491 05 10 3491 02 30 0306 56 30 0313 03 11 8060 02 30 0306 56 30 0309 11 12 2840 02 2 125 b4 mm 8 29 mm 3 4 19 mm 50 Ibs 23 kgs 750 Ibs 340 kgs MODEL 11 169 SPECIFICATIONS COVER DIGITAL CONTROL MODULE ALLOW 4 102 mm FOR REMOVAL COVER TERMINAL BLOCK EXTERNAL WIRING COVER POSITION SENSING ia 6 7 8 175 51 4 112 292 mm ALLOW 6 152 mm FOR REMOVAL MOUNTING HOLES 3 8 16 UNC 2B x 1 2 13 mm DEEP 4 HOLES EQUALLY SPACED ON A 5 127 mm DIA B C t 8 1 4 210 mm MAX ALLOW 4 102 mm FOR REMOVAL 1 15 32 37 mm 001 03 3 4 19 mm OR 1 1
56. ITCHES CW LIMIT cw ccw 101 0 91 FOR 100 or 90 OF RANGE 2 AUXILIARY eZ pu SWITCHES 12 4 AUXILIARY 2 SWITCHES 12 CONTACTS CLOSED CONTACTS OPEN Standard Over travel Limit and Auxiliary Switch Settings 52 SWITCH ADJUSTMENTS Control drives are shipped with over travel limit switches factory set for either 101 11 159 209 309 409 or 91 11 169 269 369 469 of travel unless otherwise specified at time of order Limit switches must be set inside the range of the fixed non adjustable built in mechanical stops to prevent stalling of the motor Limit switches can be reset to limit travel of the output shaft to any angle down to a minimum of 60 Auxiliary switches are set as shown in the figure at left unless otherwise specified at time of order NOTE The over travel limit switches are the switches located closest to the drive body To adjust the over travel limit switches it is necessary to remove the control end cover Switches are operated by cams which are clamped onto the control shaft Setting a switch involves loosening the cam moving the output shaft to the desired position and positioning the cam so that it just operates the switch at that point In the following procedure the use of a continuity meter is recommended to determine when the switch opens or closes If such a meter is not available it is possible to hear
57. LINE MENUS ARE COMMON TO ALL HART COMMUNICATOR APPLICATIONS MANY SUBMENUS EXIST 3 PROVIDES AN EXTENDED LIST OF DRIVE PARAMETERS 34 Alarm Mask Device Information 1 Tag BECK2006 2 Descriptor 3 Message 4 Model 11 159 5 Drive S N 6 Instld 23 05 2006 7 Setup 23 05 2006 8 Calbrtd 28 05 2006 9 Review Poll addr 0 Configuration 1 General Setup 2 PositionSensrSetup 3 Demand Setup 4 Feedback Setup 5 Torque Setup 6 Restore to Factory 7 Use Default Setup Statistics 1 Starts 485213 2 Reversals 242606 3 Stalls 0 4 OverTorques14 5 Pk Torque 12796 6 TotRunTm 532688 7 High Temp 155 degF 8 Low Temp 23 degF Manual Operation 1 Op Mode Follow 2 Demand 45 3 3 Reset Stall Diagnostics 3 CW Torque 4 CCW Torque 5 Alarm Setup 6 RealTimeClock Calibration Trim 1 PresCPS V 2 Loop Dem 3 Feedback 4 Trq Thrust 2 816 11 29 11 29 3 Figure 1 PositionSensrSetu Set Pos 0 Set Pos 100 PresCPS V CPS Zero CPS Span CPS RngLwr CPS RngUpr Pos S N Snsr Dir r Demand Setup DemRngLwr DemRngUpr Dem Curve Dem Curve Spel LOS Mode LOS Pos DemLimLwr DemLimUpr Oo Feedback Setup 1 FB RngLwr 2 FB RngUpr 3 Feedback 4 FB Curve 1 5 Torque Setup 1 Trq Thrust 2 Ovt Prot 3 ShutDwnTrq 4 Trq Nul
58. POWER VOLTAGE REPLACE DCM BOARD REPLACE HANDSWITCH SEE PG 77 REMOVE REPLACE CONTROL END FUSE COVER TO CHECK CW LIMIT SWITCH IS PROPER AC POWER VOLTAGE vEs PRESENT ON CW LIMIT SWITCH GRN WIRE amp TERM CONSULT FACTORY FOR ASSISTANCE IS GRN WIRE CONNECT CONNECTED TO WIRE THE CW LIMIT CORRECTLY SWITCH NC CONTACT REPLACE CW LIMIT SWITCH SEE PG 76 NOS POWER VOLTAGE TERMINAL A amp V7 COVER TO CHECK POWER VOLTAGE PRESENT ON CCW WIRE amp TERM B MOVE HANDSWITCH TO THE CCW POSITION IS PROPER AC ACROSS REMOVE CONTROL END CCW LIMIT SWITCH IS PROPER AC IMIT SWITCH RED IS RED WIRE CONNECTED TO THE CCW LIMIT SWITCH NC CONTACT REPLACE CCW LIMIT SWITCH SEE PG 76 FROM PAGE 62 CONNECT WIRE CORRECTLY 63 DCM 2 HART INTERFACE Troubleshooting ELECTRONICS DIAGNOSTICS CHART 2 CONNECT HART COMMUNI CATOR amp ESTABLISH COMMUNICATIONS ARE ANY HART ERROR MESSAGES DISPLAYED ON THE COMMUNICATOR VIEW ALL DYNAMIC INFOR MATION DISPLAYED IN THE ONLINE MENU WILL BOARD COMMUNICATE DO LEDs LIGHT ALTERNATELY WITH DRIVE CYCLE SET TO ALWAYS DOES COMMUNI POLL SEE PG 36 CATOR DISPLAY YES
59. PS ranges from 1 0 V at the CCW end of travel to 5 0 V at the CW end of travel A 4 20 mA position feedback signal is available for remote position indication see page 17 Ifthe CPS Position signal to the DCM 2 is out ofthe calibrated range limits the STAT and POSITION LEDs will light and the drive will not operate until the limits are adjusted or the CPS is corrected Alarm indication is available at terminal E TORQUE PROTECTION FOR DRIVES EQUIPPED WITH THIS OPTION DCM 2s are equipped with a torque sensing module that will light the STAT and TRQ THRUST LEDs in the event excessive torque is detected This alarm is normally set to activate when torque exceeds 105 of the drive rating Torques above 150 of the drive rating will cause the DCM 2 to stop trying to run in the direction of the high torque When the over torque condition is corrected the drive will automatically resume normal operation The torque sensing module also provides a number of torque related features using the HART interface see page 48 Torque alarm may be enabled or disabled using the HART see page 48 or Serial interface see page 71 Torque alarm levels may be adjusted using the HART or Serial interfaces Alarm indication is available at terminal E STALL PROTECTION AND ANNUNCIATION If the drive output shaft cannot reach a desired position within approximately 300 seconds the DCM 2 shuts off power to the motor and the STAT
60. Stalls Overloads Positive amp Negative Peak Load 96 Positive amp Negative Peak Torque 9o inches Extend and Retract Inhibit Setting Alarms Displays measured temperatures in the No argument drive F Low extreme Present temperature High extreme Displays the drive s present torque No argument measurement as a percentage of rated torque DCM 2 SERIAL INTERFACE Command Error Codes___ Command Error Codes When an error is encountered using the serial commands an ERROR XX message is returned The table below provides a description of the error codes XX Description Information Invalid selection Displayed when an unknown command has been entered Value too big Displayed when an entered numeric value exceeds expected parameters Value too small Displayed when an entered numeric value is less than expected parameters Data length error Displayed when the wrong number of arguments is entered General error Displayed when a combination of circumstances prevents a better description of the error Process too high Displayed when the entered value exceeds acceptable parameters when calibrating a 096 value Process too low Displayed when the entered value is less than acceptable parameters when calibrating a 10096 value Span too small Displayed when entered values for a 096 point and a 100 point are too close Busy Displayed when a memory store is requested and another memory store is al
61. THE CW amp CCW MOVEMENT INHIBITORS DISPLAY ANY PARAMETERS THAT DISPLAY ON STATUS INDICATE THAT IT IS PREVENT ING THE DRIVE FROM MOVING READ PARAMETERS AND ACT ACCORD INGLY CALL FACTORY FOR ASSISTANCE DEMAND SIGNAL OUT OF RANGE PREV NEXT v EXPECTED DRIVE YES DOES THE DRIVE APPEAR TO OSCILLATE ABOUT A FIXED POINT CHECK VOLTAGE AT DCM TEST POINTS TP4 amp 1 SEE FIG P 78 IS PROPER VOLTAGE PRESENT 0 100 1 5 V REPLACE CPS CALL FACTORY FOR ASSISTANCE INDICATES THAT THE DEMAND SIG NAL TO THE DRIVE IS OUTSIDE THE CALIBRATED RANGE ORLOST VERIFY SIGNAL CHECK DEMAND CAL RECAL DEMAND IF NECESSARY HAS ERROR BEEN ELIMINATED NO YES NOTE ADDITIONAL ERROR MESSAGES AND WARNINGS MAY DISPLAYED ON THE HART COMMUNICATOR THOSE NOT MENTIONED HERE ARE EITHER REDUNDANT OR NOT RELATED TO ERRORS THAT PREVENT THE DRIVE FROM RESPONDING amp POSITIONING CORRECTLY MOST ARE DESCRIPTIVE AND ARE DISCUSSED UNDER THE APPROPRIATE SECTION ELSEWHERE IN THIS MANUAL DISPLAY PROCESS APPLIED TO THE NON PRI MARY VARIABLE IS OUTSIDE THE OPER ATING LIMITS OF THE FIELD DEVICE NEXT PRESS NEXT DISPLAY TORQUE IS EXCES SIVE PREV NEXT INDICATES THAT y DRIVE TORQUE OUT4 PUT IS GR
62. TRIST SEROS OTR b 100 STALL on TEMP F LO w FB OPEN SETOM 92 b 10 STOPILIMT AXNOMEDE O 23 24 DCM 2 LOCAL INTERFACE Operation Status Indication LEDs When the STAT LED is lit the applicable status indication LED s pictured below will light to reveal the condition s as described below An alarm is also available at terminal E When the condition is corrected the status will automatically reset Each status LED is described below with a more detailed explanation of the function provided on page 21 DEMAND Loss of the Demand input signal POSITION The CPS Position signal to the DCM 2 is out of the calibrated range limits The lower limit is 5 and the upper limit is 105 of the calibrated range This LED may also indicate a CPS or internal wiring failure TRQ THRUST This LED indicates that excessive torque is present over 105 of the drive rating This LED is functional only when the drive is equipped with optional torque sensing STALL The drive is in a stall condition and stall protection has been activated TEMP F Drive s internal temperature is outside of rating FB OPEN External position Feedback signal is enabled but not wired to an external load or the wiring has failed between the drive and the monitoring device STOP LIMIT Handswitch is in STOP position or the drive is at a limit and is not in balance
63. al values No arguments are required Examples include the stat command and the signals command 3 Set only commands These commands serve only to make a parameter change Typically they apply to the drive calibration This type of command requires an argument but unlike dual purpose commands they return an error message when entered without an argument Examples include the demis and posis commands 4 Execute action commands These commands serve to reset enable or disable features and do not require an argument Entering these commands produces an immediate action Examples include the revert and command The available commands are listed on page 68 and each is described in more detail on pages 69 through 72 The command description explains the use or uses of the command while the argument column describes the applicable arguments for those commands that require them In the command tables arguments are denoted as n Note that the commands described as sets and or displays signify dual purpose commands that can be used with or without an argument for setting or verifying configuration settings 67 68 DCM 2 SERIAL INTERFACE commands SERIAL COMMANDS The following is a list of serial commands available through the RS 232 interface Error codes associated with these commands are listed on page 73 General Configuration Commands p 69 stepsize drvdir stalltime sernum Reset Factor
64. an be fully edited Review Scrolls through all device information items as well as all the other DCM 2 settings without accessing each item individually This is an excellent tool for quickly determining how a particular drive is setup To edit individual entries the user must exit Review and proceed to the appropriate menu and item Poll Address This entry can be edited however it is normally set to O A polling address from 1 to 15 can be entered if the drive resides on a common HART network with other HART devices 37 38 DCM 2 HART INTERFACE communication Configuration Menu Block 3C The Configuration menu serves as the gateway to all of the drive operating setup parameters The user can select any of five different setup submenus that can be used to configure the drive based on the physical layout and the desired operation The five setup submenus are described below In addition to these five setup menus there is a Restore to Factory selection which resets the drive configuration to its as shipped settings There is also a User Default Setup setting which resets the drive configuration to the settings typical of the applicable drive model type General Setup Submenu Block 4B This menu sets drive operating parameters The nine parameter entries are as follows 1 Drive dir Defines the rotation of the drive output shaft given an increasing Demand signal looking into the output shaft Opt
65. ariation to these instructions may be necessary depending on the version of HyperTerminal being used Once the computer has been connected to the DCM 2 access HyperTerminal by clicking first on Start then Programs then Accessories then Communications then HyperTerminal Double click on the Hypertrm exe icon to start the program Once HyperTerminal is running it is necessary to set up a file with the proper settings to communicate with the DCM 2 Proceed as follows 1 If prompted to install modem answer no Proceed to enter a name e g DCM 2 and select an icon any will suffice in the Connection Description box Click the OK button 2 The Connect to box should open next At the bottom of the box set the Connect using selection to the computer COM port that has been connected to the DCM 2 Click the OK button 3 The COM port properties box should open next This is where the communication settings are established The correct settings are a Bits per second 1200 b Data bits 8 c Parity none d Stop bits 1 e Flow control 7 none 4 With the appropriate settings entered from Step 3 above click OK Communications should now be enabled 5 Press the Enter key twice Ok should be displayed indicating that HyperTerminal is
66. art up shut down or some other condition that might require a large change in Demand from the controller STEP 3 With the desired value correctly typed into the entry box push the F4 function key which is defined as the ENTER key at the bottom of the display Pushing this key enters the value and reverts the display back to the General Setup main menu STEP 4 At the bottom of the General Setup menu the F2 function key should now be defined as the SEND key Push this key to execute the change WARNING Carefully follow the on screen warnings and messages when proceeding because changing drive setup parameters can cause the drive to reposition This can adversely affect the process and cause potentially dangerous conditions OVERTRAVEL ANNUNCIATION When communicating with the DCM 2 via the 275 HART Communicator a number of different informational messages may be displayed for certain conditions that may exist One such message is H S in STOP or drive at limit sw This is displayed anytime the DCM 2 is attempting to reposition the output shaft but is unable to due to a break in the electrical power to the motor This can happen if the Handswitch is put in STOP or if an over travel limit switch is open Normally this is a useful message that should be displayed however in certain situations like split range operation see split ranging page 57 it can become a nuisance For example in a split range
67. board assembly Do not separate the stator or circuit boards from their mounting plates The rotor should be held inside the stator with rubber bands for protection during shipment 77 MAINTENANCE COMPONENT REPLACEMENT To 1 To remove the CPS 2 Run the control drive to its midpoint of travel with the local Handswitch If the standard rotation of 100 has been reduced to 80 the midpoint of travel is 40 Disconnect 120 V ac power to the drive Remove the terminal DCM 2 compartment and control end covers 1 2 bolt heads Record the wire colors on the terminal block of the CPS 2 see illustration at right then disconnect the wires The terminals are spring loaded To remove a wire press the tip of a small screwdriver into the slot at the top of the small lever Push down to open the spring loaded contact and release the wire Pull the wires from the transformer see illustration at right back through the wire hole in the CPS 2 Loosen and remove the 3 hex studs that clamp the CPS 2 in place Ensure that the inboard hex stud is not loosened as the outboard stud is loosened Slide the CPS 2 stator assembly off the three mounting bolts Note the position of the rotor clamp then loosen the rotor clamp screw and remove the rotor from the shaft install the new CPS 2 Remove the rotor from the replacement CPS 2 assembly Slide the rotor clamp end first onto the control shaft
68. connect power from the switch terminals first 1 Remove the control end cover and the terminal block cover 1 2 bolt heads 2 Use the electric Handswitch to drive the shaft so that the switch cam is accessible Using a 7 64 hex wrench loosen the screw so that the cam is just snug on the shaft 3 Move the output shaft to the desired position 4 Turn the Handswitch to the STOP position 5 Disconnect power from the drive and switch terminals 6 Connect the continuity meter across the appropriate terminals See the diagram on page 17 or the drive wiring diagram Rotate the cam to operate the switch Tighten the cam locking screw to 5 56 torque 8 Disconnect the meter and reconnect power 9 Move the drive s output shaft in the desired direction so that the cam lobe moves away from the switch lever If not correct return to step 2 and reset the cam to the proper orientation 10 Replace covers and tighten cover bolts to 10 Ib ft 14 torque 53 54 DCM 2 HART INTERFACE caiibration Position POSITION SENSOR SETUP In order to correctly position the drive output shaft in response to the input Demand signal the DCM 2 board receives a position signal from the drive s position sensor CPS and compares this actual position to the desired Demand input This process requires that the DCM 2 interprets the CPS signal appropriately for the full range of desired travel The Po
69. convenient field installation see page 5 Installing Direct coupled Drive CAUTION Whenever a control drive is being mounted on a valve it is good practice to remove the valve from service and observe these precautions Know what fluid is in the line Wear proper protective equipment Disconnect electrical power Depressurize the pipeline Refer to the valve maintenance manual for specific instructions Consult the Beck Valve Mounting Specification sheet shipped with the drive for instructions Installing a Unitized Valve Drive Assembly on a Pipeline Inspect the valve and pipe flanges to ensure they are clean Be certain that other pipelines in the area are free from pipe scale or welding slag that could damage the gasket surfaces Carefully lift the assembly and position the valve in the pipeline Install and tighten the flange bolts according to the valve and or gasket manufacturer s instructions NOTE The valve may have undergone temperature variations in shipment This could result in seepage past the stem seals Refer to the valve manufacturer s maintenance instructions for packing adjustments INSTALLATION ELECTRICAL NOTE All Beck drives are shipped from the factory ready for installation no electrical adjustments are required before placing them in operation Each drive is set up and calibrated to the customer s specifications that were written into the equipment order Two co
70. ction of this manual This section of the manual covers how the drive is configured and gives instructions for changing each particular setup parameter available It is intended to build upon the Communications Section which provides a detailed description of the HART Menu Tree and defines all the parameters and commands If unfamiliar with the HART communicator and Beck drives please review the Communications section before proceeding There are a number of configuration setup parameters that can be changed to custom tailor the drive s operation to the application needs The remainder of this section provides instructions for changing each of these parameters The instructions below assume that the user has a model 275 HART Communicator attached to the Demand wiring at drive terminals AA and BB or anywhere across the wires all the way back to the source of the Demand signal has established communications with a particular drive and has a copy of the HART Menu Tree Figure 1 page 34 available DRIVE SHAFT TRAVEL Drive shaft travel refers to the direction the output shaft of the drive moves in response to an increasing Demand input signal The travel is either clockwise CW or counterclockwise CCW The control loop operation and physical design of the final control element determine the drive travel suitable for an application If the drive travel needs to be changed this is easily accomplished by changing the DCM 2 config
71. d require no maintenance for the life of the motor GEAR TRAIN The gear train is a four stage reduction spur gear drive constructed with only heat treated alloy steel and ductile iron gears for durability and long life The drive train consists of the control motor and Handwheel reduction gears main gear output shaft and crank arm The main gear output shaft and third stage gears are common to all units of a particular drive model The second and first stage gears are part of the field interchangeable gear module Different combinations of gear modules and drive motors determine the drive s output torque and timing See Table 9 page 83 for details On all models except the 11 169 the output shaft is limited by mechanical stops to 108 of rotation On model 11 169 drives the output shaft is limited by mechanical stops to 98 of rotation Optional main gear output shaft assemblies are available that permit multi revolution output rotation Mechanical stops are not included on these models Mechanical transmission of output shaft position to the control end is provided by a right angle gear set driven directly by the output shaft SELF LOCKING MECHANISM SLM An integral part of every control motor is the self locking mechanism This mechanical device couples the motor to the gear train and transmits full motor torque when rotated in either direction When the motor is de energized the SLM instantaneously locks and hold
72. dSw AUTO OFF OFF OFF OFF OFF OFF OFF OFF Local Cntrl Status Calibrate Set Pos 100 Set Pos 0 Set Dem 100 Set Dem 0 OFF OFF OFF OFF OFF CW Inhibitors Balance Supervisory Stall OverTrq Thr Switch Block Bad Pos Sig Bad Dem Sig Local Cal ON OFF OFF OFF OFF OFF OFF OFF CCW Inhibitors Balance Supervisory Stall OverTrq Thr Switch Block Bad Pos Sig Bad Dem Sig Local Cal ON OFF OFF OFF OFF OFF OFF OFF Alarm Mask DemandLOS Trq Thrust High Stall Trq Thrust Stop Stop Limit FeedbackLOS Temperature PositionLOS RTC Fail Torq Thrust MeasFail PositionA D Error DemandMeasFail ON Reserved 1 ON PositionLOS ON TemperatureMeasFail MemoryFail ON InvalButtonPress ON DemandTooHigh ON DemUnderHART FF Ctl ON DemUnderPAT Ctl ON HANDHELD COMMUNICATOR WIRING CONNECTIONS CONTROL ROOM FIELD CONTROLLER DEMAND FIELD JUNCTION BOX OUTPUT TO DRIVE OR TERMINATION MARSHALLING CABINET ACCEPTABLE COMMUNICATOR CONNECTION POINTS POLARITY NOT IMPORTANT A2500 load resistor may be required for proper HART communication when the DCM has been modified for 1 5 V Demand signal operation ES DEMAND SIGNAL TO DRIVE WIRING TERMINAL AA amp BB 35 36 DCM 2 HART INTERFACE communication The DCM 2 board is the control center of the drive Drive configuration and calibration are accessed and set through the DCM 2 board Using
73. designed to accept a maximum position signal range of 0 25 to 5 35 V dc and can be calibrated anywhere within this range depending on the type of CPS and desired stroke of the drive Normally new drives would be calibrated for a 1 5 V dc position signal Retrofit applications are typically calibrated for a 0 45 2 6 V dc range 60 Message Analog output 1 and its digital representation are outside the operating range limits and not responding to input The Position Signal is less than 5 or greater than 105 Position signal in LOS Position out of accurate measurement range Description This is an additional standard HART defined message that appears whenever the HART primary variable Position signal is outside the design or calibrated range It accompanies the message above This is a Beck specific message that appears after the HART defined messages above It specifically pinpoints the position signal to the DCM 2 as the problem source and indicates that the signal is outside the calibrated range limits The upper and lower limits are 5 and 105 of the calibrated range respectively This is a Beck specific message that appears after the HART defined messages above It specifically pinpoints the position signal to the DCM 2 as the problem source and is intended to indicate a CPS or wiring failure The message is triggered when the position signal is outside the minimum and maximum limits of 0
74. desired CW travel limit If the stopping point is reached the switch is properly set Loosening Switch Cam 13 Repeat instructions for setting CCW travel limit switch noting that referenced directions of rotation should be opposite of those used for CW switch setting Connect continuity meter across terminals B and N 14 Replace covers and tighten cover bolts to 10 Ib ft 14 Nem torque 15 Rotate index or index pointer on models 11 159 or 169 to correspond with output shaft rotation Setting Auxiliary Switches Standard switch settings for drives with 2 or 4 auxiliary switches are shown on the diagram on page 26 The heavy line indicates a closed circuit Follow these instructions to change the operating point of auxiliary switches NOTE In the following procedure it is assumed that switch settings are to be adjusted so that contacts are open when the desired position is achieved If they are to be adjusted to close it may be necessary to reverse the operating mode of the switch by moving the wire lead to the other terminal on the switch itself Be sure to disconnect power from the switch terminals first 1 Remove the control end cover and the terminal block cover 1 2 bolt heads 2 Use the electric Handswitch to drive the shaft so that the switch cam is accessible Using a 7 64 hex wrench loosen the screw so that the cam is just snug on the shaft 3 Move the output shaft to the desired position
75. difference Square Function Beck drives can be set up to position the output shaft proportionally to the square of the Demand input signal see table below This function is factory configurable or may be configured using the HART or Serial interface Square Function Actual Output Position of Span Standard Output of Span 29 30 DCM 2 LOCAL INTERFACE Calibration Position POSITION CALIBRATION In order to correctly position the drive output shaft in response to the Demand input signal the DCM 2 receives a position signal from the drive s position sensor and compares this actual position to the Demand input This process requires that the DCM 2 interprets the position signal appropriately for the full range of desired travel This procedure will calibrate the DCM 2 to accept the position signal and interpret the appropriate 0 10096 range Note that all drives come factory calibrated and there is no need to recalibrate unless changes in operation are desired Itis also possible to calibrate the position signal using the HART or Serial interface Calibration Procedure NOTE Prior to adjusting the travel range electronically using the DCM 2 it is recommended that the over travel protection switches be reset just outside the intended travel range see page 26 1 Remove the DCM 2 cover 1 2 bolt heads 2 Position the drive at the desired minimum position i e the desired physical posi
76. drive s intended full range of electronic operation typically 100 The limit switches are positioned to provide an electrical overtravel protection typically 101 If the drive is short stroked i e the full travel rotation from 0 100 is reduced to less than the standard 100 rotation see page 55 it may be desirable to reset the over travel limit switches see page 52 If the limit switches are not reset Handswitch operation of the drive CW CCW will still result in the original full range of travel It is best to calibrate the drive and then set the limit switches when short stroking the drive The switches should be set just outside the calibrated range to avoid tripping the switch at the 0 and 100 positions The auxiliary switches are also cam operated but have no affect on drive and DCM 2 operation Therefore the auxiliary switches can be adjusted at any time without affecting performance or calibration Models 11 169 269 369 amp 469 Standard Group 11 drives are equipped with fixed non adjustable built in mechanical stops All output shaft rotation must occur within these stops which are approximately 108 apart except for the 11 169 stops which are 98 apart The over travel limit switches are used to limit the electrical control range of the drive These switches are cam operated and are set slightly wider apart then the drive s intended full range of electronic operation typically 90
77. e Demand signal is greater than the Position signal ON indicates that a Demand error condition exists check the operating mode settings Position ON indicates that the Position signal may be out of range or saturated Trq Thrust ON indicates that the Torque or Thrust sensor signal may be out of range or saturated Stall ON indicates that the motor may be stalled Temperature indicates that a temperature fault exists FB Open ON indicates that the feedback loop is open or out of range Limit ON indicates that a limit switch has been triggered Acknowledge Acknowledge indicator is Operating Status Submenu Block 5C This menu displays the ON or OFF status of eight drive parameters Dem Limits Pos Limits Temp Limits Torq Limits Over Torq Stop Stalled Feedback Open and Switch Block See below CONDITION DESCRIPTION DEMAND LOS The Demand Signal is outside of the intended limits see Demand Setup menu THRUST OVERRANGE The Torque Thrust is greater than the output rating STALL Stall condition has been detected see General Setup menu Motor power has been removed due to excessive output thrust Motor power is blocked check switches The Feedback signal is enabled but the loop is open TEMPERATURE The temperature is outside of OVERRANGE 40F to 185F POSITION OVERRANGE The Position signal is less than 5 or greater than 105 OVERTRQ THRUST PROTECTION
78. e HART communicator and Beck drives please review the Communications section of this manual before continuing The DCM 2 can be calibrated by using the Position Setup and Demand Setup menus Normally calibration should not require adjustment however if the Position or Demand requires minor adjustment the Calibration Trim menu may be used Any calibration changes that are made using any of the above described methods can be reversed by using the Restore to Factory feature in the Configuration menu Note that implementing the Restore to Factory feature returns all settings to the as shipped factory settings DIRECTION OF SHAFT ROTATION CW VERSUS CCW Direction of shaft rotation is determined when looking at the end of the output shaft see figures below Direction of rotation is defined as the direction of output shaft rotation produced by an increasing demand signal Unless otherwise specified at the time of order the output shaft is factory set to rotate clockwise in response to an increasing signal CALIBRATION PRIORITY Models 11 159 209 309 amp 409 Standard Group 11 drives are equipped with fixed non adjustable built in mechanical stops All output shaft rotation must occur within these stops which are approximately 108 apart The over travel limit switches are used to limit the electrical control range of the drive These switches are cam operated and are set slightly wider apart then the
79. e pipe Left hand threads are internal to the linkage kit assembly making final length adjustments quick and easy To order pipe linkage kits first obtain the approximate overall linkage length A in the figure below Select the kit part number from Table 1 below For lengths beyond those listed in the table contact your Beck sales engineer START UP INSTRUCTIONS After the drive is mounted and its wiring connections are made it is ready to be tested for proper operation NOTE All Beck drives are shipped from the factory ready for installation no electrical adjustments are required before placing them in operation Each drive is set up and calibrated to the customer s specifications that were written into the equipment order Turn on the power supply Operate the drive ae with the Handswitch and run it through its full stroke both directions Observe that the driven device travels through its desired stroke If satisfactory LINKAGE set Handswitch to the AUTO position END Turn on the controller and operate the drive by T P NOTE To calculate 21 Bu 2 22 length of pipe required or valve strokes in the proper direction fora change subtract Length in control signal Ifit does not first check for proper LINKAGE PIPE of 2 Linkage Ends wiring connections and verify control signal at the LENS IH LENGTH shown in Table 1 drive If the wiring is correct then c
80. ee Table 5 below 2 switches 20 3202 11 4 switches 20 3202 12 Motor capacitor See Table 5 below Gasket set DCM Board 22 5012 59 Model 11 159 169 20 3110 01 Model 11 209 269 Fuse 7A 125V 11 1373 01 Model 11 309 369 20 3110 02 Model 11 409 469 20 3110 03 CPS 2 20 3400 09 TABLE 5 MOTORS CAPACITORS AND RESISTORS USED ON MOTOR CAPACITOR RESISTOR MODEL NO PART NO VOLTAGE HERTZ PART NO VALUE PART NO VALUE 20 2700 20 60 14 2840 02 11 5802 03 50 14 2844 13 11 5802 03 11 159 169 20 2701 20 60 14 2844 11 11 5802 02 50 2 14 2840 11 11 5802 02 20 2704 21 60 14 2844 16 20 1971 13 50 14 2844 19 20 1971 13 60 14 2844 05 20 1971 12 50 14 2844 06 20 1971 12 11 209 269 and 120 120 120 11 309 369 20 2705 21 120 120 120 20 20 2201 31 60 14 2844 17 20 1971 03 50 14 2844 16 20 1971 03 14 2844 17 20 2201 32 60 14 2844 15 20 1971 04 50 14 2844 05 20 1971 04 11 409 469 14 2844 15 20 2201 33 1 60 14 2844 15 20 1971 06 14 2844 09 50 14 2844 15 20 1971 10 14 2844 05 14 2844 09 This is a resistor assembly 80 APPENDIX COMPONENTS DRIVE COMPONENTS FOR MODEL 11 159 169 Body rear Body front Output shaft assembly and main gear Spring washer Ball bearing output shaft Seal output shaft Gear 3rd combination Gear module assembly see Table 9 page 88 for part number Control motor
81. el limit switch settings must be changed in the field Itis advisable to operate the drive fully in each direction using the electric Handswitch to check switch settings before attempting to change them Follow these instructions if they require adjustment 1 Remove the control end cover and terminal block cover 1 2 bolt heads 2 Usethe electric Handswitch to drive the control shaft so that the CW switch cam screw is accessible Using a 7 64 hex wrench loosen the screw so that the cam is just snug on the shaft see illustration below Move the output shaft clockwise to the desired CW limit Turn the Handswitch to the STOP position Disconnect power from the drive Turn the Handswitch to the AUTO position Connect the continuity meter across terminals B and M Rotate the cam until the meter shows no continuity switch contacts open switch clicks A 8 Tighten the cam locking screw to 5 16 56 N m torque 9 Disconnect meter and turn the Handswitch to the STOP position 10 Reconnect drive power 11 Rotate the drive s output shaft in the CCW direction away from the CW travel limit Note the direction of rotation of the lobe of the cam The correct cam lobe motion is away from the Switch lever with the switch lever on the lower part of the cam If not correct return to step 2 and reset the cam to the proper orientation 12 Rotate the output shaft again to the
82. ement without charge at Beck s factory of any defective equipment covered by this warranty or 2 at Beck s option a full refund of the purchase price In no event will Beck s liability exceed the contract price for the goods claimed to be defective THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER EXPRESS OR IMPLIED WARRANTY INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER OBLIGATIONS OR LIABILITIES OF BECK In no case shall Beck be liable for any special incidental or consequential damages based upon breach of warranty breach of contract negligence strict tort or any other legal theory Such damages include but are not limited to loss of profits loss of revenue loss of use of the equipment or any associated equipment cost of capital cost of any substitute equipment facilities or service downtime the claims of third parties including customers and injury to property Buyer acknowledges its responsibilities under OSHA related laws and regulations and other safety laws regulations standards practices or recommendations that are principally directed to the use of equipment in its operating environment Buyer acknowledges that the conditions under which the equipment will be used its use or combination with or proximity to other equipment and other circumstances of the operation of such equipment are matters beyond Beck s control Buyer hereby agrees to indemnify Beck against all claim
83. eptable value is the Demand at 0 plus 4 00 mA For example if the 096 Demand signal is 4 00 mA then the 10096 Demand signal must be 8 00 mA or greater The maximum acceptable value is 21 00 mA A 4 mA Demand signal must be present at drive terminals 14 amp 15 A 20 mA Demand signal must be present at drive terminals 14 amp 15 n 0 linear n 1 square root n 4 special curve n 5 square n the Demand signal in mA below which LOS occurs For example in a 4 20 mA drive if the desired LOS is 596 below the minimum signal then n 3 20 mA oR n sip gtp or pat Note n values must be set separately n the desired position of the drive expressed as a percentage of drive travel e g if the desired LOS position is 50 then n 50 00 Position and Feedback Signal Commands Command travel n fdbkOpctma n fdbk100pctma n fdbkfunc n posis n trimfdbk4ma n trimfdbk20ma n Description Sets and or displays the value that represents 100 travel Sets and or displays the mA value of the Feedback signal that represents the 096 drive position Sets and or displays the mA value of the Feedback signal that represents the 10096 drive position Sets and or displays whether or not the drive Feedback signal is enabled Sets the point of drive travel in relation to the drive s current position This command should only be used when the drive is at a known positi
84. er allows the user to define the position in percentage of travel to where the output shaft will move during Loss of Signal conditions May be set between 5 00 and 105 0095 7 DemLimLwr Sets the minimum usable value of Demand Below this value the Loss of Signal condition will be set Values between 0 mA and 12 mA may be selected This value should be set lower than the low Demand Range DemRngLwr 8 DemLimUpr Sets the maximum usable value of Demand This value should be set higher than the upper Demand Range DemRngUpr Feedback Setup Submenu Block 4E This menu is where all the Feedback signal related drive parameters are set The four parameter entries are as follows 1 FBRngLwr The value of the Feedback signal in mA that corresponds to a 0 output shaft position This value can range between 3 0 mA and 16 0 mA 2 FBRngUpr The value of the Feedback signal in mA that corresponds to a 100 output shaft position This value can range between 7 0 mA and 21 0 mA 3 Feedback Enables or Disables the Feedback signal 4 FB Curve Allows a choice in the relationship between the applied Feedback signal and the actual position of the drive Choices are Linear amp Inverted Demand InvDem Torque Setup Submenu Block 4F This menu is where all the Torque related drive parameters are set The five parameter entries are as follows 1 Trq Thrust Enables or Disables torque related functions
85. es not light but the POSITION LED does light the signal is out of acceptable range and was not accepted by the DCM 2 NOTE When either of the above procedures is performed both the 0 and 100 positions are automatically set 31 DCM 2 LOCAL INTERFACE Troubleshooting Connect proper NO Is AC voltage at power Is there a jumper Does drive Does motor terminals B amp C between 102 amp YES from terminal A work properly appear to to terminal C CW energize 132 V Does drive work with Handswitch YES Is there 0 volts Replace the fuse Install Does drive Does drive run across fuse F1 See diagram on jumper work properly fandomiy and or of the DCM p 78 for location erratically YES v Replace Go back Does output shaft Check for correct Is the i lg NO RIC network PWR LED lit the move with network DCM start Switch in STOP see p 79 Check Check SLM for Replace Is the STAT LED 4 Is the R C drive wear rebuild or re faulty on the DOM lit network correct calibration place as necessary components Is the TRQ THRUST LED lit Is the POSITION LED lit Is the DEMAND LED lit
86. ets the Demand signal value that corresponds to 0 drive position Argument n and Information n 7 stepsize in degrees The minimum value that can be entered is 0 10 which is also the standard value The maximum value is 2 50 n 0 indicates Extend or n 1 indicates Retract n time in seconds Time to stall is configurable from 30 to 300 seconds The default value is 300 seconds n 7 serial number Argument n and Information No additional argument required n 1 ESR D n 10 DCM 2 or n 239 BECK MK2 Argument n and Information n the Demand signal as a decimal in milliamps The minimum acceptable value is 0 50 mA The maximum acceptable value is 100 Demand less 4 00 mA For example if the 100 Demand signal is 20 00 mA then the 0 Demand signal must be 16 00 mA or less 69 70 DCM 2 SERIAL INTERFACE Note For specific information on the following functions see the HART interface section of the manual Demand Signal Commands con t Command dem100pctma n trimdem4ma 4 trimdem20ma 20 demfunc n demlosgtp n Description Sets the Demand signal value that corresponds to 100 drive position Calibrates the Demand signal at 4 mA This command should only be used when the Demand signal at the drive is 4 mA If the Demand signal at the drive is greater or less than 4 mA an error will be returned Note This parameter is factory configu
87. f travel Normally Set by the factory 7 CPS RngUpr Displays the CPS voltage at the highest available point of travel Normally set by the factory 8 Pos S N A number which uniquely identifies the position sensor May be edited 9 Snsr Dir Displays which direction of output shaft movement will yield an increasing internal Position Sensor signal Normally set at factory to CW Incr signal increases as the output shaft rotates CW Demand Setup Submenu Block 4D This menu is where all the Demand input signal related drive parameters are set The eight parameter entries are as follows 1 DemRngLwr The value of the Demand signal in mA that corresponds to 0 Normally set to 4 00 mA this value should be set above the DemLimLwr value 2 DemRngUpr The value of the Demand signal in mA that corresponds to 100 Normally set to 20 00 mA this value should be set below the DemLimUpr value 3 Dem Curve Allows a choice in the relationship between the applied Demand signal and the desired position of the output shaft Choices are Linear Square Root Dem Curve Special amp Square 4 Dem Curve Spcl When Dem Curve above is set to Special this command allows access to a submenu to setup the preferred Demand curve 5 Los Mode Sets the output shaft response to a loss of Demand signal condition Can be set to Stay or Go to Pos 6 Los Pos If Los Mode has been set to Go to Pos this paramet
88. gn range of the drive The lower and upper limits are 0 1 V dc and 5 55 V dc respectively Note that current input DCM 2 boards utilize a 250 Ohm input resistor to convert the current signal to voltage DCM 2 HART INTERFACE Maintenance Alarm Messages Demand Signal and Process Variable Messages con t Message Description The Torque Thrust is greater than the This is a Beck specific message that can appear after the HART output rating defined Process applied to the non primary variable is outside the operating limits of the field device message mentioned previously It serves to further define the condition and indicates that the drive s torque output is exceeding 105 of the calibrated torque range of the drive Motor power has been removed due This Beck specific message appears after the Torque is excessive excessive output torque message if the torque measurement has exceeded 150 of the calibrated range and thus gone into a protective mode of operation to prevent excessive torque in the event of an obstruction or other problem The drive ceases driving against the load until the condition is reset Although unlikely it is possible to also get a Drive in stall message see misc messages with this message The temperature is outside of 40F to This is a Beck specific message that can appear after the HART 185F defined Process applied to the non primary variable is outside the operati
89. gnal from the drive as measured in mA at terminals 16 amp 17 The minimum value is 19 mA 19 000 and the maximum value is 21 mA 21 000 Argument n and Information n the zero torque value in counts This number is determined during manufacture and is noted on a tag affixed to the drive body within the electronics compartment 71 72 DCM 2 SERIAL INTERFACE commands Note For specific information on the following functions see the HART interface section of the manual Torque Sensing Commands con t Command Description Argument n and Information torqconst n Assigns the count value to be n the torque span value in counts associated with the torque span This This number is determined during number is unique to each drive manufacture and is noted on a tag affixed to the drive body within the electronics compartment torgenable n Enables or disables the torque n 0 disabled or 1 enabled measurement feature of the drive Diagnostic and Information Commands Command Description Argument n and Information signals Displays the present Position signal No argument of the drive in volts and the Demand signal in milliamps Displays information on the status of No argument the drive including Time Date Demand 96 and settings Position 9o inches Error 96 Stepsize inches 96 Deadband inches 96 Motor Status Run Time Line Frequency Starts ext ret total Reversals
90. h the valve or damper may travel less than 100 The general requirements for a good linkage are 1 It must be rigid enough to carry the link thrust without bending or deforming 2 It must have a built in means of adjustment so that the length of the connecting link can be changed a small amount 3 Rod end bearings similar to those furnished on the Beck crank arm should be used at both ends of the connecting link This type of device permits small angular misalignments and helps prevent binding of the linkage 4 The radius of the Beck crank arm must be calculated so that it will move the valve or damper lever through the correct arc as the lever travels from 0 to 100 5 The drive and valve damper shafts must be parallel and the linkage should be in a plane perpendicular to the shafts The following procedure is recommended to couple the linkage between the Beck drive and the driven shaft this procedure assumes that the Beck drive will open the damper valve in response to an increasing signal 1 Position the driven shaft to the closed position 2 Set the driven shaft lever to its predetermined starting angle in relation to the driven shaft and output shaft centerline 3 Remove the rod end from the Beck crank arm Attach to the connecting link 4 Adjustthe connecting link to the predetermined length 5 Connect the connecting link to the driven lever at the predetermined radius 6 Loosen the Beck crank a
91. hange the amp Y from Linkage Length direction of output shaft rotation see applicable 9 4 shown at left instructions on page 31 51 or 69 i N LINKAGE G END ROD END SUPPLIED WITH LINKAGE KIT TABLE 1 PIPE LINKAGE KITS Length of 2 Linkage Ends Total Adj Linkage Length Min Pipe Nipple Beck Pipe Thread Linkage Kit Approx No 11 159 11 209 11 309 11 409 Range A 22 84 559 2 134 mm 31 120 787 3 048 mm 22 45 559 1 143 mm 31 84 787 2 134 mm 33 1 4 120 845 3 048 mm 37 120 940 3 048 mm 22 1 2 36 572 914 mm 31 1 2 72 800 1 829 mm 33 3 4 96 857 2 438 mm 37 1 2 120 953 3 048 mm 23 1 4 34 590 864 32 1 4 48 819 1 219 34 1 2 72 876 1 829 38 1 4 120 972 3 048 1 25 mm 1 1 2 38 mm 1 25 mm 1 1 2 38 mm 2 51 mm 2 1 2 64 mm 1 25 mm 1 1 2 38 mm 2 51 mm 2 1 2 64 mm 1 25 mm 1 1 2 38 mm 2 51 mm 2 1 2 64 mm Length 1 1 2 38 mm 1 3 4 44 mm 1 1 2 38 mm 1 3 4 44 mm 2 51 mm 2 1 2 64 mm 1 1 2 38 mm 1 3 4 44 mm 2 51 mm 2 1 2 64 mm 1 1 2 38 mm 1 3 4 44 mm 2 51 mm 2 1 2 64 mm Part No 1 1 2 38 mm 20 1730 05 20 1 2 521 mm 20 1740 06 29 1 4 743 mm 20 1730 05 20 1 2 521 mm 20 1740 06 29 1 4 743 mm 20 1750 05 31 1 4 794 mm 20 1760 05 34 1 2 876 mm 20 1730 06 21 533 mm 20 174
92. he calibrated 096 value the DCM 2 senses a lost Demand input and executes the configured loss of signal action Changing Loss LOS of Signal Action STEP 1 From the HART communicator Online menu move to the Demand Setup menu and select the 105 Mode parameter This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figure 1 page 34 to navigate STEP 2 With the LOS Mode parameter selected press the right arrow key to display the two entry choices Stay or Go to Pos Use the up and down arrow keys to select the desired parameter STEP 3 With desired choice selected push the F4 function key which is defined as the ENTER key at the bottom of the display Pushing this key enters the selected parameter and reverts the display back to the Demand setup main menu If the Go to Pos choice was selected go to STEP 4 if Stay was selected go to STEP 6 STEP 4 After entering Go to Pos select the LOS Pos parameter and use the right arrow key to display the modifiable entry block Unless otherwise specified this value is set to 50 at the factory Using the alphanumeric keypad enter the desired loss of signal position as a percentage of full output shaft travel Values from 5 to 105 are valid STEP 5 With desired value correctly typed into the entry box push the F4 fu
93. import Device Description Language Files DDL that are certified by the HART Communications Foundation USING THE HART COMMUNICATOR The HART Communicator leads should be connected in parallel with the analog Demand signal wiring see Figure on page 35 This allows the communicator to simultaneously communicate over the analog input wires This does not disturb the analog command signal or disrupt the DCM 2 functions However any program changes to the DCM 2 will momentarily suspend the operation of the board maintains last state while the change is implemented Typically this is only for a second or two With the communicator connected in parallel anywhere across the analog Demand wires it is ready to communicate Turn on the communicator and wait for communications to be established Once communicating the Online display Figure 1 menu block 1 will appear in the communicator window If the drive is multidropped with other devices on a single HART network the first display screen will list all devices and require a selection before the Online display is shown The Online display provides online information about the present drive operating conditions Entering any of the menus shown in Figure 1 is accomplished by following the display and using the communicator s arrow keys If the communicator is unable to communicate with the DCM 2 it will display the message No Device Found If this occurs check to make
94. in the General Setup menu OverTorques Logs and displays the total number of times that excessive torque was detected at the output shaft Pk Torque Logs and displays the maximum torque sensed at the output shaft TotRunTm Logs and displays the total run time of the drive motor in seconds High temp Logs and displays the highest temperature in degrees Fahrenheit measured by a temperature sensor resident on the DCM 2 board Low temp Logs and displays the lowest temperature in degrees Fahrenheit measured by a temperature sensor resident on the DCM 2 board Manual Operation Menu Block SE This menu is used to allow manual drive operation with the HART communicator There are three manual operation procedures available 1 Op mode Block 4G This procedure allows the user to select the operating mode of the DCM 2 There are four possible choices Follow Hold Stay and Stop Follow mode is the normal state of operation and allows the DCM 2 to control the drive operation by responding to the analog input Demand signal when the drive Handswitch is in the automatic position The Hold mode causes positioning according to the HART Interface Demand Value The Stay mode causes the output shaft to remain stationary and maintain its present position Note that in Stay mode the Handwheel cannot be freely turned The Stop mode removes power from the motor N
95. ine that no binding occurs between linkage and crank arm or valve damper lever arm Surrounding objects must not interfere Do not change limit switch settings to obtain desired valve or damper travel This shortens the travel of the feedback device and reduces the control resolution repeatability accuracy of the drive and available torque For an input control signal change do not adjust the linkage Refer to the Calibration section of this manual Link Assist The Beck Link Assist computer program optimizes the linkage configuration for your load s torque characteristics to help you select the minimum drive size for your application Contact your Beck Sales Engineer to take advantage of Beck s Link Assist program Linkage Kits Available Standard Beck linkage kits are made to accommodate a wide variation in linkage lengths without requiring modification of end fittings This adaptability makes it possible to order the essential linkage end connections even though the exact linkage length may not be known until the valve damper and drive are mounted in place Each linkage kit includes the essential pipe linkage end connections rod end and all necessary hardware Schedule 40 pipe is not included and must be cut to length and threaded in the field see Table 1 below for instructions to calculate pipe length To simplify installation of the pipe link the kit accepts NPT right hand threads on both ends of th
96. inkage to deliver greater torque where needed so that drive size and resultant cost can be minimized Valves can be furnished by Beck as unitized assemblies with control drives mounted and tested in the factory Depending on the valve and application valves can be mounted directly or using a bracket and linkage Also drives may be installed in the field with mounting hardware furnished by Beck or the customer Drives for dampers are generally installed at the site on a mounting platform separate from the damper BECK LINKAGE KITS Beck hex and pipe linkage kits are available for completing the mechanical connection from the drive crank arm to the load Through the use of a standardized selection the linkage can be ordered even if the exact length is not determined until the drive and driven device are installed Beck foot mounted drives are furnished with a crank arm and rod end see pages 8 10 and 13 for dimensions All rod ends furnished by Beck incorporate bearings to accommodate some lateral misalignment Once the connection is made linkage kits can be adjusted x1 1 2 38 mm without removal of the crank arm or load lever making final mechanical calibration simple PRODUCT DESCRIPTION GENERAL SPECIFICATIONS ALL MODELS Drive Power 120 V ac single phase 50 or 60 Hz Allowable Tolerance 10 240 V ac single phase 50 or 60 Hz 15 Max Current and Power 120 V ac 240 V ac 11 159 169 11 209
97. ions available are clockwise CW or counterclockwise CCW When the drive direction parameter is changed the DCM 2 automatically reverses the analog position feedback signal such that itis 4 mA at the 096 input signal position and 20 mA at the 100 position No recalibration of the CPS is required This parameter is normally set to CW on an increasing Demand signal unless the user specified CCW prior to shipment of the drive 2 MaxTravel The maximum available travel distance of the output shaft in degrees This value is entered manually and must correspond to the actuator design 3 Travel The number of degrees of output shaft travel for 10096 span Edit this value to use a span shorter than the allowable MaxTravel 4 StepSize The typical change in Demand signal that can occur before the output shaft will reposition expressed in percent of span 5 Stall time The DCM 2 provides stall protection to the entire drive by shutting off power to the motor and providing a HART alarm This entry configures the stall time required to trigger the stall protection At the factory stall time is normally set to 300 seconds but can be edited and set for any value between 30 and 300 seconds This value should be longer than the timing for full drive travel 6 StallProt This entry is setas either Enabled or Disabled lt is used to remove motor power if Stall time is reached 7 LimitSwitch This entry is set as eithe
98. l 5 Trq Const Op Mode Follow Hold RunCW RunCCW Stay Status LED Status Operating Status Switch Status Line Freq CW Inhibitors CCW Inhibitors NOONAN Tests 1 FB Out Test 2 Board Self Test 3 Identify Device 4 Board Reset CW Torque 1 Segment 1 2 Segment 2 Segment 10 CCW Torque 1 Segment 1 2 Segment 2 Segment 10 Alarm Setup 1 AlarmPol 2 Alarm Mask RealTimeClock 1 RTC Day 2 RTC Month 3 RTC Year 4 Hour 24 5 Minute 2 816 1 000 v 4 000 v 1 000 v 5 000 v 454 CW Incr 4 00 mA 20 00 mA Linear Stay 50 00 3 20 mA 22 00 mA 4 00 mA 20 00 mA Enabled Linear Enabled Enabled 150 163 TK 279 TK Local Cntrl Status 0 12 5 6 62 Drops Out Dem Curve Spcl 1 DemNode1X 2 DemNode1Y 3 DemNode2X 4 DemNode2Y 0 0 5 5 DemNode21X DemNode21Y 100 100 LED Status Status Reverse Forward Demand Position Trq Thrust Stall Temperature FB Open Limit Acknowledge OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF Operating Status Dem lt gt Limits Pos lt gt Limits Temp lt gt LimitsOFF Torq lt gt Limits Over Torq StopOFF Stalled Feedback Open Switch Block OFF OFF OFF OFF OFF OFF Switch Status LV Lim CCW LV Lim CW OvrRd CCW OvrRd CW OvrRd Stop HndSw CCW HndSw CW Hn
99. l prevent the drive from repositioning during this procedure 3 Apply the desired 096 Demand input signal to the drive Following the example above the minimum signal for the first drive would be 4 mA The second drive s minimum signal would be 12 mA If the drive has not been wired the Demand input signal is connected at terminals AA and BB as shown in the diagram on page 17 4 Press and hold the CALIBRATE pushbutton on the DCM 2 customer interface panel then press the SET DEM 0 pushbutton until the ACKNOWLEDGE LED is lit 5 Apply the desired 100 Demand input signal to the drive Following the example above the maximum signal for the first drive would be 12 mA The second drive s maximum signal would be 20 mA 6 Press and hold the CALIBRATE pushbutton on the DCM 2 customer interface panel then press the SET DEM 100 pushbutton until the ACKNOWLEDGE LED is lit 7 Repeat this process for the remaining drives to be split ranged 8 Run the drive through its full operating range to ensure proper response to the Demand input signal 9 Replace the DCM 2 cover Tighten the cover bolts to 10 Ib ft 14 Nem torque If the ACKNOWLEDGE LED does not light but the DEMAND LED does light the signal is out of acceptable range and was not accepted by the DCM 2 This is typically caused by trying to set 0 and 100 values too close together i e less than 4 mA
100. n It is sometimes desirable or necessary to have more than one final control element controlling a single process Often this type of control strategy requires that two to four Beck drives each respond to different portions of one 4 20 mA Demand signal from the control system This type of operation is called split range operation For example consider the most common split range scenario two drives split ranged for 5096 of the 4 20 mA Demand signal input Both drives are wired in parallel to receive the same 4 20 mA signal note that the 250 Ohm R11 resistor see DCM 2 illustration on page 78 must be removed from one of the two drive DCM 2 boards to allow HART communications If more than two drives are split ranged the R11 resistor must be removed from all the DCM 2 boards but one but each drive s interpretation of the signal must be different One drive must interpret 4 12 mA as 0 100 Demand one drive must interpret 12 20 mA as 0 100 Demand This requires that the drives have different Demand signal calibrations To set up a split range operation follow the steps listed below see page 24 for location of pushbutton controls NOTE Ensure that the L O S Loss of Demand input signal settings of the drives are appropriate for the configuration See page 21 for information on changing L O S settings 1 Remove the DCM 2 cover 1 2 bolt heads 2 Ensure the Handswitch is in the STOP position This wil
101. nction key which is defined as the ENTER key at the bottom of the display Pushing this key enters the value and reverts the display back to the Demand Setup main menu STEP 6 At the bottom of the Demand Setup menu the F2 function key should now be defined as the SEND key Push this key to execute the change 47 48 DCM 2 HART INTERFACE Configuration and Setup WARNING Carefully follow the on screen warnings and messages when proceeding because changing this parameter online could cause the drive to reposition This can adversely affect the process and cause potentially dangerous conditions Changing LOS Trip Point STEP 1 From the HART communicator Online menu move to the Demand Setup menu and select the DemLimLwr parameter This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figure 1 page 34 to navigate STEP 2 With the DemLimLwr parameter selected press the right arrow key to display the modifiable entry block Using the alphanumeric keypad enter the desired Demand signal lower limit value in mA outside of the Demand signal range STEP 3 With desired value correctly typed into the entry box push the F4 function key which is defined as the ENTER key at the bottom of the display Pushing this key enters the value and reverts the display back to the Demand
102. ndensation has formed in the control compartments Damage due to moisture while in storage is not covered by warranty UNPACKING Beck drives are packed in standardized cardboard shipping containers Drives mounted on valves are strapped to a skid and crated After unpacking the wooden platform may be used to transport the drive to the installation site 15 16 INSTALLATION INSTALLATION MECHANICAL Beck Group 11 drives may be installed in any convenient orientation because the gearing does not require an oil bath Refer to the outline dimension drawings on pages 8 14 for physical dimensions and required clearances Installing a Drive with Linkage When installing a Beck drive in a location remote from the damper or valve be sure it is firmly bolted to a flat mounting surface that will not yield to the stresses created from operating the device A rigid vibration free surface will generally prolong the life of the drive s components The output shaft of the drive should be parallel to the damper or valve shaft and the linkage should be in a plane perpendicular to that of the two shafts Small misalignments can be tolerated if a rod end fitting is used on the driven lever similar to that on the Beck crank arm The drive s crank arm can be positioned at any angle on the shaft Beck drives can be furnished with valves mounted as unitized assemblies ready for pipeline installation Beck linkage kits are available for
103. nduit connections are provided for power and signal wiring to the drive The 1 2 conduit is provided for signal wiring connections and the 1 conduit is provided for power and auxiliary switch connections A sealant must be used on threaded conduit connections to keep moisture out Conduits should be routed from below the drive so that condensation and other contaminants entering the conduit cannot enter the drive Power and signal wires must be routed to the drive separately and be either shielded cables or installed in conductive conduit and or cable trays A large clearly labeled terminal block on the top of the drive is enclosed in a separate gasketed metal enclosure Terminals will accommodate up to 12 AWG 3 31 mm wiring See page 4 for location of the terminal block CAUTION Always close covers immediately after installation or service to prevent moisture or other foreign matter from entering the drive Refer to the wiring diagram furnished with your Beck drive for proper AC power and signal connections Itis advisable to provide normal short circuit protection on the AC power line A copy of the wiring diagram is shipped with each drive and is fastened to the inside of the terminal block cover If there is no wiring diagram available you may obtain a copy from Beck by providing the serial number of your drive Your Beck drive has been supplied to match the signal source in your control loop If it does not match a 25
104. ng limits of the field device message mentioned previously It serves to further define the condition and indicates that the drive s internal temperature is outside the 40 to 195 F 40 to 919 range Demand Signal is out of limit The Demand Signal has exceeded its measurable limits and has entered saturation The value reported for Demand does not reflect the actual value Loop Current Detected while under This is a Beck specific alarm message that alerts the user HART FF Control that analog current is present on the Demand terminals while operating the drive using the HART configurator Manual Operation menu lt is used to avoid confusion when a board is left in one of the manual operation modes and is not properly restored to FOLLOW mode Loop Current Detected while set for LOS PAT mode Proportional mode is a special Demand mode where PAT discrete logic inputs are used in place of the Analog Demand signal When operating in PAT mode no Demand current should be present If current is detected this alarm will be asserted Position Signal Messages The position signal is defined as the signal from the position sensor CPS to the DCM 2 Message Description Process applied to the primary variable This is a standard HART defined message that appears is outside the operating limits of the field whenever the HART primary variable Position signal is outside device the design or calibrated range The DCM 2 is
105. nimum radius portion of the cam when setting the switches Position the switch assembly so that the switch is just actuated DO NOT overstress the switch lever Tighten both screws to 10 Ib in 14 Nem torque and remove the shim When properly adjusted the switch lever should remain in contact with the cam throughout the control drive travel Adding Switches It is usually possible to add switches to a control drive in the field Remove the control end cover 1 2 bolt heads If the drive has no auxiliary switches it is possible to add up to four switches See Table 4 page 79 for switch assembly part numbers Install wiring onto the switch push on lugs and route the wires into the control drive terminal area Remove the terminal cover and solder wires to the underside of the terminal assembly according to the wiring diagram included with the new switch assembly Install the new switch assembly and adjust according to the preceding instructions SELF LOCKING MECHANISM SLM In normal service the SLM friction surface should not require replacement however a combination of excessive modulation and load can cause wear to the SLM mechanism f the SLM has been damaged rebuild kits are available see Table below SLM Rebuild Kits typically consist of friction material spring spring pin thrust washer pinion steel balls locking disc steel shims control motor gasket terminal joints slip on terminal and instruction sheet
106. ns 83 20 20 20 Installation Electrical 16 Installation Mechanical 16 Linkage 18 EinksASSISEIM a 18 Loss of Demand input signal 21 Maintenance 74 Motors capacitors and resistors table 79 Outline dimension drawings 8 14 Product 2 222 2 87 Product description 4 Repairs how to obtain service 87 Safety 2 15 SG VICO 87 SIE 87 Im 20 76 Spare parts recommended 79 Specifications general 6 Specification 87 Stall protection and annunciation 21 Start up 19 Stop Limit indication 21 Storage information 15 Rcs 20 Table of contents 3
107. nu Select the General Setup submenu Select the Travel parameter Reduce the stroke by entering a percentage of full travel not less than 6096 of the maximum travel of the drive 55 56 DCM 2 HART INTERFACE caiibration Feedback FEEDBACK SIGNAL CALIBRATION DCM 2 boards have the capability of providing a 4 20 mA output signal so that the drive s true output shaft travel can be monitored remotely The signal comes calibrated from the factory to provide a precise 4 20 mA signal corresponding to 0 100 drive travel Normally calibration is not required even if the position reference calibration or direction of travel are changed because the DCM 2 automatically compensates for these changes and appropriately scales the position feedback signal If the Feedback must be changed it is accomplished by using a Hart communication device First navigate to the Configuration menu Next select the Feedback Setup submenu Through this submenu the Feedback range may be changed as well as the curve Online help is available through the communication device DCM 2 HART INTERFACE Calibration Demand DEMAND SIGNAL CALIBRATION DCM 2 boards are designed to accept a 4 20 mA or 1 5 V dc analog Demand signal Narrower spans within this range can also be accommodated for split range operation see explanation following The input comes calibrated from the factory for the full range unless otherwise specified lt is not nece
108. oad Number 60 Hz Number Torque 14 9733 01 80 Ib ft 108 N m 23 kgs 49 14 9733 02 60 Ib ft 81 N m 14 766 56 Ibs 14 9733 03 40 Ib ft 54 N m 25 kgs kgs 14 9733 04 20 Ib ft 27 N m 14 9733 03 80 Ib ft 108 N m 20 2701 20 32 14 9733 04 40 Ib ft 54 N m 14 9733 05 15 Ib ft 20 N m 11 209 12018 14 9730 04 125 Ib ft 169 N m 54 kgs 20 2704 21 35 14 9730 05 175 lb ft 237 N m 14 9730 08 250 lb ft 339 N m 7 125 lbs 20 2704 21 35 14 9730 09 300 Ib ft 407 N m 99 mes 3 40 36 57 kgs 14 9730 04 300 lb ft 407 4 500 Ibs 2 115 Ibs 041 k st 14 9730 05 400 Ib ft 542 60 54 11 369 95 20 2705 21 56 52 kgs 14 9730 08 550 lb ft 746 68 14 9730 09 650 lb ft 881 N m 90 14409 27018 14 9732 02 800 lb ft 1 085 N m 54 122 kgs 14 9732 03 1 500 Ib ft 2 034 N m 90 waco 216 20 2201 21 31 14 9732 04 1 000 Ib ft 1 356 N m 68 98 kgs 14 9732 05 350 lb ft 475 N m 22 9 000 Ibs 4 14 9732 07 550 lb ft 746 N m 36 082 kgs 14 9732 02 1 800 lb ft 2 440 N m 54 20 2201 22 32 i 14 9732 05 650 Ib ft 881 N m 22 14 9732 07 1 000 Ib ft 1 356 N m 36 14 9732 07 1 000 Ib ft 1 356 N m 22 CAUTION Use only the motor and gear housing combinations listed above other combinations may cause internal damage to the drive and or damage to external equipment lise 1 5 68 11 269 361 52 kgs 14 9730 02 125 Ib
109. on of travel Trims the Feedback signal at 4 mA If the Feedback signal is not within 1 mA of 4 mA an error will be returned Note Feeback sourcing circuit is factory calibrated and normally does not require recalibration Trims the Feedback signal at 20 mA If the Feedback signal is not within 1 mA of 20 mA an error will be returned Note Feeback sourcing circuit is factory calibrated and normally does not require recalibration Torque Sensing Commands Command Description Assigns the count value to be associated with 0 torque This number is unique to each drive Argument n and Information n the desired length of travel in degrees n the desired Feedback signal for 096 drive position in mA The minimum value is 3 mA 3 00 and the maximum value is at least 4 mA less than the Feedback signal value for the 100 drive position n the desired Feeback signal for 100 drive position in mA The minimum value must be at least 4 mA greater than the Feedback signal value for the 0 drive position The maximum value is 21mA 21 00 n 0 no feedback or 1 feedback n the present drive position as a degree of full drive travel to establish where the 0 point of travel should be n the present Feedback signal from the drive as measured in mA at terminals 16 amp 17 The minimum value is 3 mA 3 000 and the maximum value is 5 mA 5 000 n the present Feedback si
110. oportional to the square root of the Demand Signal The Dem Curve Special relationship allows a customized Demand curve to be setup through a special submenu The Square relationship produces a non linear drive response proportional to the square of the Demand signal For example a 25 input Demand is interpreted as 0 25 or 0 0625 6 25 The square relationship helps to linearize flow response of final control elements that have quick opening characteristics Changing Characterization STEP 1 From the HART communicator Online menu move to the Demand Setup menu and select the Dem Curve parameter This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figure 1 page 34 to navigate STEP 2 With the Dem Curve parameter selected press the right arrow key to display the four entry choices Linear Square Root Dem Curve Special or Square Use the up and down arrow keys to select the desired parameter STEP 3 With desired choice selected push the F4 function key which is defined as the ENTER key at the bottom of the display Pushing this key enters the selected parameter and reverts the display back to the Demand Setup main menu If Dem Curve Special is selected proceed to the Dem Curve Special sub menu to setup the desired curve STEP 4 Atthe bottom of the Demand Setup menu
111. ote that in Stop mode the Handwheel can be freely turned All operating modes can be overridden by the drive Handswitch 2 Demand This procedure sets the effective Demand signal If Op mode is set to Hold entering a valid value 5 to 105 will control the motor If Op mode is set to Follow the value will follow the Demand analog signal unless an alarm condition exists 3 Reset Stall This procedure resets normal drive operation after a stall condition has caused the drive to shut down Selecting this option and following the prompts will restore operation Note that stall conditions can also be reset by simply reversing the input Demand signal or cycling the drive ac power Diagnostics Menu Block This menu provides access to all the DCM 2 stored online diagnostic information about drive operation The menu provides six submenus accessing drive statistics and online drive status Status Submenu Block 4H This menu provides access to six submenus displaying various drive status settings LED Status Operating Status Switch Status Local Cntrl Status CW Inhibitors and CCW Inhibitors LED Status Submenu Block 5B This menu displays the ON or OFF status of each of the LEDs on the DCM 2 See below ON indicates that an operating condition is inappropriate see Operating Status menu Reverse ON indicates that the Demand signal is less than the Position signal Forward ON indicates that th
112. pped with over travel limit switches factory set for either 101 11 159 209 309 409 or 91 11 169 269 369 469 of travel unless otherwise specified at time of order Limit switches must be set inside the range of the built in non adjustable mechanical stops to prevent stalling of the motor Limit switches can be reset to limit travel of the output shaft to any angle down to a minimum of 60 Auxiliary switches are set as shown in the figure at left unless otherwise specified at time of order NOTE The over travel limit switches are the switches closest to the drive body To adjust the over travel limit switches it is necessary to remove the control end cover Switches are operated by cams which are clamped onto the control shaft Setting a switch involves loosening the cam moving the output shaft to the desired position and positioning the cam so that it just operates the switch at that point In the following procedure the use of a continuity meter is recommended to determine when the switch opens or closes If such a meter is not available it is possible to hear the switch click as the contacts open and close CAUTION Do not attach the meter or attempt to move the switch cams until the drive is disconnected from the line voltage and auxiliary switches are disconnected from external power sources Setting Over travel Limit Switches CW and CCW This procedure should be used if the factory over trav
113. pplied to the non primary This is a standard HART defined message that appears whenever variable is outside the operating limits of one of the three HART non primary variables Demand signal the field device Torque Temperature are outside their design or calibrated ranges The Demand input signal to the drive is typically the problem Source however the message can also appear if either the torque measurement optional or temperature measurement is outside the design or calibrated ranges The Beck specific messages below provide more descriptive information The Demand Signal is outside of the This is a Beck specific message that can appear after the HART intended limits see Demand Setup defined message above It specifically pinpoints the Demand input menu signal to the DCM 2 as the problem source and indicates that the signal is outside the calibrated range limits The lower limit is configurable as a percentage of the calibrated range default is 5 The upper range is the highest readable input voltage 5 5 VDC expressed as a percentage of the calibrated range e g approximately 112 for a 4 20 mA or 1 5 V dc standard input range Demand out of accurate measurement This is a Beck specific message that can appear after the Demand range signal out of range message above It further defines the demand signal problem by indicating that the signal is not only out of the calibrated range but also out of the desi
114. r Accept or Alert and is used to define whether contacting a limit switch outside of the normal travel range 096 to 10096 will cause an error condition 8 PositionUnit Sets the numeric unit of measure for the output shaft position in degrees deg 9 Temperature Unit The unit of measure for temperature May be set for Fahrenheit degF or Celsius degC PositionSensrSetup Submenu Block 4C This menu is where all position sensor and external position feedback signal setup is performed The eight parameter entries are as follows 1 Set Pos 0 Selecting this parameter sets the present position of the drive to the minimum travel position Equivalent to pushing the SET POS 100 pushbutton 2 Set Pos 100 Selecting this item sets the present position of the drive to the maximum travel position Equivalent to pushing the SET POS 100 pushbutton 3 PresCPS V Displays the present value of the internal Position Sensor voltage which may also be measured at TP4 and TP1 on the DCM 2 board May be edited in the Calibration Trim menu for trimming the Position Sensor A D converter 4 CPS 7 Displays the CPS voltage at the zero percent output shaft position May be edited to define the CPS voltage at the lowest operating point of travel 5 CPS Span Displays the CPS voltage span for the maximum allowable output shaft travel 6 CPS RngLwr Displays the CPS voltage at the lowest available point o
115. rable to reset the over travel limit switches see page 26 If the limit switches are not reset Handswitch operation of the drive CW CCW will still result in the original full range of travel It is best to calibrate the drive and then set the limit switches when short stroking the drive The switches should be set just outside the calibrated range to avoid tripping the switch at the 0 and 100 positions The auxiliary switches are also cam operated but have no affect on drive and DCM 2 operation Therefore the auxiliary switches can be adjusted at any time without affecting performance or calibration Models 11 169 269 369 amp 469 Standard Group 11 drives are equipped with fixed non adjustable built in mechanical stops All output shaft rotation must occur within these stops which are approximately 108 apart except for the 11 169 stops which are 98 apart The over travel limit switches are used to limit the electrical control range of the drive These switches are cam operated and are set slightly wider apart then the drive s intended full range of electronic operation typically 90 The limit switches are positioned to provide an electrical overtravel protection typically 91 If the drive is short stroked i e the full travel rotation from 0 100 is reduced to less than the standard 90 rotation see page 30 it may be desirable to reset the over travel limit switches see page 26 If the limit
116. re 1 page 34 to navigate STEP 2 With the Feedback parameter selected press the right arrow key to display the two entry choices Enabled or Disabled Use the up and down arrow keys to select the desired parameter Enabled enables the output signal while Disabled disables the output STEP 3 With desired choice selected push the F4 function key which is defined as the ENTER key at the bottom of the display Pushing this key enters the selected parameter and reverts the display back to the Setup Checklist main menu STEP 4 At the bottom of the Setup Checklist menu the F2 function key should now be defined as the SEND key Push this key to execute the change This change should not effect drive positioning but as with all configuration changes carefully follow the on screen warnings and messages when proceeding DEMAND SIGNAL CHARACTERIZATION The Beck DCM 2 is designed to receive a 4 20 mA 1 5 V input Demand signal respond by repositioning the drive output shaft in proportion to the signal There are four ways in which the DCM 2 can interpret the Demand signal Linear Square Root Dem Curve Special and Square The Linear interpretation which is most commonly employed simply causes the drive to position the output shaft in a one to one relationship with the Demand For example 1 change in Demand always causes 1 position response The Square Root relationship produces a response pr
117. ready in process Not implemented Displayed when an entered command is defined but cannot be implemented 73 74 MAINTENANCE ROUTINE Beck drives require only a minimum of routine maintenance 4A visual inspection is in order to verify that the connection to the final control element is intact and operating normally If vibration is present check the electrical terminal connections and other hardware for tightness LUBRICATION Periodic lubrication is not required on Beck control drives However it is recommended that during major shutdowns or outages the drives in the most severe applications be inspected to determine the need to relubricate the drive gear train If your drive has a linkage to extend the life of the linkage rod ends they should be included in your scheduled lubrication program CAUTION If your drive has a linkage before removing the gear module assembly block the control drive crank arm to prevent the crank arm and the gear train from moving when the change module is removed To inspect the gears remove the gear module assembly on the 11 209 269 309 369 and 409 469 On Model 11 159 169 the motor must be removed to access the gears Clean the gears thoroughly removing all old lubrication 11 409 Gear Module Examine the gear teeth shaft bore and gear shafts for signs of excessive wear scoring or other damage If evidence of this damage is present the drive should be re
118. red and normally does not require recalibration Calibrates the Demand signal at 20 mA This command should only be used when the Demand signal at the drive is 20 mA If the Demand signal at the drive is greater or less than 20 mA an error will be returned Note This parameter is factory configured and normally does not require recalibration Sets and or displays the Demand signal input characterization function The DCM 2 provides linear square root special curve or square function characterization Sets and or displays the Demand signal threshold below which the DCM 2 recognizes that the signal is lost The threshold is entered as a value in mA This command also sets and or displays the action initiated by the drive during LOS Loss Of Signal LOS action options are sip stay in place or gtp go to position Note that the command always reports both settings but only sets one argument at a time The command must be used twice to set the threshold and action If the action is gtp then the command demlosgtp see below must also be set The option pat is also available to prevent error messages if the DCM 2 is not being used with a Demand signal Sets and or displays the position to which the drive will run upon loss of the Demand signal LOS This command has no effect if the drive is set to sip stay in place Argument n and Information n the Demand signal as a decimal in miliamps The minimum acc
119. rings should be replaced To remove scrape all of the old adhesive and gasket material from the body housing and cover Cement the new gasket to the drive body using a gasket cement such as 3M 847 Rubber and Gasket Adhesive or equivalent SEALS Worn or damaged output shaft control end shaft and motor shaft seals should be replaced to prevent damage to internal bearings and drive train parts To remove the shaft seal push the blade of a small screwdriver along the shaft and under the seal lip CAUTION The seal is approximately 1 4 6 mm wide Do not force the screwdriver blade beyond the width of the seal damage to the shaft bearing could result Pry up on the seal and force it out of the housing Clean the shaft and housing then press in the replacement seal with the closed side facing outward BEARINGS The Beck control drive contains ball bearings on the output shaft control end shaft and motor shaft Bushings and thrust washers are used on combination gears Field replacement of these components is not recommended Motor shaft bushings in the body of the 11 159 169 and 11 409 469 can be replaced TIP To remove fill the bushing with a heavy grease Select a drive pin that slip fits into the bushing Insert the pin into the bushing and tap with a mallet This will force the bushing out of the body casting MOTOR The control motor is not field repairable Disassembly of the motor will result in a loss of to
120. rm clamping bolts 7 Position the drive s output shaft to correspond with the driven shaft s fully closed position 8 Set the crank pin on the Beck crank arm to the predetermined radius 9 Swing the crank arm into position to assemble the rod end to the crank arm crank pin 10 Tighten the crank arm clamp bolts to the torque recommended on pages 8 10 and 13 11 Tighten the coupling and rod end jam nuts 12 Lubricate rod end bearings 13 Carefully move the drive s output shaft to correspond with the driven shaft s fully open position Check that no binding occurs between the linkage crank arm driven shaft lever and surrounding obstructions Also observe that the driven shaft rotates the proper amount Ensure that the drive reaches the proper limit and shuts off If binding in the linkage occurs due to too much travel of the driven lever reduce the crank arm radius on the Beck drive rather than adjusting the connecting link length Return to step 5 and repeat adjustments To adjust the linkage length alter the thread engagement in the couplings The couplings have right and left hand threads so itis not necessary to disconnect the ends to make a length adjustment The stud threads must be engaged 1 2 diameters deep into the rod ends Make adjustments by altering thread engagement in couplings only Be careful not to expose more than 7 178 mm of stud between rod end and coupling Once again check operation to determ
121. rol drive is designed for long term durability Gear modules and motors can be interchanged in the field to alter the torque and timing as needed if the application requirements change Mechanical stops in the gear train prevent overtravel An easy to turn spoke free Handwheel is incorporated into the design to allow manual operation during installation or power outages The Handwheel can be used to move dampers and valves to any position smoothly and easily under full load conditions Dampers and valves may also be operated at their individual locations with built in electric Handswitches The heavy duty crank arm if applicable of these control drives can be field adjusted to travel anywhere in the 360 range The forged rod end fitting may be field adjusted to any point in the cast DicitaL MobpuLE DCM 2 OVER TRAVEL AND AUXILIARY SWITCHES DS m ES SENSING DEVICE slot of the crank arm Special linkage arrangements allow total application versatility for connection directly on or remote from the driven load Beck s Digital Control Module DCM 2 provides precise drive control in response to a modulating Demand input signal It also provides intelligent calibration easy drive setup changes and diagnostic information A local interface provides quick pushbutton setup and diagnostics without the need for a handheld or remote device A HART communica
122. rque that can only be restored by returning the motor to the factory for re magnetizing CAUTION If your drive has a linkage before removing the control motor block the control drive crank arm to prevent the crank arm and the gear train from moving when the motor is removed To remove the motor first disconnect the motor wires in the terminal compartment of the control drive In the 11 159 169 drives the Handswitch must first be removed from the body before removing the terminal block and plate as an assembly Follow the instructions in the paragraphs below In the 11 209 269 309 369 and 409 469 drives remove the terminal block and plate as an assembly Remove the black wire from the terminal post cut the red motor wire near the red yellow red butt joint and disconnect the green wire from the motor capacitor Remove the mounting bolts and motor Carefully slide the motor out of the drive body To install the motor insert the three wire sleeve through the wire hole in the motor mount and into the terminal compartment Carefully slide the motor into the drive body Rotate the motor shaft if necessary to engage the pinion with the first combination gear Install motor mounting bolts and torque to recommended values See pages 8 14 for torque values Reconnect the motor wires See the following section for reinstalling the terminal plate Motor Resistor and Capacitor The motor resistor and capacitor are located
123. rrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figure 1 page 34 to navigate STEP 2 With the Trg Thrust parameter selected press the right arrow key to display the two entry choices Enabled or Disabled Use the up and down arrow keys to select the desired parameter Enabling this parameter will activate the torque measurement features and displays while disabling the parameter will turn them off STEP 3 With the desired choice selected push the F4 function key which is defined as the ENTER key at the bottom of the display Pushing this key enters the selected parameter and reverts the display back to the Torque setup main menu Carefully follow the on screen warnings and messages to return to normal operation Enabling Over torque Protection STEP 1 From the HART communicator Online menu move to the Torque Setup menu make sure that the Trq Thrust parameter is enabled if not enable it using the prior procedure and select the Ovt Prot parameter This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figure 1 page 34 to navigate STEP 2 With the Ovt Prot parameter selected press the right arrow key to display the two entry choices Enabled or Disabled Use the
124. s STALL n o TEMP F OPEN E 2 STOP LIMIT ACKNOWLEDGE DCM 2 LOCAL INTERFACE Calibration Beck drives are shipped completely calibrated to the customer s specifications that were written into the equipment order and are ready to be installed If the need arises to change the drive calibration first confirm that the drive is installed as specified and operating properly before proceeding with the change Position reference and demand calibration are performed using the DCM 2 customer interface panel but may also be configured using the HART or Serial interface Calibration of over travel limit and auxiliary switches must be performed using the procedure beginning on page 26 CALIBRATION PRIORITY Models 11 159 209 309 amp 409 Standard Group 11 drives are equipped with fixed non adjustable built in mechanical stops All output shaft rotation must occur within these stops which are approximately 108 apart The over travel limit switches are used to limit the electrical control range of the drive These Switches are cam operated and are set slightly wider apart then the drive s intended full range of electronic operation typically 100 The limit Switches are positioned to provide an electrical overtravel protection typically 101 If the drive is short stroked i e the full travel rotation from 0 100 is reduced to less than the standard 100 rotation see page 30 it may be desi
125. s damages costs or liabilities including but not limited to attorney s fees and other legal expenses whether on account of negligence or otherwise except those claims based solely upon the negligence of Beck and those claims asserted by Beck s employees which arise out of or result from the operation or use of the equipment by Beck s employees Note Internal water damage is not covered by warranty Copyright 2006 by Harold Beck amp Sons Inc Beck Control Drives are covered by the following patents 3 667 578 4 690 168 6 563 412 B2 6 639 375 B2 and 6 769 527 B1 with other patents pending 87 Serving the Process Industries since 1936 BECK HAROLD BECK amp SONS INC 11 TERRY DRIVE NEWTOWN PENNSYLVANIA 18940 USA PHONE 215 968 4600 FAX 215 860 6383 www haroldbeck com 12 06
126. s the output shaft in position HANDWHEEL Every Beck control drive is furnished with a Handwheel to permit manual operation of the valve or damper without electrical power Its solid construction design includes no spokes or projections and turns at a safe slow speed Handwheel is located at the rear of the control motor housing The Handwheel is coupled directly to the motor shaft and rotates when the motor runs Manual operation of the Handwheel with electric Handswitch in STOP position turns the motor and the rest of the drive train without incorporating a clutch HANDSWITCH A local electric Handswitch is provided on Beck drives to permit operation at the valve or damper independent of the controller As a safety feature the Handswitch is designed so that the controller can operate the drive only when itis in the AUTO position The sequence of the Handswitch is AUTO STOP CW STOP CCW When the Handswitch is turned fully clockwise AUTO should be indicated In the AUTO position two contacts are closed and the DCM 2 completes the control circuit In the CW or CCW positions contacts are closed to operate the drive independently of the controller In the STOP position all contacts remain open To prevent Handswitch initiated motion remove the jumper between terminals A and C CAUTION AC power to the drive must be turned off before removing
127. sitionSensrSetup submenu is used to set the DCM 2 to accept the CPS position signal and interpret the appropriate 0 100 range Beck drives are shipped completely set and calibrated to the customer specifications and are ready for installation Normally no adjustments are necessary If however the position calibration needs to be changed the PositionSensrSetup submenu must be used The PositionSensrSetup is accessible through the Configuration menu The PositionSensrSetup submenu will allow resetting of the minimum travel position of the drive Set Pos 0 and the CPS voltage at the minimum travel position CPS Zero Online help is available through the communication device Short stroke Operation Reducing Full Travel Typically it is best to use the 100 travel of the drive in response to the 0 100 Demand input signal In certain applications as a last resort it may become necessary to reduce the full travel of the drive In these applications the DCM 2 can be calibrated to accommodate reduced stroke The recommended minimum full travel is 60 although itis advisable to make the range as close to 10096 as possible for the highest position resolution attainable with the CPS and to avoid possible reduction in torque Reducing the full travel is referred to as short stroking the drive This can be easily accomplished by using a HART communication device First navigate to the Configuration me
128. split range operation A square function is available to position the drive s output shaft proportionally to the square of the input signal This function is factory configurable specify at time of order or may be configured using the HART interface see page 46 or Serial interface see page 70 D Q Il Ed E HOgFec c id TTITT O 4 Lr x BECK nnnnnnnnmnnmnnm DCM 2 LOCAL INTERFAC
129. ssary to calibrate the Demand input when the drive is installed If the Demand must be changed it is accomplished using a HART comunication device First navigate to the Configuration menu Select the Demand Setup submenu Through this submenu the Demand range limits and curve specifications may be changed Online help is available through the communication device Split Range Operation It is sometimes desirable or necessary to have more than one final control element controlling a single process Often this type of control strategy requires that two to four Beck drives each respond to different portions of 4 20 mA Demand signal from the control system This type of operation is called split range operation For example consider the most common split range scenario two drives split ranged for 50 of the 4 20 mA Demand signal input Both drives are wired in parallel to receive the same 4 20 mA signal note that the total loop resistance should be 250 Ohms as specified by the HART communications protocol The 250 Ohm R11 resistor see DCM 2 illustration on page 78 must be removed from one of the two drive DCM 2 boards to allow HART communications If more than two drives are split ranged the R11 resistor must be removed from all the DCM 2 boards but one but each drive s interpretation of the signal must be different One drive must interpret 4 12 mA as 0 100 Demand and one drive must interpret 12 20 mA as 0 100
130. sure the leads are securely connected to the Demand wiring and retry If communications still do not occur the communicator polling setup may be improperly set Check the utility menu and make sure communications polling is set to always poll communicator keypad and display is shown on page 35 There are four sections 1 the liquid crystal message display 2 four function keys beneath the LCD display 3 six navigational keys in the center section 4 alphanumeric entry keys at the bottom For a complete description of the communicator please see the HART Communicator manual that is shipped with the communicator The alphanumeric keys are used to type in entries Whenever a selected menu or method requires a value or description to be entered this key pad is used Since each key represents four different characters three shift keys are provided at the bottom of the pad particular alphanumeric character is selected by pushing the shift key then pushing the alphanumeric key MENU DESCRIPTIONS See Figure 1 Page 34 Online Menu Block 1 When communications are established with the communicator the Online menu is displayed This is the gateway to all the other menus and it also provides current information about the drive Numbered items 2 through 7 provide live dynamic values of the drive s output position in percent the Demand signal to the drive in percent the Demand signal in milliamps the torque output of
131. switch to CW CCW per direction drive does not move Does Handwheel shudder about one position Does the voltage across terminals B U B V line voltage NO Replace Handswitch see p 77 YES Consult Factory Check linkage and driven element Is binding or an obstruction present Is the TEMP LED lit Restore ambient temperature to drive s rated range Clear obstruction Is the OPEN LED lit Is a feedback loop of 800 ohms or less connected to the terminal board Does voltage from CW CCW switch YES green red to term B line voltage Is green red wire connected to NC switch contact NO Replace limit switch see p 76 Connect wire properly LED lit in AUTO Is the STOP LIMIT Is the Handswitch NO Consult Factory Clear obstruction Place Handswitch in AUTO modulate control signal both ways Does drive respond correctly and is STALL LED out YES NO Yy Apply correct Replace Is the TEMP F s i ji db aie loop the in AUTO LED still lit resistance DCM YES Replace the DCM Cycle drive power off and on NO Replace the DCM YES Confirm _ proper operation of drive
132. switches are not reset Handswitch operation of the drive CW CCW will still result in the original full range oftravel Because the over travel limit switches define the maximum electrical drive range if they are to be reset they should be adjusted before performing DCM 2 demand and position calibration procedures The auxiliary switches are also cam operated but have no affect on drive and DCM 2 operation Therefore the auxiliary switches can be adjusted at any time without affecting performance or calibration 25 DCM 2 LOCAL INTERFACE Calibration Switches NOTE Your Beck drive was shipped from the factory ready for installation no electrical adjustments are required before placing it in operation Each drive is set up and calibrated to the specifications that were written into the equipment order Under normal operating conditions there is no need to recalibrate the control drive However if the application requirements change or are different than specified on the equipment order the drive should be recalibrated according to the following procedures OVER TRAVEL CCW LIMIT LIMIT SWITCHES CW LIMIT cw ccw 101 0 91 FOR 100 or 90 OF RANGE 2 AUXILIARY eZ pu SWITCHES 12 4 AUXILIARY 2 SWITCHES 12 CONTACTS CLOSED CONTACTS OPEN Standard Over travel Limit and Auxiliary Switch Settings 26 SWITCH ADJUSTMENTS Control drives are shi
133. the drive in which the DCM 2 board is installed It normally is set at the factory if the board is installed in a drive The user can edit the field if desired Drive S N This entry displays the serial number of the drive in which the DCM 2 board is installed It normally is set at the factory if the board is shipped in a drive If the DCM 2 is shipped as a spare or replacement part the Drive S N field will be blank The user can edit the field if desired Installed This is a date entry that is normally used to indicate the date that the drive or DCM 2 board was installed The date format is mm dd yyyy and it can be edited Setup This is a date entry that is normally used to indicate the date that the DCM 2 drive setup was performed Although this entry is viewed and can be edited in the Device Information menu the user is prompted at the end of performing a Setup to enter a date Entering the date at the prompt automatically updates the date displayed The date format is mm dd yyyy and it can be edited Calibrated This is a date entry that is normally used to indicate the date that the DCM 2 drive was last calibrated Although this entry is viewed and can be edited in the Device Information menu the user is prompted at the end of performing any Calibration method to enter a date Entering the date at the prompt automatically updates the date displayed here The date format is mm dd yyyy and it c
134. the jumper SWITCHES Two over travel limit switches and up to four optional auxiliary switches are provided on Beck drives Switch cams are clamped onto the control shaft which rotates in relation to the output shaft Cam position is field adjustable Switches are rated 6 A 120 V ac All auxiliary switch connections are made on the terminal block LOSS OF DEMAND INPUT SIGNAL L O S When the Demand input signal drops to approximately 5 the DCM 2 considers the Demand input signal to be invalid DCM 2s are typically configured to stop the drive during L O S conditions but may be configured by the factory or by using the HART or Serial interface to run the drive to a predetermined position Under the L O S condition the STAT and DEMAND LEDs will light When the input signal is corrected the drive will automatically resume normal operation The value for LOS activation is configurable using the HART see page 47 or Serial interface see page 70 Alarm indication is available at terminal E POSITION CONTACTLESS POSITION SENSOR CPS The CPS provides the DCM 2 with a continuous feedback signal proportional to the position of the drive s output shaft The position sensing function of the CPS is provided by a ferrite magnetic sensing element An electronic circuit translates the signal from the ferrite magnetic sensor into a position signal used by the DCM 2 to control the drive The typical output voltage of the C
135. the switch click as the contacts open and close CAUTION Do not attach the meter or attempt to move the switch cams until the drive is disconnected from the line voltage and auxiliary switches are disconnected from external power sources Setting Over travel Limit Switches CW and CCW This procedure should be used if the factory over travel limit switch settings must be changed in the field It is advisable to operate the drive fully in each direction using the electric Handswitch to check switch settings before attempting to change them Follow these instructions if they require adjustment 1 Remove the control end cover and terminal block cover 1 2 bolt heads 2 Usethe electric Handswitch to drive the control shaft so that the CW switch cam screw is accessible Using a 7 64 hex wrench loosen the screw so that the cam is just snug on the shaft see illustration below Move the output shaft clockwise to the desired CW limit Turn the Handswitch to the STOP position Disconnect power from the drive Turn the Handswitch to the AUTO position Connect the continuity meter across terminals B and M Rotate the cam until the meter shows no continuity switch contacts open switch clicks A 8 Tighten the cam locking screw to 5 16 56 N m torque 9 Disconnect meter and turn the Handswitch to the STOP position 10 Reconnect drive power 11 Rotate the dri
136. tion of the drive s output shaft corresponding to the 0 Demand input signal 3 Ensure the Handswitch is in the STOP position This will prevent the drive from repositioning during this procedure 4 Press and hold the CALIBRATE pushbutton on the DCM 2 customer interface panel then press the SET POS 0 pushbutton until the ACKNOWLEDGE LED is lit 5 Position the drive at the desired maximum position i e the desired physical position of the drive s output shaft corresponding to the 10096 Demand input signal 6 Ensure the Handswitch is in the STOP position This will prevent the drive from repositioning during this procedure 7 Press and hold the CALIBRATE pushbutton on the DCM 2 customer interface panel then press the SET POS 100 pushbutton until the ACKNOWLEDGE LED is lit 8 Optional Adjustthe over travel limit switches see page 26 just outside the 0 and 100 limits 9 Verify that the drive s 0 and 100 positions are correct If not repeat this procedure 10 Replace the compartment cover and tighten the cover bolts to 10 Ib ft 14 N m torque If the ACKNOWLEDGE LED does not light but the POSITION LED does light the signal is out of acceptable range and was not accepted by the DCM 2 Short stroke Operation Reducing Full Rotation Typically it is best to use the full 100 90 for quarter turn valve drives rotation of the drive in response
137. tions interface allows remote access of all features and information A serial interface also allows for drive configuration changes drive information reporting and to assist in troubleshooting Beck s CPS 2 Contactless Position Sensor provides accurate position measurement in demanding environmental conditions with no contacting or wiping surfaces to wear or intermittently lose contact The CPS 2 provides infinite resolution with linearity error of less than 1 of span over full control drive travel Beck electronic control drives are designed with individual weatherproof enclosures to protect the main components The cutaway illustration below is intended to provide the user with a basic orientation to the product WIRING TERMINAL BLOCK CRANK ARM LINKAGE re 2 GEAR TRAIN AND Motor Housines TYPICAL APPLICATIONS Beck control drives are ideally suited for use on ball plug and butterfly valves as well as dampers and fluid drives When equipped with a sheave and multi turn option consult your Beck Sales Engineer for details the drive can be used to raise and lower a weight balanced damper DCM 2 equipped Beck drives are designed for precise position control in modulating applications The drive is best utilized when its full travel is employed to achieve its greatest sensitivity and resolution although the driven device may operate through a considerably smaller range Beck drives can be configured with special l
138. ts include all nameplate data of the Beck drive with the order 81 82 APPENDIX COMPONENTS in 16 SS m iz inm p 4 15 13 14 ITEM NO 1 2 3 4 5 6 7 8 9 A ITEM DESCRIPTION NO DESCRIPTION Body rear Body front Output shaft assembly and main gear Spring washer Ball bearing output shaft Seal output shaft Gear 3rd combination Pin 3rd combination gear Thrust washer Gear module assembly see Table 9 page 88 for part number Control motor see Table 5 page 84 for part number TABLE 8 DRIVE COMPONENTS FOR MODEL 11 409 469 Handwheel Gasket control motor Gasket body Gasket gear module Gasket control end cover Control end cover Control end cover extension Terminal block amp barrier plate Gasket barrier plate DCM amp terminal compartment cover Gasket DCM amp terminal cover Barrier insulator terminal compartment Index 459 only Bracket 469 only Note To ensure exact replacement parts include all nameplate data of the Beck drive with the order 9 GEARS TORQUE AND TIMING OPTIONS Models Models Motor 159 amp 09 69 Drive Maximum Current 0 Gear Timing Timing Model Approx Overhung Motor Part 120 V ac Module sec 100 sec 90 Number Weight L
139. turned to the factory for a detailed examination of the main gear which requires complete disassembly of the drive See HOW TO OBTAIN SERVICE on page 87 If there is no evidence of damage to the gearing recoat the teeth and shaft bores of all gears with a heavy layer of Fiske Lubriplate GR 132 or equivalent GR 132 is an E P grease with polymer additives The ball bearing on the output shaft and crown gear shaft have added double grease seals and require no maintenance for the life of the bearings Inspect all grease seals and replace any that show wear Reassemble the drive referencing pages 8 14 for appropriate bolt torques MAINTENANCE COMPONENT REPLACEMENT This section covers replacement of many components of the drive Note that some components are not field repairable Refer to the drive outline dimension drawings on pages 8 14 and to the cutaway illustration on page 4 for location of components on the drive If it should ever be necessary to replace the output gear shaft or output shaft bearings a major overhaul is required and the drive should be returned to the factory During a major overhaul the factory repair department will update the drive to include all possible engineering improvements See HOW TO OBTAIN SERVICE on page 87 GASKETS During routine service inspect the cover motor and change gear plate gaskets for wear or damage In order to protect internal components worn or damaged gaskets and O
140. under the terminals in the terminal compartment To replace a resistor or capacitor remove the terminal cover In the 11 159 169 drives the Handswitch must first be removed from the body before removing the terminal block and plate as an assembly Follow the instructions in the following paragraph In the 11 209 269 309 369 and 409 469 remove the terminal plate Remove the existing part and transfer the wires one at a time to the replacement part Inspect the terminal plate gasket and replace if necessary To ensure a watertight seal between the plate and gasket coat the gasket with a thin film of grease before replacing the terminal plate Torque the screws to 3 Ib ft 4 Nem 15 76 MAINTENANCE COMPONENT REPLACEMENT OVER TRAVEL LIMIT AND AUXILIARY SWITCHES Complete switch assemblies may be replaced It is not possible to replace individual switches To replace switch assemblies remove the control end cover 1 2 bolt heads and extensions if applicable Remove the screws holding the switch assembly to the plate and slide it out to the side Transfer the wires one at a time to the replacement assembly using the push on lugs provided Install the replacement assembly and note that it rotates around one screw to permit an adjustment of the cam to switch lever spacing and switch operating point To set the switch place a 030 75 mm shim between the cam and switch lever The switch lever should be on the low or mi
141. uration Changing Drive Shaft Travel STEP 1 From the HART communicator Online menu move to the General Setup menu and select the Drive Dir parameter This is accomplished by using the up and down arrow keys to select the appropriate item in each menu and then moving forward by pressing the right arrow key Follow the Menu Tree Figure 1 page 34 to navigate STEP 2 With the Drive Dir parameter selected press the right arrow key to display the two entry choices CW incr and CCW incr Use the up and down arrow keys to select the desired parameter STEP 3 With desired parameter selected push the F4 function key which is defined as the ENTER key at the bottom of the display Pushing this key enters the value and reverts the display back to the General Setup main menu STEP 4 At the bottom of the General Setup menu the F2 function key should now be defined as the SEND key Push this key to execute the change WARNING Carefully follow the on screen warnings and messages when proceeding because changing this parameter will cause the drive to reposition This can adversely affect the process and cause potentially dangerous conditions STEP SIZE The step size is the incremental movement of the drive shaft in response to signal changes The step size is factory set at 0 15 unless otherwise specified at the time of order The step size is adjustable from 0 1 to 2 5 To adjust the
142. using the HART see page 46 or Serial see page 71 interface Alarm indication is available at terminal E STOP LIMIT INDICATION The STAT and STOP LIMIT LEDs will light if the Handswitch is in the STOP position These LEDs will also light if the drive is at a limit and is not in balance Alarm indication is available at terminal E 21 22 DIGITAL CONTROL MODULE DCM 2 INPUT DIGITAL CONTROL MODULE DCM 2 Beck modulating drives are equipped with a precision digital control module DCM 2 designed to receive conventional 4 20 mA or 1 5 V dc control signals directly eliminating the need for contact protection devices relays switches and reversing starters The DCM 2 modulates the drive output shaft in response to an analog Demand input signal and is designed to operate continuously in temperatures up to 185 F 85 The DCM 2 provides intelligent calibration easy drive setup changes and diagnostic information Local interface provides quick pushbutton setup and diagnostics without the need for a handheld or remote device see page 23 AHART communications interface allows remote access of all features and information see page 36 A Serial interface also allows for drive configuration changes drive information reporting and to assist in troubleshooting see page 66 The DCM 2 permits two or more Beck drives to be operated by a single signal source See pages 29 and 57 for details on
143. ve s output shaft in the CCW direction away from the CW travel limit Note the direction of rotation of the lobe of the cam The correct cam lobe motion is away from the Switch lever with the switch lever on the lower part of the cam If not correct return to step 2 and reset the cam to the proper orientation 12 Rotate the output shaft again to the desired CW travel limit If the stopping point is reached the switch is properly set Loosening Switch Cam 13 Repeat instructions for setting CCW travel limit switch noting that referenced directions of rotation should be opposite of those used for CW switch setting Connect continuity meter across terminals B and N 14 Replace covers and tighten cover bolts to 10 Ib ft 14 torque 15 Rotate index or index pointer on models 11 159 or 169 to correspond with output shaft rotation Setting Auxiliary Switches Standard switch settings for drives with 2 or 4 auxiliary switches are shown on the diagram on page 54 The heavy line indicates a closed circuit Follow these instructions to change the operating point of auxiliary switches NOTE In the following procedure it is assumed that switch settings are to be adjusted so that contacts are open when the desired position is achieved If they are to be adjusted to close it may be necessary to reverse the operating mode of the switch by moving the wire lead to the other terminal on the switch itself Be sure to dis
144. ves for split range operation 4 Board reset This procedure resets the board without powering down the drive There are many communicator procedures that implement the reset procedure automatically to ensure the proper initialization of the DCM 2 board however manually implementing the reset procedure is not typically necessary CW Torque Submenu Block 4J This menu displays the torque applied over ten segments of travel of the drive shaft CCW Torque Submenu Block This menu displays the torque applied over ten segments of travel of the drive shaft Alarm Setup Submenu Block 41 This menu allows customization of alarm indication 1 AlarmPol This determines whether the alarm relay Drops Out or Pulls In to indicate an alarm 2 Alarm Mask This leads to a submenu where alarm conditions may be set Alarm Mask Submenu Block 5H This menu allows alarm conditions to be ignored such as DemandLOS Stall FeedbackLOS or other conditions which may occur under normal operation and that may prove a nuisance during normal HART operation RealTimeClock Submenu Block 4M This menu allows the date and time to be set The settings are as follows 1 2 3 4 5 RTC Day Numerical entry sets the day of the month RTC Month Numerical entry sets the month RTC Year Numerical 4 digit entry sets the year Hour 24 Numerical entry sets the hour of the day 1 24 Minute
145. y Settings Commands p 69 restoremodes harttype Demand Signal Commands p 69 amp 70 demOpctma dem100pctma trimdem4ma trimdem20ma demfunc demlos demlosgtp Position amp Feedback Signal Commands p 71 posisd psisp fdbkOpctma fdbk100pctma trimfdbk4ma trimfdbk20ma fdbkfunc travel Torque Sensing Commands p 71 amp 72 torqOk torqconst torqOpct torq100oct torqenable Diagnostic and Information Commands p 72 signals stat tempf torque Note For specific information on the following functions see the HART interface section of the manual General Configuration Commands Command stepsize n stalltime n Description Sets and or displays the size in degrees of one incremental movement of the output shaft Sets and or displays the drive output shaft direction resulting from an increasing Demand signal Sets and or displays the time allowed for the drive to reach its Demand target If the drive cannot reach the target in the allotted time a stall condition is initiated Sets the serial number of the drive in which the DCM 2 is installed Model number information is derived from the serial number Reset Factory Settings Commands Command restoremodes 1 harttype n Description Resets the drive configuration back to the original factory settings Sets and or displays the DCM 2 HART device type Demand Signal Commands Command demOpctma n Description S
146. y suited for globe valves from 1 to 8 25 to 203 mm diameter Beck s unique Tight Seater coupling provides positive seating of valves CONTENTS Product Description nnn rnnt nennen nein 4 General mU 6 Outline Dimension 8 Install ti n ME dan one 15 Jes EDA 17 18 20 Digital Control Module DCM 2 22 DCM 2 Local Interface Operation M ELEM 23 CAND RAT ON 25 26 Bump 28 eje M 30 Direction dede er 31 32 DCM 2 HART Interface 34 Configuration and Setp 44 CAI RATION 50 52 POSION 54 c 56

Beck, R&J ELECTRIC ACTUATORS FOR INDUSTRIAL PROCESSCONTROL 11-1_9 User's Manual

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Beck, R&amp;J ELECTRIC ACTUATORS FOR INDUSTRIAL PROCESSCONTROL 11-1_9 User's Manual

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Beck, R&J ELECTRIC ACTUATORS FOR INDUSTRIAL PROCESSCONTROL 11-1_9 User's Manual