AERCO AF120-S US Installation Instructions

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Page 1

”

shafts

nstallation Instruction

uick-Mount Visual Instructions for Mechanical Installatio

Quick-Mount Visual Instructions

. Rotate the damper to its fail-safe position.

f the shaft rotates counterclockwise, mount the “CCW” side of the actuator out f it rotates clockwise, mount the actuator with the “CW” side out

2. If the universal clamp is not on the correct side of the actuator, move it to the correct side

. Slide the actuator onto the shaft and tighten the nuts on the V-bolt with a 10mm wrench to 6-8 ft-lb of torque

. Slide the anti-rotation strap under the actuator so that it engages the slot at the base of the actuator. Secure the strap to the duct work with #8 self-tapping screws

OTE: Read the “Standard Mounting” instructions, on the next page, for more detailed information

mensions (Inches [mm])

min. 3 1/2"

[90]

min. 3/4"

[20]

IND-AF2 Position Indicator

(optional)

emove or 3/4” o 1.05

IND-AF2 Position Indicator

(optional)

M40024 - 05/10 - Subject to change. © Belimo Aircontrols (USA), Inc

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Page 2

Installation Instruction

Beli

enclosure must be used to shield

shaf

saf

off

rotated counterclockwise (

), this is a CCW installation. If the shaft rotated

)

clockwise (

), this is a CW installation. In a CCW installation, the actuator side

)

All

Short Shaft Installation

section.

)

Limiting, Mechanical Minimum Damper Position

4. Lock th

6. Slide

desired locatio

echanical Installatio

Determining Torque Loading and Actuator Sizing

Damper torque loadings, used in selecting the correct size actuator, should be

rovided by the damper manufacturer. If this information is not available, the

ollowing general selection guidelines can be used.

Damper Type Torque Loadin

Opposed blade, without edge seals

or non-tight close-off application

arallel blade, without edge seals,

or non-tight close-off application

Opposed blade, with edge seals

or tight close-off application

Parallel blade, with edge seals

or tight close-off application

The above torque loadings will work for most applications under 2 in. w.g. static

ressure or 1000 FPM face velocity. For applications between this criteria and 3 in.

w.g. or 2500 FPM, the torque loading should be increased by a multiplier of 1.5. If

he application calls for higher criteria up to 4 in. w.g. or 3000 FPM, use a multiplier

of 2.0

3 in-lb/sq. ft

4 in-lb/sq. ft

5 in-lb/sq. ft

7 in-lb/sq. ft

orque Loading Char

Mechanical Operation

he actuator is mounted directly to a damper shaft up to 1.05” in diameter b means of its universal clamp. A crank arm and several mounting brackets are available for applications where the actuator cannot be direct coupled to the damper

t. The AF series actuators provide true spring return operation for reliable fail

e application and positive close-off on air tight dampers. The spring return

stem provides constant torque to the damper with, and without, power applied to

the actuator. The AF…-S versions are provided with 2 built-in auxiliary switches.

hese SPDT switches are provided for safety interfacing or signaling, for example, for fan start-up. The switching function at the fail-safe position is fixed at +5°, the other switch function is adjustable between +25 to +85°.

Automatic Airtight Dampers/Manual Override

he AF series provides 95° of rotation and is provided with a graduated position

ndicator showing 0° to 95°.

he AF has a unique manual positioning mechanism which allows the setting of any

amper position within its 95° of rotation. A pre-tensioned spring automatically tightens damper when power is applied to the actuator, compensating for damper

eal deterioration.

he actuator is shipped at +5° (5° from full fail-safe) to provide automatic

ompression against damper gaskets for tight shut-off. When power is applied, the manual mechanism is released and the actuator drives toward the full fail-safe

osition.

Standard Mounting

NOTE: The AF…series actuator is shipped with the manual override adjusted

or a +5° position at the universal clamp (not at full fail-safe, 0°). This allows or automatic compression of damper blade seals when the actuator is in use,

roviding tight shut-off. This assumes that the damper is to have tight shut

at the fail-safe position. If tight close-off is desired at the opposite irection from fail-safe, the manual override should be released so the ctuator can go to the full fail-safe position. See the manual override

instructions

. Manually move the damper to the fail-safe position (usually closed). If the shaft

Damper Area (sq. ft.)

46810

579

Torque Loading (in-lb/

sq. ft.)

General Information

mo actuators should be mounted indoors in a dry, relatively clean environment

ree from corrosive fumes. If the actuator is to be mounted outdoors, a protective

M40024 - 05/10 - Subject to change. © Belimo Aircontrols (USA), Inc.

For new construction work installing contractor to allow space for mounting and service of the Belimo actuator on

he shaft. The damper shaft must extend at least 3 1/2” from the duct. If the shaft extends less than 3-1/2” or if an obstruction blocks access, the shaft can be extended with the AV 10-18 shaft extension accessory or the actuator may be mounted in its short

haft configuration.

the actuator.

order dampers with extended shafts. Instruct the

marked “CCW” faces out, while in a CW installation, the side marked “CW” faces

other steps are identica

out.

. The actuator is usually shipped with the universal clamp mounted to the “CCW”

ide of the actuator. To test for adequate shaft length, slide the actuator over the haft with the side marked “CCW” (or the “CW” side if this is the side with the lamp). If the shaft extends at least 1/8” through the clamp, mount the actuator

as follows. If not, go to the

. If the clamp is not on the correct side as determined in step #1, re-mount the

lamp as follows. If it is on the correct side, proceed to step #5. Look at the niversal clamp. If you are mounting the actuator with the “CCW” side out, osition the clamp so that the pointer section of the tab is pointing to 0° (see

Figure

and the spline pattern of the clamp mates with spline of the actuator.

lip the clamp over the spline. (Use the same procedure if the “CW” side is out.) If

your application requires a mechanical minimum position, read theRotation

e clamp to the actuator using the retaining clip.

. Verify that the damper is still in its full fail-safe position.

the actuator over the shaft

7. Position the actuator in the

8. Tighten the two nuts on the clamp using a 10mm wrench or socket using 6-8 t-lb of torque.

. Slip the stud of the anti rotation strap into the slot at the base of the actuator.

The stud should be positioned approximately 1/16 of an inch from the closed end of the slot. Bend the stra duct with #8 sel

as needed to reach the duct. Attach the strap to the

tapping screws

section.

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Page 3

CCW

-5

FIGU

nstallation Instruction

ion

6. Positi

Fig

details.

sed

ppli

echanical Installat

Short Shaft Installation

f the shaft extends at least 3/4” from the duct, follow these steps

. Determine the best orientation for the universal clamp on the back of the actuator.

he best location would be where you have the easiest access to the V bolt nuts on

he clamp

2. Engage the clamp to the actuator as close as possible to the determined location . Lock the clamp in place using the remaining retainer clip. . Verify that the damper is still in its full fail-safe position

5. Slide the actuator over the shaft.

on the actuator in the desired location

7. Tighten the two nuts on the clamp using a 10mm wrench or socket using 6-8

t-lb of torque.

. Slip the stud of the anti-rotation strap into the slot at the base of the actuator.

he stud should be positioned approximately 1/16 of an inch from the closed end of the slot. Bend the strap as needed to reach the duct. Attach the strap to the duct with #8 self tapping screws.

. If damper position indication is required, use the optional IND-AF2 pointer. See

ure A

Jackshaft Installation

he AF… series actuator is designed for use with jackshafts up to 1.05” in iameter. In most applications, the AF actuator may be mounted in the same

anner as a standard damper shaft application. If more torque is required than one AF actuator can provide, a second AF actuator may be mounted to the jackshaft usin

the ZG-102 multiple actuator mounting bracket. See wiring guide for wiring

AF ACTUATORS WHICH MAY BE USED ON ONE SHAF

odel Maximum Quantity Per Sha

F24(-S) U

F120(-S) U

F230(-S) U

F24-SR US

MOUNTING: If the actuators are mounted on the opposed ends of the shaft, the actuator direction must be selected care

f rotation is rever

ully. Usually, the direction

Correct clamp mounting position if actuator is at full fail-safe.

Correct pointer mounting position if actuator is at full fail-safe.

CCW

Correct pointer mounting position when actuator is at 5° preload.

CWCCW

Correct pointer mounting position if actuator is at full fail-safe.

Multiple Actuator Mounting

more torque is required than one AF actuator can provide, a second AF actuator

ay be mounted to the shaft using the ZG-102 multiple mounting bracket.

TE: The manual positioning mechanism cannot be used in multiple actuator

cations.

pecial Wiring and Additional Information: See wiring guid

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CWCCW

RE A – Universal Clamp and IND-AF2 Pointer (optional)

ositions indicating fail-safe and pre-load setting

M40024 - 05/10 - Subject to change. © Belimo Aircontrols (USA), Inc

Page 4

Rotation Limitation

See

Limiting the d

The angle of rotation limiter, ZDB-AF2 US, is used in conjunctionwith the tab on the

niversal clamp or IND-AF2 position indicator which comes with the ZDB-AF2 US. In

order to function properly, the clamp or indicator must be mounted correctly.

Figure A.

The ZDB-AF2 US may not work in certain mounting orientations using the ZG-106 or

G-107 mounting brackets. It will not work with the ZG-108 mounting bracket.

amper rotation must be accomplished by adjusting the crank arm

linkage.

The ZDB-AF2 US may be used in 2 ways to control the rotational output of the AF

eries actuator. One use is in the application where a damper has a designed

otation less than 90°. An example would be a 45° or 60° rotating damper. The

other application would be to set a minimum damper position which can be easily

et or changed without having to remove the actuator from the damper.

Damper Rotation Limiting

1. Determine the amount of damper rotation required . Locate the Angle of Rotation Limiter (ZDB-AF2 US) on the actuator so that its

edge lines up with the degree graduation on the actuator face which corresponds with the required rotation. See Figure

3. Find the appropriate cross-hair location through the slot of the limiter. This is the

crew mounting location . Pierce through the label material to allow easy fastening of the retaining screw . Position the limiter back to the desired position, making sure the locating “teeth”

on the limiter are engaged into the locating holes on the actuator

6. Fasten the limiter to the actuator using the self tapping screw provided. . Test the damper rotation either manually with the manual crank or apply power

and if required, a control signal. Re-adjust if necessary.

Installation Instruction

echanical Installatio

Screw secured at these cross hairs

Angle of rotation is now set at 40°.

FIGURE C – ZDB-AF2 US, Securing the Angle of Rotation Limite

Secure angle-ofrotation limiter

Screw

Philips screwdriver

M40024 - 05/10 - Subject to change. © Belimo Aircontrols (USA), Inc.

800-543-9038 USA 866-805-7089 CANADA 203-791-8396 LATIN AMERICA

Page 5

Installatio

n Instruction

ocation.

direction.

- Rotate

about a 1/

- i

of arro

(

)

“unlocked

sec.

used to

120

250

2.5A

adj

3. R

FIGU

Mechanical Installatio

Manual Override

he AF series actuators can be manually positioned to ease installation or for mergency positionin

. The manual override will only work if no power is available to the actuator.

2. Insert the manual crank (shipped with the actuator) into the hexagon hole located on either side of the actuator. An illustration, located on the label, shows the l

. Turn the crank in the direction shown on the label (clockwise on the “CW” side,

ounterclockwise on the “CCW” side). It will take approximately 19 revolutions to

rotate the full 95° of rotation

. To lock the actuator in the required position, rotate the crank quickly in the opposite

direction, 1/2 of a revolution. The “lock closed” icon on the label shows the correct

5. The manual override may be disengaged in 2 ways.

the crank

winding. The “lock open” icon shows the correct direction.

Apply power to wire 1 and 2. The actuator will automatically disengage the

override function and will go to the “on” position in the case of the On/Off versions. Or, in the case of the proportional versions, go to the 0 signal position and then go to the position corresponding to the control signal. The actuator will now work normally.

4 revolution in the same direction as the initial

Auxiliary Switches

he AF series actuators may be ordered with 2 built-in SPDT auxiliary switches used

or safety interfacing or signalling, for example, for fan start-up. The switch position

ear the fail-safe position is fixed at 5°. The other is adjustable between 25 and 85° f rotation. The crank, supplied with the actuator, or a3mm allen wrench is djust the switching position.

SWITCH RATING

oltage

VA VA

wo methods may be used to adjust the switching point of the adjustable switch

ethod 1 - See Figure

1 The actuator must be in its fail-safe position.

. Insert the crank into the hexagon shaped hole located in the center of the

ustable switch pointer otate the crank until the switch pointer is at the desired switch point in degrees s shown.

AF... Serie

Factory setting 85°

60 70

25…85°

esistive Load Inductive Load

Rotate with crank handle

Crank

25…85°

Handl

60° set

25…85°

60 70

Winding the

damper actuator

nsert crank handle

turn handle in direction

Locking the

damper actuator

rotate crank handle 1/2

turn in the direction shown by the “locked” icon.

Unlocking the

damper actuato

2 options

- rotate crank handle 1/4 rn in the direction

hown by the

” icon.

- remote control b

upplying power to the nit for > than 3

Testing the Installation Without Power

he actuator/damper installation may be tested without power at the actuator. Refer

o the manual positioning section of the instructions. Move the damper to its full

non-fail-safe position using the manual crank. Disengage the manual position

echanism and have the damper go to full fail-safe position. Correct any echanical problems and retest

ethod 2 - See Figure

1. Position the damper to the point at which you want the switch to activate. This may be done by using the manual override or by providing the appropriate

roportional signal to AF24… modulating type actuator. The position of the witch pointer is not important during this step

. Insert the crank into the hexagon shaped hole located in the center of the

djustable switch pointer

. Rotate the switch pointer to just past the switch point indicating arrow as shown

AF... Seri

Actuator after locking

Crank

25…85°

60 70

Handl

Switch operates

25…85°

Switch does not operate

25…85°

60 70

IGURE G

M40024 - 05/10 - Subject to change. © Belimo Aircontrols (USA), Inc

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Page 6

KH-AF (-1) crank arm

with

Installation Instruction

AF Crank a

The retaining clip supplied with the clamp is

used to mount the KH-AF

The KH-AF (-1)

dditi

AFV V-bol

”

(

)

Non-Direct Mounting Method

ncluding Retaining Rin

rank arm

H-AF (-1) may also be used to simultaneously direct couple to a damper shaft and rovide an a it must be used for this non-direct application (see illustration this page

TWO SIZES ARE AVAILABLE:

KH-AF-1

KH-AFV

ote: KH-AF (-1) crank arms cannot be used on AF Series 1 actuators

Dimensions (Inches [mm])

crank arm is used in non-direct coupled mounting applications. The

onal crank arm connection to a second damper. The KH-

or round shafts up to 3/4” or square shafts up to 5/8

or jackshafts up to 1.05

V-bolt kit for KH-AF(-1) crank ar

dim sca

-1

KH-AF

KH-AF non-direct mounting with ZG-108 mounting bracket

M40024 - 05/10 - Subject to change. © Belimo Aircontrols (USA), Inc.

Multiple dampers direct coupled to one actuator with linkage to

erate the other damper.

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k ar

KH-8 cr

Page 7

nstallation Instruction

ill

Thi

Electrical Operatio

General

he AF series actuators utilize brushless DC motor technology. The AF uses this

otor in conjunction with an Application Specific Integrated Circuit (ASIC). In the On

Off versions of the AF, the ASIC monitors and controls the actuator’s rotation and a

igital rotation sensing function to prevent damage to the actuator. The AF24…

odulating type actuators incorporate a built in microprocessor. The microprocessor

provides the intelligence to the ASIC to provide a constant rotation rate and knows

he actuator’s exact zero position.

Brushless DC Motor Operation

elimo’s brushless DC motor spins by reversing the poles of stationary lectromagnets housed inside of a rotating permanent magnet. The electromagnetic

poles are switched by a special ASIC circuit developed by Belimo. Unlike the

onventional DC motor, there are no brushes to wear or commutators to foul.

Overload Protection

he AF series actuators are protected from overload at all angles of rotation. The

SIC circuit constantly monitors the rotation of the DC motor inside the actuator and stops the pulses to the motor when it senses a stall condition. The DC motor remains energized and produces full rated torque to the load. This helps ensure that

ampers are fully closed and that edge and blade seals are always properly

ompressed.

Motor Position Detection

elimo brushless DC motors eliminate the need for potentiometers for positioning in

odulating type actuators. Inside the motor are three “Hall Effect” sensors. These

sensors detect the spinning rotor and send pulses to the microprocessor which

ounts the pulses and calculates the position to within 1/3 of a revolution of the

otor.

Control Accuracy and Stability

F24-SR US actuators have built-in brushless DC motors which provide better accuracy and longer service life.

The AF24-SR US actuators are designed with a unique non-symmetrical dead

and. The actuator follows an increasing or decreasing control signal with a 80 mV resolution. If the signal changes in the opposite direction, the actuator w

not respond until the control signal changes by 200 mV.

ctuators to track even the slightest deviation very accurately, yet allowing the actuator to “wait”

ignal instability

or a much larger change in control signal due to control

s allows these

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Page 8

are followed

Ga20

The AF

Installation Instruction

eneral Wiring Instruction

WARNING The wiring technician must be trained and experienced with electronic circuits. Disconnect power supply before attempting any wiring connections or changes. Make all connections in accordance with wiring diagrams and follow all applicable local and national codes. Provide disconnect and overload protection as required. Use copper, twisted pair, conductors only. If using electrical conduit, the attachment to the actuator must be made with flexible conduit.

Always read the controller manufacturer's installation literature carefully

efore making any connections. Follow all instructions in this literature. If you

have any questions, contact the controller manufacturer and/or Belimo.

Transformers

The AF24 . . actuators require a 24 VAC class 2 transformer and draws a maximum

f 10 VA per actuator. The actuator enclosure cannot be opened in the field, there re no parts or components to be replaced or repaired.

– EMC directive: 89/336/EEC – Software class A: Mode of operation type 1 – Low voltage directive: 73/23/EEC

CAUTION: It is good practice to power electronic or digital controllers from a separate power transformer than that used for actuators or other end devices. The power supply design in our actuators and other end devices use half wave rectification. Some controllers use full wave rectification. When these two different types of power supplies are connected to the same power transformer and the DC commons are connected together, a short circuit is created across one of the diodes in the full wave power supply, damaging the controller. Only use a single power transformer to power the controller and actuator if you know the controller power supply uses half wave rectification.

Multiple Actuators, One Transformer

ultiple actuators may be powered from one transformer provided the following rules

. The TOTAL current draw of the actuators (VA rating) is less than or equal to the

2. Polarity on the secondary of the transformer is strictly followed.

rating of the transformer

his means that

ll No. 1 wires from all actuators are connected to the common leg on the

ransformer and all No. 2 wires from all actuators are connected to the hotleg.

Mixing wire No. 1 & 2 on one leg of the transformer will result in erratic operation or failure of the actuator and/or controls.

Multiple Actuators, Multiple Transformers

ultiple actuators positioned by the same control signal may be powered from

multiple transformers provided the following rules are followed:

. The transformers are properly sized

2. All No. 1 wires from all actuators are tied together and tied to the negative leg o the control signal. See wiring diagram.

Wire Length for AF... Actuators

Keep power wire runs below the lengths listed in the Figure H If more than on actuator is powered from the same wire run, divide the allowable wire length by the

umber of actuators to determine the maximum run to any single actuator.

Example: 3 actuators, 16 Ga wire

350 Ft ÷ 3 Actuators = 117 Ft. Maximum wire ru

AXIMUM WIRE LENGTH FOR 10V

ire Size

12 Ga 900 Ft. 14 16

ax. Feet.

Ft. Ft.

ire Size

8 Ga 220 Ft

ax. Feet

Ft.

FIGURE

Wire Type and Wire Installation Tips

For most installations, 18 or 16 Ga. cable works well with the AF24... actuators. Use code-approved wire nuts, terminal strips or solderless connectors where wires are joined. It is good practice to run control wires unspliced from the actuator to the controller. If splices are unavoidable, make sure the splice can be reached for

ossible maintenance. Tape and/or wire-tie the splice to reduce the possibility of

the splice being inadvertently pulled apart

24... proportional actuators have a digital circuit that is designed to ignore most unwanted input signals (pickup). In some situations the pickup may be severe enough to cause erratic running of the actuator. For example, a large inductive load

high voltage AC wires, motors, etc.) running near the power or control wiring may cause excessive pickup. To solve this problem, make one or more of the followin changes:

1. Run the wire in metallic conduit

2. Re-route the wiring away from the source of pickup

3. Use shielded wire (Belden 8760 or equal). Ground the shield to an earth ground.

Do not connect it to the actuator common.

Initialization of the AF24-SR US

When power is initially applied, the actuator will first release its manual preload

osition (This assumes a manual position has been set). The actuator will then rotate to the full fail-safe position. At this point the microprocessor recognizes that the actuator is at full fail-safe and uses this position as the base for all of its position calculations. The microprocessor will retain the initialized zero during short power

ailures of up to 20 seconds. For power failures greater than 20 seconds, the actuator would naturally return to its full fail-safe position prior to the microprocessor losin its memory. The actuator will also re-initialize if the manual position mechanism is

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Page 9

ocedure

See Note 1.

.NOTE:

Startup and Checkou

Instructions For AF24-SR U

AF24-SR US Electrical Check-out Procedure

TEP Pr

ontrol signal is applied to actuator. Actuator will move to its “Control

Check power wiring Correct any problems.

Turn reversing switch to the correct position. Make sure the switch is turned all the way left or right.

ake sure the control signal positive

(+) is connected to Wire No. 3 and control signal negative (-) is connected to wire No. 1. Most control problems are caused by reversing these two wires. Verify that the reversing switch is all the way CCW or CW.

Check input signal with a digital volt meter (DVM). Make sure the input is within the range of the actuator. For

F24-SR US this is 2 to 10 VDC or 4 to

20 mA

The input signal must be above the 2 VDC or 4 mA to have the actuator move.

heck damper torque requirement

ctuator works properly. Test

controller by following controller manufacturer's instructions

Expected Response

ignal” position

Power supply rating should be the total power requirement of the actuator(s). Minimum voltage of 19.2 VAC or 21.6 VDC.

Actuator will move to its “Control

ignal” position

Drives to “Control Signal” position

Input voltage or current should be ±1% of what controller's adjustment or programmin

ndicate.

orque requirement is actuator’s

inimum torque

ives Expected Response

o To Step…

ctuator operates properlyStep 7. No response at all Step 2

ower wiring corrected, actuator egins to drive Step 1.

ctuator operates properlyStep 7. Does not drive toward “Control Signal

ctuator operates properlyStep 7.

ontroller output (actuator input)

s correct. Input Polarity Correct

tep 6.

efective Actuator eplace Actuator - See Note 2.

Operation is reversed Step 3. Does not drive toward "Control Signal Position" Step 4.

Power wiring corrected, actuator still

oes not drive Step 4.

osition” Step 4

Step 5.

Reprogram, adjust repair or replace controller as needed Step 1.

ecalculate actuator requirement an

correct installation.

oes Not Giv

Expected Response

Go To Step…

NOTE 1 Check that the transformer(s) are sized properly.

• If a common transformer is used, make sure that polarity is observed on the secondary. This means connect all No. 1 wires to one leg of the transformer and all o. 2 wires to the other leg of the transformer.

• If multiple transformers are used with one control signal, make sure all No. 1 wires are tied together and tied to control signal negative (-).

• Controllers and actuators must have separate 24 VAC/VDC power sources

NOTE 2 If failure occurs within 5 years from original installation date, notify Belimo and give details of the application.

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AERCO AF120-S US Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual