Beck 22-309, 22-809, 22-409 Quick Reference

Page 1
MODELS
Group 22 - Quick Reference
PAGES 2-7 -- WIRING CONNECTIONS
PAGES 8-11 -- ELECTRONICS
PAGES 12-13 - MAINTENANCE KITS
PAGES 14-17 -- TROUBLESHOOTING
22-309 22-409 22-809
PAGES 18-19 -- HART MENU
This reference supports
Group 22 actuators
using DCM-2 part numbers:
12-8224-41
12-8224-45
12-8224-51
12-8224-55
E L E C T R I C A C T U A T O R S F O R I N D U S T R I A L P R O C E S S C O N T R O L
Page 2
INSTALLATION - ELECTRICAL
Group 22
Quick Reference
POWER QUALITY
Power quality disturbances such as power outages, transient voltages, harmonic distortions, and electrical noise should be accounted for during installation of your drive. Protecting your drive from these conditions can reduce downtime and promote a longer lifetime for the equipment. Following the recommendations below will maximize the protection.
a Select wiring materials according to the correct
ampacity ratings dictated by national and local regulations.
a Shielded, twisted pair cables can be used for
signal connections to avoid being affected by electrical noise. These signal wires, based on Noise Susceptibility Level (NSL) per IEEE-518, fall into the level 1 classification. A braided shield will be more effective than a wrapped foil shield. Signal wire shields should be connected to the drive casting grounding screw. If grounding at the signal source is required, then the shield should not be grounded at the drive.
a Raceways such as conduits and trays have
to be grounded at both ends to properly meet immunity requirements.
a An AC power ground connection should be
made between the power source and the Beck drive. Grounding connections including wire and metal conduit are permitted, except the drive-grounding conductor may not be connected to a structured metal frame of a building.
a Surge suppression equipment that meets
Underwriters Laboratory (UL) Standard 1449 may be used to protect against transient voltage conditions.
a Power Conditioners may be used to regulate
the supply voltage and maintain a constant voltage level. They are helpful in protection against voltage sags and swells, as well as some measure of electrical noise protection.
a Harmonic lters may be used to minimize the
effects of supply voltage waveform distor­tions and are used in applications that incur a large amount of high-frequency electronic noise.
ELECTRICAL INSTALLATION
Three 1” N.P.T. conduit connections are provided for power and signal wiring to the drive. One conduit is provided for signal wiring connections, and the other conduits are provided for power and auxiliary switch connections. Use of a sealant on the threaded conduit connections is recommended to keep moisture out. Routing the conduits from below the drives will help to prevent water and other contaminants from entering the drive. Power and signal wires should be routed to the drive separately. Shielded cables are recommended, otherwise the wires should be installed in conductive conduit and/or cable trays. Large, clearly labeled terminal blocks are enclosed in a gasketed compartment. Terminals will accommodate up to 12 AWG (3.31 mm2) wires. Refer to the wiring diagram furnished with your Beck drive (fastened to the inside of the terminal block cover) for proper AC power and signal connections. It is advisable to provide normal short circuit protection on the AC power line. For maximum safety, the Beck drive body should be grounded. Separate ground terminals are provided in the wiring compartment for power and signal wiring. Wire size 12 AWG (3.31 mm2) is recommended for this purpose.
TERMINAL CONNECTIONS
The Group 22 terminal block assemblies have screw-down clamp terminals with separation barriers and nylon paper electrical shields (shields not shown on terminal connection diagrams). The terminals can accept a variety of lug types or a bare wire. The maximum wire size capacity is #12 AWG (3.31 mm2).
TERMINAL SCREW TORQUES
Regardless of wire termination type, each terminal screw should be torqued to the proper specification upon landing your wire. All input power terminal screws (terminals 1 to 3) on the model 22-309 and 22-409 should be tightened to 10 lb-in. The input power terminal screws on the model 22-809 and the optional transformer enclosure for 22-309 and 22-409 drives should be tightened to 20 lb-in. All signal wiring terminal screws (terminals 4 to 21) on all Group 22 models should be tightened to 9 lb-in. Both the power and signal ground screws should be tightened to 20 lb-in.
2
Page 3
Group 22
Quick Reference
SUPPLY POWER
TERMINALS 1, 2, AND 3
Standard supply power for the model 22-309 is single-phase 120 VAC (refer to the drive nameplate for specific rating). Input power connects line to terminal 1, neutral to terminal 2, and ground to the enclosure power ground screw. Terminal 3 is unused for 120 VAC operation. Standard supply power for the model 22-409 is three-phase 208 VAC. Standard supply power for the model 22-809 is three-phase 480 VAC. Lines 1, 2, and 3 connect to terminals 1, 2, and 3 respectively on each of these drives. The ground wire should be connected to the enclosure power ground screw. Alternate voltage options include single-phase 240 VAC for the model 22-309 and three-phase 208, 240, 380, 416, 480, & 575 VAC for all Group 22 models. The model 22-309 and 22-409 require an optional transformer enclosure to accommodate any non-standard voltage configuration. Group 22 drives are equipped with a transient protector assembly installed across each, or a combination of terminals 1, 2, and 3 (dependent upon your drive model and configuration). Note: The transient protector assembly should not be removed.
AUXILIARY LIMIT SWITCHES
TERMINALS 4 THROUGH 9
Group 22 drives include two single pole double throw (SPDT) auxiliary limit switches rated for 1 Amp at 250 VAC. These switches may be useful for discrete position indication. The limit switches are actuated by adjustable cams on the control shaft (located with the position sensing device). Details on standard factory switch settings can be found in the configuration section of this manual.
AUTO MODE INDICATION
TERMINALS 10 AND 11
A dry contact is available at terminals 10 and 11 to indicate when the handswitch is in the AUTO position. The switch contact is Form A; when the handswitch is not in the AUTO position, the contact is open and when the handswitch is in the AUTO position, the contact is closed. The contact is rated for 1 Amp at 250 VAC.
CAUTION
Always close covers immediately after installation or service to prevent moisture or other foreign matter from entering the drive.
SYSTEM ALARM
TERMINALS 12 AND 13
Indication of the system alarm is available as a dry contact at terminals 12 and 13. The factory standard is a form B contact configuration (open on alarm). It is configurable to a form A configuration (closed on alarm). Reference the configuration section of the manual for additional details on how to change this functionality. The contact is rated for a maximum of 80 milliamps at 120 VAC/VDC.
DEMAND SIGNAL
TERMINALS 14 AND 15
The DCM monitors an analog 4-20 milliamp input signal at terminals 14 (–) and 15 (+), and positions the output shaft position to match in response. The standard response is to follow the demand signal linearly.
FEEDBACK SIGNAL
TERMINALS 16 AND 17
When feedback sourcing is enabled, the DCM-2 transmits a 4-20 milliamp position feedback signal on terminals 16 (–) and 17 (+) that is proportional to the drive output shaft position.
CONTROL OVERRIDE INPUTS
TERMINALS 18 THROUGH 21
Analog signal operation may be overridden by using discrete input signals on the control override input terminals. CW (19), CCW (20), and STOP (21) terminals require connection to a common (COM) terminal (18) to perform the override as shown in the table below.
Terminal
Connections
19 to 18 Clockwise Rotation
20 to 18 Counter-Clockwise Rotation
21 to 18 Stop in Current Position
The connection to terminal 18 is designed to be made through relay contacts or through a solid state switch capable of sinking at least 5 milliamps DC. When the circuit is open, terminals 19, 20, and 21 should measure +12 VDC with respect to terminal 18.
CAUTION
Do not connect an external voltage source to override terminals 18–21; an external voltage source may damage the DCM circuitry.
Output Shaft
Action
3
Page 4
INSTALLATION - WIRING
Surge
Suppressor
Assembly
(22-309)
MODEL 22-309 & 22-409 TERMINAL CONNECTIONS
Control Override
Demand Signal
Feedback Signal
Signal
Ground
Inputs
System Alarm
Handswitch
Auto Indication
Auxiliary Switch 2
Auxiliary Switch 1
80-4280-02
Rev. 05.3
18
19
14
1721162015
13
12
11
10
9
8
7
6
5
4
Transient Protector
Assembly
(22-409)
3
2
Power
1
Ground
OPTIONAL
TRANSFORMER
ENCLOSURE POWER
CONNECTIONS
FOR MODELS 22-309 / 22-409
Transient Protector
Assembly
(22-309)
Power
Ground
Power
3
2
1
Power
4
(Refer to page 41 for replacement
fuse part numbers)
1
2
3
OPTIONAL ENCLOSURE
Page 5
80-4280-02
Rev. 05.3
MODEL 22-309 & 22-409 TYPICAL WIRING SCHEMATIC
(a wiring schematic specic to each drive is located under the wiring terminal cover)
EXTERNAL
HART
COMMUNICATION
TERMINALS
CONTROL OVERRIDE INPUTS
DEMAND SIGNAL
See terminal
connction
table below
STOP
CCW
CW
COM
ORG
RED
BRN
BLK
WHT
GRY
GRN
YEL
ORG
RED
BRN
J4-3
J4-2
J4-1
J4-10
J4-9
J4-8
J4-5
J4-4
PP-3
PP-2
PP-1
PP-5
TORQUE
SENSING
J2-5
J2-6
DCM FUSES
F1,F2,F3
(8A 250V)
J3-1
J2-4
J2-3
J2-2
DIGITAL
CONTROL
MODULE
(DCM-2)
J3-4
J3-3
J2-1
J3-2
AUTO CCW
J5-1
HANDSWITCH
CW
5 4 3 12 109
RED
ORG
YEL
GRN
J5-2
J3-9
J3-8
J5-3
J5-4
J3-7
J3-6
J5-5
BRN
J5-6
J3-5
STOP
WHT
PP-9
PP-16
PP-15
J4-7
J4-6
PP-11
PP-12
PP-13
PP-14
BLK
PP-10
AUTO
12
11
ORG
RED
VIO
BLU
BRN
RED
ORG
YEL
BRN
RED
SYSTEM ALARM OPENS ON ALARM 120 VAC/VDC 80mA MAX.
PM-1
PM-2
PM-3
PM-4
HANDSWITCH AUTO INDICATION 250VAC, 1 AMP
CONTROL DRIVE OUTPUT SHAFT POSITION FEEDBACK TO CUSTOMER
MOTOR
USE FUSE KIT
P/N 12-8061-53
CUSTOMER TERMINAL BLOCK
BRN
ORG
YEL
PSL-1
PSL-3
PSL-4
CCW
CW
TRAVEL LIMITS
RED
PSL-2
RED
BRN
ORG
YEL
J1-1
J1-2
J1-3
J1-4
CONTACTLESS
POSITION
SENSOR
GRN
J1-5
BLU
J1-6
PSA-6
S2
PSA-5
PSA-4
PSA-3
PSA-2
S1
PSA-1
INPUT / FEEDBACK SIGNALS:
ISA TYPE 4, CLASS U, POWER ISOLATED
TERMINAL CONNECTION TABLE
22-309 22-409
Operating Voltage Phases Single-Phase Three-Phase
Operating Voltage Refer to drive nameplate for
voltage rating (120 or 240 VAC)*
Terminal 1 Line Line 1
Terminal 2 Neutral Line 2
Terminal 3 Unused Line 3
*Other operating voltages are available with an optional transformer. Fuse F3 is only applicable to the model 22-409.
WHT
GRY
VIO
BLU
GRN
YEL
208 VAC*
AUXILIARY SWITCHES 250VAC, 1 AMP
5
Page 6
INSTALLATION - WIRING
MODEL 22-809 TERMINAL CONNECTIONS
80-4280-02
Rev. 05.3
Demand Signal
Auxiliary Switch 1
Auxiliary Switch 2
Handswitch Auto Indication
14
5
4 7 8 9 10 11 12 136
Feedback Signal
Control Override Inputs
Signal Ground
2015 16 17 18 19
21
System Alarm
Switch Ground
Transient Protector Assembly
Power
Power Ground
6
Page 7
80-4280-02
MODEL 22-809 TYPICAL WIRING SCHEMATIC
(a wiring schematic specic to each drive is located under the wiring terminal cover)
Rev. 05.3
EXTERNAL
HART
COMMUNICATION
TERMINALS
CONTROL OVERRIDE INPUTS
DEMAND SIGNAL
3-PHASE POWER
REFER TO DRIVE NAMEPLATE FOR VOLTAGE RATING
LINE 3
LINE 2
LINE 1
ORG
RED
BRN
G
STOP
CCW
CW
COM
ORG
RED
BRN
BLK
WHT
GRY
GRN
YEL
BLK
BLK
BLK
GRN
G
J4-3
J4-2
J4-1
J4-10
J4-9
J4-8
J4-5
J4-4
PP-3
PP-2
PP-1
PP-5
TRAVEL LIMITS
TORQUE
SENSING
J2-5
J2-6
J2-4
DCM FUSES F1,F2,F3 (8A 250V)
J3-1
BRN
PSL-1
CCW
CW
J2-3
J2-1
J2-2
DIGITAL
CONTROL
MODULE
(DCM-2)
J3-4
J3-2
J3-3
ORG
YEL
RED
PSL-4
PSL-3
PSL-2
HANDSWITCH
STOP
ORG
YEL
J3-8
J3-7
J5-3
J5-2
ORG
J1-3
SENSOR
YEL
J1-4
RED
J3-6
J5-4
CW
BRN
J5-5
GRN
J1-5
J3-5
WHT
BLU
J1-6
J5-6
PP-9
PP-16
PP-15
PP-11
PP-12
PP-13
PP-14
PP-15
PP-16
AUTO CCW
5 4 3 12 109 1112
GRN
J3-9
J5-1
RED
BRN
J1-2
J1-1
CONTACTLESS
POSITION
J4-7
J4-6
BLK
PP-10
S2
S1
AUTO
ORG
RED
VIO
BLU
BRN
RED
ORG
YEL
PSA-6
PSA-5
PSA-4
PSA-3
PSA-2
PSA-1
BRN
RED
PM-1
PM-2
PM-3
PM-4
PM-5GRN
PM-6BLU
WHT
GRY
VIO
BLU
GRN
YEL
HANDSWITCH AUTO INDICATION 250VAC, 1 AMP
SYSTEM ALARM OPENS ON ALARM 120 VAC/VDC 80mA MAX.
CONTROL DRIVE OUTPUT SHAFT POSITION FEEDBACK TO CUSTOMER
MOTOR
AUXILIARY SWITCHES 250VAC, 1 AMP
Three-Phase
Voltage Rating Fuse Rating
208 10 Amps, 600 Volts 12-8061-51
240 10 Amps, 600 Volts 12-8061-51
380 4 Amps, 600 Volts 12-8061-52
416 4 Amps, 600 Volts 12-8061-52
480 4 Amps, 600 Volts 12-8061-52
575 4 Amps, 600 Volts 12-8061-52
* Kits also include (3) 8 Amp, 250 Volt DCM fuses.
Fuse Kit
Part Number*
INPUT / FEEDBACK SIGNALS:
ISA TYPE 4, CLASS U, POWER ISOLATED
CUSTOMER TERMINAL BLOCK
#
7
Page 8
ELECTRONICS
DIGITAL CONTROL MODULE (DCM-2)
Group 22
Quick Reference
The DCM-2 is a micro-processor based circuit board assembly that serves as the actuator’s control center. The DCM-2 chassis assembly is comprised of a Control circuit board, a Driver circuit board (inverter circuit), additional circuit components like capacitors and transformers, and an aluminum chassis to which both the boards and the components are fastened. The whole assembly is mounted in the actuator’s DCM compartment (see photo). The main function of the DCM-2 chassis assembly is to be the actuator’s positioner. The control board compares the Demand input signal to the actuator shaft position feedback signal from the Contactless Position Sensor (CPS-4) located in the control end compartment (see photo). See the troubleshooting section of this manual for details regarding the fuse locations, the test point locations, and expected test point voltage levels.
INTERFACES
The DCM-2 has three configuration interfaces: a local pushbutton interface, a HART interface, and a serial port interface.
DCM
COMPARTMENT
PUSHBUTTONS
The local pushbutton interface is integral to the DCM-2 assembly. It requires no additional equipment to perform calibration procedures, but is limited in functionality. This interface also has LEDs for diagnostic information.
HART
The HART interface may be accessed by a HART handheld communicator* or a HART equipped control system. All electronic calibration, configuration, and diagnostics can be accomplished through HART communications.
SERIAL PORT
The serial port interface is accessible by connecting a computer to the DCM-2 using a Beck serial cable**. All electronic calibration and configuration can be accomplished through the serial port interface.
* See the HART appendix for details on connecting via HART communicators. ** See the serial port appendix for details on connecting via the serial port.
CONTROL END
The DCM-2 chassis assembly is mounted in a dedicated compartment (see photo) and normally does not need to be removed.
Accessing the DCM-2 assembly may be required for configuration or diagnostic purposes using either the pushbutton or serial port interfaces.
If the DCM-2 needs to be repaired for any reason, the whole chassis should be removed and replaced as an assembly. See the Maintenance section of this manual for complete details on chassis removal and installation.
COMPARTMENT
8
Page 9
MOUNTING
SCREWS
MODEL 22-309 DIGITAL CONTROL MODULE (P/N 12-8224-41)
STATUS INDICATION
LEDs
1 1
J5
1
12-8224-41
DEMAND
POSITION
TORQUE
STALL
TEMP °F
FB OPEN
UVOLT
TP4
ACKNOWLEDGE
1
J5
TP1
J2
SERIAL
PORT
J4 J3A J3B
10
FWD
REV
R
CALIBRATE
SET POS 100%
SET POS 0%
SET DEM 100%
SET DEM 0%
INPUT
RESISTOR
R11
STAT
OVERVIEW
LEDs
TB6
PWR
TB5
TP3
F2
F1
TP2
TB1 TB2 TB3 TB4
1
PUSHBUTTON
Group 22
Quick Reference
LOCAL
INTERFACE
MOUNTING
SCREWS
DCM
FUSES
MOUNTING
SCREWS
SERIAL PORT
MODEL 22-409 & 22-809 DIGITAL CONTROL MODULE (P/N 12-8224-51)
STATUS INDICATION
LEDs
OVERVIEW
LEDs
PUSHBUTTON
INTERFACE
FWD
STAT
REV
PWR
12-8224-51
DEMAND
POSITION
TORQUE
STALL
TEMP °F
FB OPEN
UVOLT
TP1
SERIAL
PORT
J4 J3A J3B
ACKNOWLEDGE
TP4
J5
1
CALIBRATE
SET POS 100%
SET POS 0%
SET DEM 100%
SET DEM 0%
INPUT
RESISTOR
R11
F3
TP3
DCM
TP2
F2
F1
FUSES
8 AMP
FUSES
LOCAL
MOUNTING
SCREWS
SERIAL PORT
9
Page 10
ELECTRONICS
Group 22
Quick Reference
OVERVIEW LEDs
There are four LEDs in the upper right corner of the DCM-2 circuit board. These provide an overview of DCM-2 status.
PWR
This LED is lit when power is applied to the drive. After initial power up, this LED pulses from bright to dim indicating the micro­processor is operating.
STAT
This LED is lit when a system alarm occurs. When the STAT LED is lit, typically a status indication LED will be illuminate to further explain the status.
REV
This LED is lit when the drive is instructed to move in the reverse direction. The instructions may come from a demand signal, a control override input, the handswitch, HART, or serial commands.
FWD
This LED is lit when the drive is instructed to move in the forward direction. The instructions may come from a demand signal, a control override input, the handswitch, HART, or serial commands.
FWD
STAT
REV
PWR
DEMAND
POSITION
TORQUE
STALL
TEMP °F
FB OPEN
UVOLT
ACKNOWLEDGE
CALIBRATE
SET POS 100%
SET POS 0%
SET DEM 100%
SET DEM 0%
LOCAL PUSHBUTTON
INTERFACE / LEDs
STATUS INDICATION LEDs
The status indication LEDs are located on the left side of the local pushbutton interface. The applicable status indication LED(s) will illuminate when the “STAT” LED is lit, to reveal the condition(s) as described below. When more than one status LED is required at one time, the illuminated LEDs will cycle rather than illuminate all at once. Refer to the troubleshooting section of this manual for corrective actions that will eliminate system alarms, status indication LEDs from being lit, and the STAT LED from being lit.
DEMAND
The demand signal is outside of the acceptable range of values. (Standard current range is 3.2 - 21.0 mA DC)
POSITION
The internal position signal from the CPS-4 is outside of the acceptable range of values. (Standard voltage is 1.3 - 3.7 volts DC)
TORQUE
The torque sensed at the output shaft of the actuator exceeds the torque alarm threshold. (Standard torque alarm threshold is 105%)
STALL
The drive is in a stall condition and stall protection has been activated.
TEMP °F.
The temperature sensed at the DCM-2 is outside of the acceptable range. (Acceptable range is -40°F to 185°F (-40°C to 85°C)
FB OPEN
The feedback current loop is disconnected, open, or does not sense a load.
UVOLT
The operating voltage is below the rated voltage tolerance (under voltage condition). This LED could also be lit if an individual phase of a three-phase operating voltage is lost.
ACKNOWLEDGE
Temporarily lit when a pushbutton configuration operation is performed to confirm that the pushbutton configuration operation has been completed.
When a status LED is lit the system alarm contact will change state. Indication of the system alarm is available as a dry contact at terminals 12 and 13. The standard factory setting is for the contact to be closed in the normal state and open in an alarm state.
10
Page 11
Group 22
Quick Reference
LOCAL PUSHBUTTON INTERFACE
The five pushbuttons located on the local pushbutton interface are used for simple calibration features. To utilize the pushbuttons, the user must press and hold the calibrate button, then press and hold the button for the desired function. Pressure should be maintained until the “ACKNOWLEDGE” LED lights; this confirms receipt of the pushbutton command. See the calibration section of this manual for further explanation of the calibration procedures.
CAUTION
Pressing the following buttons may change calibration and cause the drive to reposition.
CALIBRATE
As a safety feature, this button must be pressed and held simultaneously with another pushbutton to perform a calibration.
SET POS 100%
Calibrates the DCM-2 to recognize the current output shaft position as the 100% position.
SET POS 0%
Calibrates the DCM-2 to recognize the current output shaft position as the 0% position.
SET DEM 100%
Calibrates the DCM-2 to recognize the currently applied demand signal as the 100% demand signal.
SET DEM 0%
Calibrates the DCM-2 to recognize the currently applied demand signal as the 0% demand signal.
CONTROL END
The control end assembly is comprised of the contactless position sensor (CPS-4), limit switches, and limit switch cams. The control end assembly is located in the actuator’s control end compartment under the cylinder shaped cover. The assembly is installed on the control shaft which is geared into the main output shaft of the actuator. As the output shaft turns it moves the control shaft , the limit switch cams, and the contactless position sensor ferrite core. The control end includes two SPDT auxiliary limit switches (labeled S1 and S2) for customer connection and two over-travel limit switches (labeled CW and CCW). The cams can be adjusted to actuate the auxiliary switches anywhere in the actuator’s range of travel.
CONTACTLESS POSITION SENSOR
(CPS-4)
The contactless position sensor (CPS-4) is a circuit board and sensor assembly that is part of the control end assembly. The CPS-4 provides the DCM-2 with a continuous position signal proportional to the position of the actuator’s output shaft. The CPS-4 is located in the actuator’s control end compartment under the cylinder shaped cover. The position sensing function of the CPS-4 is provided by a ferrite magnetic sensing element. An electronic circuit translates the voltage from the ferrite magnetic sensor into a position signal. The position signal is used by the DCM-2 to determine the actuator’s output shaft position for control and to generate an analog 4-20 milliamp position feedback signal for external use.
CONTROL END / CONTACTLESS POSITION SENSOR
THUMB NUT
THUMB NUT
COUPLING
(Do Not Adjust Set Screws (4))
SWITCH CAMS
AUXILIARY
SWITCH S2
LOCKING SCREW
AUXILIARY
SWITCH S1
CONTACTLESS POSITION SENSOR
CLOCKWISE SWITCH
COUNTER-CLOCKWISE SWITCH
(CPS-4)
PIN CONNECTORS
11
Page 12
MAINTENANCE
Group 22
Quick Reference
COMPONENT REPLACEMENT
The Group 22 was designed modularly for ease of maintenance and parts replacement. The individual components of the actuator are available in replacement parts kits as detailed in the replacement parts kits tables in this section. Each replacement parts kit includes the component(s), necessary hardware, and detailed instructions for installation of the parts.
HOW TO ORDER SPARE PARTS
Any customer replacement kit may be purchased for spare parts, however several kits have been selected by the factory as recommended spares. Contact your Beck Sales Engineer for questions regarding recommended replacement parts particular to your application. Parts may be ordered by mail, telephone, fax or e-mail, with the confirming order sent to the factory.
ROUTINE MAINTENANCE
Beck drives require only a minimum of routine maintenance. At regular plant maintenance intervals, a visual inspection is recommended 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. Check the conduit seals for any moisture penetration and reseal if necessary.
LUBRICATION
The Group 22 control drive has a grease filled gear housing, so periodic lubrication is not required. However, to extend the life of the linkage, rod ends should be lubricated periodically.
GASKETS
During routine service, inspect the cover gaskets for wear or damage. In order to protect internal components, worn or damaged gaskets and O-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.
MOTOR
The motor assembly is not field-repairable and is intended to last for the lifetime of the actuator. Disassembly of the motor will result in a loss of torque that can only be restored by returning the motor to the factory for re-magnetizing. If you suspect a motor problem, contact the factory for assistance.
CAUTION
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. Failure to do so can cause damage to equipment and serious injury or death.
12
RECOMMENDED REPLACEMENT PARTS KITS
Applicable Model
Replacement Kit 22-309 22-409 22-809 KIT P/N
Control End Assembly X X X 12-8061-05
DCM Replacement (1-phase) X
DCM Replacement (1-phase) CE rating X
DCM Replacement (3-phase) X X
DCM Replacement (3-phase) CE rating X X
Gasket Set X X 12-8061-09
Gasket Set X 12-8061-29
Fuse Kit - 8 Amps 22-309 (120 VAC 1-phase ) & 22-409 (208 VAC 3-phase)
*Fuse Kit - 8 Amps DCM & 4 Amps - input 380, 416, 480, 575 VAC ( 3-phase )
*Fuse Kit - 8 Amps DCM & 10 Amps - input 208, 240 VAC ( 3-phase )
X X
X
X
* Select the proper Fuse Kit based on your actuator operating voltage.
12-8061-75
(DCM-2 p/n 12-8224-41)
12-8061-78
(DCM-2 p/n 12-8224-45)
12-8061-85
(DCM-2 p/n 12-8224-51)
12-8061-88
(DCM-2 p/n 12-8224-55)
12-8061-53
12-8061-52
12-8061-51
Page 13
Group 22
Quick Reference
OTHER AVAILABLE REPLACEMENT PARTS KITS
Applicable Model
Replacement Kit 22-309 22-409 22-809 KIT P/N
CPS-4 Switch Assembly X X X 12-8061-06
CPS-4 P.C. Board X X X 12-8061-07
CPS-4 Coupling X X X 12-8061-08
Mounting Shim Set X X X 12-8061-11
Handswitch Assembly X X X 12-8061-12
Capacitor X 12-8061-14
Motor X X 12-8061-01
Handwheel / Dampener X X 12-8061-02
Self Locking Mechanism Rebuild X X 12-8061-69
Motor w/ Hand crank Assembly Replacement X 12-8061-20
Handwheel / Dampener X 12-8061-22
Self Locking Mechanism Rebuild X 12-8061-23
Hand crank Assembly X 12-8061-27
Service Screw Set X X 12-8061-10
Service Screw Set X 12-8061-30
*Fuse Kit - 8 Amps-DCM, & 4 Amps - input 240 VAC ( 1-phase ) X 12-8061-50
Optional Transformer fuse (9 A - 208 VAC) (3 required) X X 11-1372-10
Optional Transformer fuse (8 A - 240 VAC) (3 required) X X 11-1372-09
Optional Transformer fuse (4 A - 380 VAC) (3 required) X X 11-1372-06
Optional Transformer fuse (4 A - 416 VAC) (3 required) X X 11-1372-06
Optional Transformer fuse (4 A - 480 VAC) (3 required) X X 11-1372-06
Optional Transformer fuse (3.5 A - 575 VAC) (3 required) X X 11-1372-08
**Transient Protector (120 VAC, 1-phase) X 12-8061-44
**Transient Protector (240 VAC, 1-phase) X 12-8061-42
**Transient Protector (208 VAC, 3-phase) X 12-8061-43
**Transient Protector (208 VAC, 3-phase) X 12-8061-45
**Transient Protector (240 VAC, 3-phase) X 12-8061-46
**Transient Protector (380 VAC, 3-phase) X 12-8061-54
**Transient Protector (416 VAC, 3-phase) X 12-8061-55
**Transient Protector (480 VAC, 3-phase) X 12-8061-47
**Transient Protector (575 VAC, 3-phase) X 12-8061-48
** Select the proper Transient Protector Kit based on your actuator operating voltage.
Transient Protector
Assembly
(22-309)
Power
Ground
GROUP 22 TRANSIENT PROTECTION
Transient Protector
Assembly
3
2
1
(22-409)
Power
Ground
3
2
1
Transient Protector
Assembly
(22-809)
Power
Ground
13
Page 14
TROUBLESHOOTING
Group 22
Quick Reference
WHERE DO I START?
The Group 22 actuator was designed so the user can quickly diagnose any actuator status conditions causing an interruption in operation. By removing the DCM compartment cover to access the DCM-2, you can view the overview and status indication LEDs. These LEDs provide an efficient means of determining the actuator problem, in many cases without the need for metering equipment. The following matrix lists some of the potential conditions that a user may experience when troubleshooting.
DCM-2
The DCM-2 board is the control center of the drive. Drive configuration and calibration are accessed and set through the DCM-2 board. The DCM-2 has the overview and status indication LEDs that indicate status and alarm conditions. More advanced troubleshooting features may be accessed via HART or serial connection (see respective appendixes in this manual). Reference Menu 8, Diagnostics menu, for troubleshooting with HART and for serial port troubleshooting use the diagnostic commands featured in the serial port appendix. The DCM-2 performs an error based positioning function. It accepts a demand signal, compares it to an internal position feedback voltage provided by the CPS-4, and controls the motor to correct for a difference. The DCM-2 includes four test points for measuring the demand and internal position signal voltages at the DCM-2. The demand signal should measure 1-5 volts DC across test points TP3 (-) and TP2 (+), proportional to the 4-20 mA demand input signal. The raw position signal should measure approximately 1.3 to 3.7 volts DC across test points TP4 (+) and TP1 (-), proportional to the output shaft’s 0-100 degree position (shaft position can be determined by viewing the mechanical index).
STATUS
INDICATION
LEDs
DEMAND
POSITION
TORQUE
STALL
TEMP °F
FB OPEN
UVOLT
ACKNOWLEDGE
TP1
SERIAL
PORT
J3 J3A J3B
10
TP4
1
J5
DCM-2 TESTPOINTS
CPS-4 TESTPOINTS
OVERVIEW
LEDs
FWD
STAT
REV
PWR
R
CALIBRATE
SET POS 100%
SET POS 0%
SET DEM 100%
SET DEM 0%
TP3
INPUT
RESISTOR
R11
TP2
1
14
CPS-4
The output voltage of the CPS-4 ranges from
1.3 to 3.7 volts DC for 100° drive shaft rotation. This can be measured across CPS-4 test points TP3(+) and TP1(-). If the position signal is outside the anticipated range, the “STAT” and “POSITION” LEDs will light, and contacts at terminals 12 & 13 will open if the PositionLOS alarm mask bit is ON (default state). When the Position signal is corrected, the drive will automatically resume normal operation. The 5 volts DC CPS-4 power supply can be measured across test points TP2(+) and TP1(-).
Page 15
Group 22
Quick Reference
CONDITIONS POSSIBLE CAUSES CORRECTIONS
1. No DCM-2 LEDs are illuminated.
2. STAT LED is illuminated. a. A status alarm is active. a. Check the status indication LEDs on
3. DEMAND LED is
illuminated.
4. POSITION LED is illuminated.
5. TORQUE LED is illuminated.
6. STALL LED is illuminated. a. Actuator has been energizing
7. TEMP F LED is illuminated. a. The measured temperature at
a. No power is applied to the
actuator.
b. Incorrect power is applied to the
actuator.
c. Main power fuse/breaker is
blown.
d. DCM-2 malfunction.
a. No demand signal.
b. Applied demand signal is outside
of configured range.
c. Polarity of applied signal wires is
reversed.
a. Position signal voltage generated
by CPS-4 read by the DCM-2 is outside of the configured range.
b. CPS-4 malfunction. c. DCM-2 malfunction.
a. Torque exceeding configured
limit (typically over 105% of rated torque) is being applied to the output shaft.
b. Torque Null and Torque Constant
values are not set correctly.
c. Torque cable is not connected to
DCM-2.
either the FWD or REV motor winding longer than the configured stall timer due to a physical obstruction.
b. The configured stall time is less
than the configured Max Travel Time.
the DCM-2 is outside of the normal operating range of -40° to 185° Fahrenheit.
a. Apply operating voltage to the
operating voltage terminals.
b. Verify correct voltage on actuator
nameplate and ensure that it is applied at the operating voltage terminals.
c. Verify fuse/breaker integrity. Replace/
reset if blown. Find cause of the short circuit.
d. Replace DCM-2.
the local pushbutton interface of the DCM-2. Continue troubleshooting based on the LEDs that are illuminated.
a. Apply a demand signal to terminals 14
(-) & 15 (+).
b. Confirm demand signal value via
HART or by measuring DC voltage across DCM-2 test points TP3(+) & TP2(-). Should see 1-5 volts for 4-20 mA applied signal.
c. Correct the polarity of the applied
control signal wires on terminals 14 (-) & 15 (+).
a. Using HART communicator check the
Position Sensor Setup menu to verify the Present CPS voltage falls within the configured CPS Zero% and Span (typical range 1.3 to 3.7 volts). OR measure DC volts between DCM-2 test points TP4 (+) and TP1 (-) to verify present CPS voltage. If the voltage is outside of the configured range, replace control end.
b. Replace control end. c. Replace DCM-2.
a. Eliminate cause of excessive torque
(i.e. binding damper, improper linkage, etc.)
b. Locate torque null and constant values
inside DCM compartment and set via HART or serial port.
c. Reconnect torque cable to DCM-2.
a. Eliminate the obstruction and reset the
stall by reversing direction on your demand signal, cycling the power, or issuing the stall reset from HART or serial command.
b. Configure the stall time to exceed the
Max Travel Time via HART or serial command.
a. Protect the actuator from the extreme
temperatures below or above the operating range to eliminate the alarm.
15
Page 16
TROUBLESHOOTING
CONDITIONS POSSIBLE CAUSES CORRECTIONS
8. FB OPEN LED is illuminated. a. The position feedback circuit current loop is not complete.
b. The position feedback is
enabled, but not in use.
9. UVOLT LED is illuminated. a. The applied operating voltage is outside of the tolerance (+10%/­15%) of the nameplate operating voltage.
b. A DCM-2 fuse is open. (or
primary transformer fuse on 22­809 is open)
c. A component failure has
occurred on the DCM-2.
10. All LEDs are illuminated or
flashing.
11. The actuator will only move at
a very slow speed when using the handswitch or override terminals.
12. FWD or REV LED illuminated,
drive is not moving, and there are no other status alarms.
13. Drive runs uncontrolled to one
end of travel.
14. Drive will not hold position with
handswitch in STOP.
a. A component failure has
occurred on the DCM-2.
a. The DCM-2 does not detect a
valid position signal from the CPS-4.
b. The drive max travel time is
set to a high value (maximum allowable time is 300 seconds).
a. Handswitch is in the STOP
position.
b. CW or CCW limit switch is open.
a. The CPS-4 is malfunctioning.
b. The DCM-2 is malfunctioning.
a. Self Locking Mechanism (SLM)
is damaged.
a. Ensure the device measuring the
4-20 mA feedback is properly terminated on terminals 16 (-) and 17 (+) and is applying a 0 ­800 ohm load resistance.
b. Disable feedback via HART or
serial command. OR terminate the feedback loop by applying a 0 - 800 ohm load resistance across terminals 16 and 17.
a. Apply the correct operating
voltage to the actuator per the voltage stamped on the nameplate.
b. Replace the open fuse with
the appropriate fuse kit; check page 17 or 19 to identify the appropriate kit for your drive.
c. Replace the DCM-2.
a. Replace the DCM-2.
a. Verify CPS-4 cable connections,
check CPS-4 raw position voltage test points TP3 and TP1 for 1.3 - 3.7 volts DC, check CPS-4 power supply test points TP2 and TP1 for 5 volts DC, and replace control end if necessary.
b. Adjust max travel time via HART
or serial closer to the minimum (30 seconds for 22-309 and 15 seconds for 22-409/22-809).
a. Place the handswitch in the
AUTO position.
b. Verify if the limit switch is set
outside of the electrically calibrated limits, readjust if necessary or replace.
a. Verify CPS-4 cable connections,
check CPS-4 raw position voltage test points TP3 and TP1 for 1.3 - 3.7 volts DC, check CPS-4 power supply test points TP2 and TP1 for 5 volts DC, and replace control end if necessary.
b. Verify the raw position signal
seen by the DCM-2 at test points TP4 and TP1 for 1.3 - 3.7 volts DC. If valid signal is measured, replace DCM-2.
a. Rebuild the SLM assembly.
80-4280-02
Rev. 05.3
16
Page 17
CONDITIONS POSSIBLE CAUSES CORRECTIONS
15. Actuator has a flashing PWR LED on, but does not respond to demand signal, handswitch, or override terminals.
16. HART communications cannot be established with the DCM-2.
a. The emergency override STOP
terminal (21) is connected to the common terminal (18).
b. The safety shutoff circuit is
damaged
c. The handswitch is damaged.
a. The device description (DD) file
is not installed.
b. The HART communicator is
not compatible with Beck equipment.
c. The HART communications
circuit on the DCM-2 is damaged.
a. Remove the connection from
terminal 21 to terminal 18.
b. Contact the factory.
c. Replace the handswitch.
a. Install the Beck MK-2 DD on your
HART device.
b. Utilize a compatible HART
communicator or configure the actuator through the serial port.
c. Replace the DCM-2.
80-4280-02
Rev. 05.3
17. Present CPS voltage appears to be within the configured range, but the position feedback signal at terminals 16 and 17 remains constant or is erratic.
18. Power LED is pulsing bright to dim.
19. Actuator output shaft rotates opposite of the desired direction when applying a 4-20 mA demand signal.
a. The position feedback circuit on
the DCM-2 is damaged.
a. This is a normal condition
indicating that the processor is functioning.
a. The rotation direction is
incorrectly configured.
a. Replace the DCM-2.
a. No action required.
a. Configure the rotation direction
using pushbutton, HART, or serial method. (page 30)
17
Page 18
APPENDIX - HART
FROM MENU 2
HART DEVICE DESCRIPTION (DD) MENU STRUCTURE
Group 22
Quick Reference
1 Functions LINK TO MENU 2 2 Position 0.0%–100.0% 3 Demand 0.0%–100.0% 4 Loop(Dem) 4.00–20.00 mA 5 Trq/Thrust Percentage 6 Temp °F. or °C. 7 Feedback 4.00–20.00 mA
FROM MENU 1
MENU 2 - FUNCTIONS
MENU 1 - ONLINE
1 Setup Checklist LINK TO MENU 3 2 Device Information LINK TO MENU 4 3 Configuration LINK TO MENU 5 4 Statistics LINK TO MENU 6 5 Manual Operation LINK TO MENU 7 6 Diagnostics LINK TO MENU 8 7 Calibration Trim LINK TO MENU 9
FROM MENU 2
MENU 3 - SETUP CHECKLIST
The setup checklist gathers some of the more commonly accessed
parameters and settings in one location for ease of access. All items
in this menu are accessible through the categorized menus that follow.
FROM MENU 2
MENU 4 - DEVICE INFORMATION
1 Tag* Alphanumeric 2 Descriptor* Alphanumeric 3 Message* Alphanumeric 4 Model# Actuator model no. 5 Drive S/N* Number 6 Instld* Date–DD/MM/YYYY 7 Setup* Date–DD/MM/YYYY 8 Calibrtd* Date–DD/MM/YYYY 9 Review LINK TO MENU 15
10 Poll Addr* Integer
FROM MENU 4
MENU 15 - REVIEW
The review menu allows the user to view many
parameters in a read-only format.
FROM MENU 2
MENU 6 - STATISTICS
1 Starts Integer 2 Reversals Integer 3 Stalls Integer 4 OverTorques Integer 5 Pk Torque Percentage 6 TotRunTm Seconds
7 High Temp Degrees
8 Low Temp Degrees
FROM MENU 2
MENU 7 - MANUAL OPERATION
1 Op Mode* Follow, Hold, Stay, Stop 2 Demand* Percentage 3 Reset Stall» Action
FROM MENU 2
MENU 9 - CALIBRATION TRIM
1 PresCPS V* Voltage 2 Loop(Dem)* 4.00 mA, 20.00 mA 3 Feedback* mA 4 Trq/Thrust* Percentage
1 General Setup LINK TO MENU 5A 2 PositionSensrSetup LINK TO MENU 5B 3 Demand Setup LINK TO MENU 5C 4 Feedback Setup LINK TO MENU 5D 5 Torque Setup LINK TO MENU 5E 6 Restore to Factory» Action 7 Use Default Setup» Action
FROM MENU 5
MENU 5A - GENERAL SETUP
MENU 5 - CONFIGURATION
1 Drive Dir* CW Incr or CCW Incr 2 Max Travel* Degrees 3 Travel* Degrees 4 StepSize* 0.100%–2.500% 5 Stall Time* 30–300 (seconds) 6 StallProt* Enabled or Disabled 7 LimitSwitch* Accept or Alert 8 PositionUnit* Degrees
9 Temperature Unit* degF or degC 10 Max Freq* Hertz 11 MaxTravelTm* Seconds 12 Power* 1-phase / 3-phase
FROM MENU 5
MENU 5B - POSITION SENSOR SETUP
1 Set Pos 0%» Action
2 Set Pos 100%» Action
3 PresCPS V Voltage
4 CPS Zero%* 1.000–5.000 v
5 CPS Span Voltage
6 CPS RngLwr Voltage
7 CPS RngUpr Voltage
8 Pos S/N* Number
9 Snsr Dir CW Incr or CCW Incr
FROM MENU 5
MENU 5C - DEMAND SETUP
1 DemRngLwr* 4.00–16.00 mA
2 DemRngUpr* 8.00–20.00 mA
3 Dem Curve* Linear, Square, Square Root,
4 Dem Curve Spcl LINK TO MENU 14
5 LOS Mode* Stay or Go-to-Pos
6 LOS Pos* -5.00%–105.00%
7 DemLimLwr* 0.00–12.00 mA
8 DemLimUpr* mA
FROM MENU 5C
Special
MENU 14 - DEM CURVE SPECIAL
1 DemNode1X* Percentage 2 DemNode1Y* Percentage 3 DemNode 2X* Percentage
FROM MENU 5
4 DemNode 2Y* Percentage
41 DemNode21X* Percentage 42 DemNode21Y* Percentage
. . .
MENU 5D - FEEDBACK SETUP
1 FB RngLwr* 3.00–16.00 mA
2 FB RngUpr* 7.00–21.00 mA
3 Feedback* Enabled or Disabled
4 FB Curve* Linear or InvDem
FROM MENU 5
MENU 5E - TORQUE SETUP
1 Trq/Thrust* Enabled or Disabled
2 Ovt Prot* Enabled or Disabled
3 AlarmLevel* Percentage
4 ShutDwnTrq* Percentage
5 Trq Null* Integer
6 Trq Const* Integer
18
Page 19
Group 22
S
Quick Reference
FROM MENU 2
1 Status LINK TO MENU 8A 2 Tests LINK TO MENU 10 3 CW Torque LINK TO MENU 11 4 CCW Torque LINK TO MENU 11 5 Alarm Setup LINK TO MENU 12 6 RealTimeClock LINK TO MENU 13
FROM MENU 8
1 LED Status LINK TO MENU 8B 2 Operating Status LINK TO MENU 8C 3 Switch Status LINK TO MENU 8D 4 Local Cntrl Status LINK TO MENU 8E 5 Line Freq Hertz 6 CW Inhibitors (1) LINK TO MENU 8F 7 CCW Inhibitors (1) LINK TO MENU 8F 8 CW Inhibitors (2) LINK TO MENU 8G
9 CCW Inhibitors (2) LINK TO MENU 8G 10 DC Volts Bus Voltage 11 PresFreq Motor Frequency
MENU 8 - DIAGNOSTICS
MENU 8A - STATUS
FROM MENU 8A
1 Status ON or OFF 2 Reverse ON or OFF 3 Forward ON or OFF 4 Demand ON or OFF 5 Position ON or OFF 6 Trq/Thrust ON or OFF 7 Stall ON or OFF 8 Temperature ON or OFF
9 FB Open ON or OFF 10 Uvolt ON or OFF 11 Acknowledge ON or OFF
FROM MENU 8A
1 Dem <> Limits ON or OFF
2 Pos <> Limits ON or OFF
3 Temp <> Limits ON or OFF
4 Torq <> Limits ON or OFF
5 Over-Torq Stop ON or OFF
6 Stalled ON or OFF
7 Feedback Open ON or OFF
8 Low Volts AC ON or OFF
FROM MENU 8A
1 Limit CCW ON or OFF
2 Limit CW ON or OFF
3 OvrRd CCW ON or OFF
4 OvrRd CW ON or OFF
5 OvrRd STOP ON or OFF
6 HndSw CCW ON or OFF
7 HndSw CW ON or OFF
8 HndSw AUTO ON or OFF
FROM MENU 8A
1 Calibrate ON or OFF
2 Set Pos 100% ON or OFF
3 Set Pos 0% ON or OFF
4 Set Dem 100% ON or OFF
5 Set Dem 0% ON or OFF
FROM MENU 8A
1 Balance ON or OFF
2 Supervisory ON or OFF
3 Stall ON or OFF
4 OverTrq/Thr ON or OFF
5 Switch Block ON or OFF
6 Bad Pos Sig ON or OFF
7 Bad Dem Sig ON or OFF
8 Local Cal ON or OFF
FROM MENU 8A
1 Inh 1 ON or OFF
2 Ovrd ON or OFF
3 LimSw ON or OFF
4 HndSw ON or OFF
MENU 8B - LED STATUS
MENU 8C - OPERATING STATUS
MENU 8D - SWITCH STATUS
MENU 8E - LOCAL CONTROL STATUS
MENU 8F - CW & CCW INHIBITOR (1)
MENU 8G - CW & CCW INHIBITOR (2)
FROM MENU 8
1 FB Out Test» Action 2 Board Self-Test» Action 3 Identify Device» Action 4 Board Reset» Action
FROM MENU 8
MENU 11 - CW TORQUE / CCW TORQUE
1 Segment 1 Percentage 2 Segment 2 Percentage
. . .
10 Segment 10 Percentage
FROM MENU 8
1 AlarmPol* Drops Out or Pulls In 2 Alarm Mask LINK TO MENU 12A
FROM MENU 8
1 RTC Day* Integer 2 RTC Month* Integer 3 RTC Year* Integer 4 Hour (24)* Integer 5 Minute* Integer
MENU 10 - TESTS
MENU 12 - ALARM SETUP
FROM MENU 12
MENU 12A - ALARM MASK
1 DemandLOS* ON or OFF 2 Trq/Thrust High* ON or OFF 3 Stall* ON or OFF 4 Trq/Thrust Stop* ON or OFF 5 Stop/Limit* ON or OFF 6 FeedbackLOS* ON or OFF 7 Temperature* ON or OFF 8 PositionLOS* ON or OFF
9 RTC Fail* ON or OFF 10 Torq/Thrust/MeasFail* ON or OFF 11 PositionA/D Error* ON or OFF 12 Demand/MeasFail* ON or OFF 13 Reserved 1* ON or OFF 14 PositionLOS* ON or OFF 15 TemperatureMeasFail* ON or OFF 16 MemoryFail* ON or OFF 17 InvalButtonPress* ON or OFF 18 DemandTooHigh* ON or OFF 19 DemUnderHART/FF Ctl* ON or OFF 20 DemUnderPAT Ctl* ON or OFF
MENU 13 - REAL TIME CLOCK
AMPLE MENU BLOCK FORMAT
Previous Menu
1 Parameter Range / Units / Info.
* Parameter names marked with an asterisk indicate that the value may be edited.
» Parameter names marked with a double arrow indicate that the menu item performs a function.
... Indicates that the menu is longer than shown
MENU # - MENU DESCRIPTION
DIAGNOSTICS
19
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