Hamilton Sundstrand Company ACT2000 User Manual

User Manual

ACT2000 All-Electric Actuator

SD-6008 Rev. 6

October 2008

PRECISION ENGINE CONTROLS CORPORATION

This manual provides installation, maintenance, and operating instructions for the ACT2000
All-Electric Actuator.

Every attempt has been made to provide sufficient information in this manual for the
proper operation and preventive maintenance of the actuator. Read this manual in its
entirety to fully understand the system.

Operating the ACT2000 All-Electric Actuator in accordance with instructions herein ensures
long term and reliable operation.

If you need additional information, please contact:

Precision Engine Controls Corporation

11661 Sorrento Valley Road
San Diego, California 92121

[phone] • [phone]

Fax: [phone]

E-mail: [e-mail]

© 2006 PRECISION ENGINE CONTROLS CORPORATION. ALL RIGHTS RESERVED

TABLE OF CONTENTS

Purpose of This Guide ................................................................................................................................... iii

Product Identification...................................................................................................................................... iii

What the User Should Know ......................................................................................................................... iv

Related Publications....................................................................................................................................... iv

1 INSTALLING THE ACT2000 ..................................................................................................................... 1

1.1 Before Beginning..................................................................................................................................... 1

1.2 General Specification Summary............................................................................................................. 3

1.3 Mechanical Installation............................................................................................................................ 4

1.4 Electrical Connections............................................................................................................................. 11

2 UNDERSTANDING THE ACT2000 .......................................................................................................... 21

2.1 System Description ................................................................................................................................. 21

2.2 Electrical Description............................................................................................................................... 21

2.3 Mechanical Description........................................................................................................................... 25

2.4 Identification Plate ................................................................................................................................... 30

3 OPERATING THE ACT2000 ..................................................................................................................... 33

3.1 Powering Up ............................................................................................................................................ 33

3.2 Finding Home Position............................................................................................................................ 33

3.3 Holding Motor Current State................................................................................................................... 34

3.4 Moving to Stop Position .......................................................................................................................... 34

3.5 Controlling Motion ................................................................................................................................... 36

3.6 Resetting the Actuator............................................................................................................................. 39

3.7 Monitoring System Health....................................................................................................................... 39

3.8 Changing Set-Up Parameters ................................................................................................................ 44

4 MAINTAINING THE ACT2000................................................................................................................... 47

4.1 Refurbishment ......................................................................................................................................... 47

5 TROUBLESHOOTING............................................................................................................................... 49

5.1 FAULT File............................................................................................................................................... 52

APPENDIX A: DECOMMISSIONING & DISPOSAL ...................................................................................... 55

APPENDIX B: GLOSSARY ............................................................................................................................. 57

PREFACE i

LIST OF FIGURES

Figure 1-1. ACT2000-590P Dimensions .............................................................................7

Figure 1-2. ACT2000-200F Dimensions ............................................................................. 8

Figure 1-3. ACT2000-590P Pin-Mounting Provisions ........................................................ 9

Figure 1-4. ACT2000-200F Flange-Mounting Provisions.................................................10

Figure 1-5: ACT2000 System Power Wiring Diagram......................................................12

Figure 1-6. Typical Power Connection With Power Supply..............................................12

Figure 1-7. Typical Power Connection With Battery.........................................................12

Figure 1-8: ACT2000 System Signal Wiring Diagram ...................................................... 16

Figure 1-9. Typical Analog Input Connection....................................................................17

Figure 1-10. Typical Analog Output Connection ...............................................................17

Figure 1-11. Typical Discrete Input Command Connection .............................................17

Figure 1-12. Typical Discrete Output Alarm Connection ..................................................18

Figure 1-13. Typical RS232 Serial Interface Connection .................................................18

Figure 2-1. ACT2000 Electronics System Block Diagram................................................23

Figure 2-2. ACT2000-590P Cut-Away View .....................................................................28

Figure 2-3 ACT2000-200F Cut-Away View...................................................................... 29

Figure 2-4. Typical Identification Plate............................................................................... 30

Figure 2-5. Typical Refurbishment Plate ........................................................................... 31

Figure 3-1. ACT2000 Basic Operation Flow Chart...........................................................35

Figure 3-2. Actuator Position vs. DEMAND, Home as Mech. Stop in Actuator ..............37

Figure 3-3. Dead Band of Actuator, Position vs. DEMAND Curve ..................................38

Figure 3-4. Actuator Position vs. DEMAND, Home as Mech. Stop in User’s System ... 38

LIST OF TABLES

Table 1-1. Wire List for ACT2000 Power Harness............................................................11

Table 1-2. Power Supply Requirements............................................................................13

Table 1-3. Wire Size for ACT2000 Power Harness.......................................................... 14

Table 1-4. Wire List for ACT2000 System Signal Harness ..............................................15

Table 1-5. Computer COM Port Pin Outs .........................................................................18

Table 1-6. Wire Size for ACT2000 Signal Harness ..........................................................20

Table 3-1. Default Configuration For FAULT Alarm ..................................................41

Table 3-2. Default Configuration For OVERTEMP Alarm .........................................41

Table 3-3. Fault Configuration For FAULT Alarm ...........................................42

Table 3-4. Fault Configuration For OVERTEMP Alarm ..................................43

Table 3-5. Typical ACT2000 Setup Parameters With Default Values............................. 45

Table 5-1. Initial Installation Troubleshooting Chart.......................................................... 50

Table 5-2. ACT2000 In-Service Troubleshooting Chart ...................................................51

Table 5-3. ACT2000 Electrical Continuity Troubleshooting Chart ...................................51

ii ACT2000 USER GUIDE

Purpose of This Guide

This publication is designed to help the user install, operate, maintain and
troubleshoot the ACT2000 All-Electric Actuator.

Product Identification

Most of the information in this manual is applicable to all generations of
the product. Where unique information applies to a specific generation,
one of the following symbols will be shown to indicate as such:

Fourth generation (isolated RS-232)

Actuator P/Ns: 50026XX-XXX or:

Any Remanufactured Part with Config 116 and above

Configuration: 116 and above

Firmware version: 3.00 and above

Third generation (isolated RS-232)

Actuator P/Ns: 50026XX-XXX or:

Any Remanufactured Part with Config 109 and DP 1028

Any Remanufactured Part with Config 110 and above

Configuration: 110 and above

Firmware version: 2.02 and above

Second generation (non-isolated RS-232)

Actuator P/Ns: 50026XX-XXX

Configuration: Between 105 and 108

Firmware versions: 2.0, 2.1

First generation (non-isolated RS-232)

Actuator P/Ns: 50023XX-XXX

Configuration: earlier than 105

Firmware versions: 1.00, 1.01

PREFACE iii

What the User Should Know

To install, operate, and troubleshoot the ACT2000, it is necessary for the
user to have a fundamental understanding of:

• Electronics concepts, such as voltage, current, and switches

• Mechanical motion control concepts, such as inertia, torque,

velocity, distance, force

Related Publications

• ActWiz Software Operations Manual (p/n SD-6010)

iv ACT2000 USER GUIDE

1 INSTALLING THE ACT2000

1.1 Before Beginning

Inspection

The ACT2000 should be inspected immediately after unpacking. Check
for dings or dents or any other obvious signs of damage. Remove the
protective caps from the connectors and check for any bent pins or
damage to the threads of the connectors. Examine the wires of the signal
and power harnesses for any signs of damage to the wire insulation.

In the event that any damage is detected, contact PECC for instructions
about how to proceed.

Note: Retain the actuator’s original shipping container. In the

event of future transportation requirements, this container
will minimize any damage during shipment.

Recommended Installation Process

Users must determine if it is best to couple the ACT2000 to the load
before or after the installation has been tested.

• Review the general specifications

• Mechanically connect the clevis of the ACT2000

• Mechanically connect the flange (ACT-2000-200F only)

• Mechanically connect the extension rod of the ACT2000

• Connect Case Ground of the ACT2000 to System Ground

• Connect the 4-wire Power Harness of the ACT2000 to the user’s

power supply or battery

• Connect the 17-wire Signal Harness of the ACT2000 to the user’s
controller

• Test the installation

INSTALLING THE ACT2000 1

Electrical Noise Guidelines

PECC has taken the following measures to reduce electrical noise with
the ACT2000:

• High-voltage wires are routed separately from low-level signals
through the use of separate power and signal harnesses.

An additional measure to reduce electrical noise is to:

• Ensure that the ACT2000 is properly grounded, as per
Section 1.4 of this manual.

Environmental Considerations

The ACT2000 operates satisfactorily with ambient air temperature of

-40 °C (-40 °F) to +93 °C (+200 °F), and is designed as an explosion-
proof assembly. The ACT2000 enclosure is Canadian Standards
Association (CSA) Type 3, European IP65.

CAUTION

Solvent/water may enter the electronics area during a high-pressure
wash, which can cause decreased performance or failure of the unit.

2 ACT2000 USER GUIDE

1.2 General Specification Summary

PARAMETER VALUE

Power Input

Voltage Range 80-160 VDC; 120 VDC nominal
Maximum Current 20 A
Typical Transient Current +20A < 60ms; +10A < 600ms; -5A < 100ms
Typical Continuous Current < 1A

Inputs and Outputs

Discrete Inputs

RUN and RESET commands

Discrete Outputs

FAULT & OVERTEMP alarms

Analog Input

DEMAND command signal

Analog Outputs

POSITION & MTR CURRENT feedback

Maximum Common Mode Voltage ±200 VDC User I/O to 120 VDC Return (less serial interface)

Performance All performance values are based on use with ACT2000 in default

Maximum Velocity 10 in/sec
Maximum Continuous Force 500 lbf (100% Duty Cycle)
Maximum Peak Force 1000 lbf (100% Duty Cycle)
Maximum Stroke 5.9 in (ACT2000-590P, configuration dependent)

Accuracy
Mean Time Before Unscheduled Removal 30,000 Hours
Life Cycles 32,000 Minimum

ON Voltage:

12 – 32 VDC,

+24 VDC nominal @ 6.5 mA

OFF Voltage:

OFF Voltage:
Effective ON Resistance
@ ≥ 1.5 VDC:

Current: 4 to 20 mA; 25 mA Maximum
Voltage: 5 VDC Maximum
Internal Impedance: 200 Ώ

Current: 4 to 20 mA
External Load Resistance: 300 Ώ, Maximum

configuration. Any changes to ACT2000 firmware settings to change stroke
profile will alter performance values.

2.0 in (ACT2000-200F, configuration dependent)

± 1% Full Stroke

1.0 VDC, maximum

32 VDC maximum @ 150 µA typical

1.1 kΏ, nominal

Environmental

Temperature, Operating Ambient:
Temperature, Storage

-40° C (-40° F) to +93° C (+200° F)

-40° C (-40° F) to +125° C (+257° F)

Environmental Rating Rated to CSA Type 3 and European IP65

Sealed against dust, protected against water

EMC Meets EN 50081-2 and EN50082-2 for DC powered industrial equipment
Vibration Meets Mil-Std-810E, Category 4 (5 – 2000 Hz)

INSTALLING THE ACT2000 3

Certifications

North American Certifications CSA Class I, Div 1, Group B, C, D; T4
European Directive Compliance (CE Mark)

EEx d, IIB+H
94/9/EC Potentially Explosive Atmospheres (ATEX) 08 ATEX 6108 X

(replaces 02ATEX6050X)
98/37/EC Machinery Directive
89/336/EEC Electromagnetic Compatibility Directive (EMC)

Materials

Housing 6061-T6 Anodized Aluminum
Conduit Union Zinc Plated Steel
Extension Rod 17-4 PH CRES
Clevis 17-4 PH CRES
Seals Nitrile, RTV and Teflon
Rod End Bearings Aluminum Bronze
Connectors Aluminum

Dimensions 5.2 in x 6.5 in x 16.7 in (ACT2000-590P)

6.0 in x 10.0 in x 12.9 in (ACT2000-200F)

Weight 35 lbs (ACT2000-590P)

50 lbs (ACT2000-200F)

; T4

2

1.3 Mechanical Installation

This section describes proper ACT2000 installation. Ensure compliance
with the factory recommendations.

Dimensions

The ACT2000 can be mounted with any directional orientation, whether
horizontal, vertical, or at an angle. Figures 1-1 and 1-3 show external
dimensions and mounting provisions for the pin-mount version of the
ACT2000. Figures 1-2 and 1-4 show external dimensions and mounting
provisions for the flange-mount version. Ensure that additional swing
clearance is factored into mounting calculations, as required.

Lifting Hazard – Do not attempt to hand-lift the actuator. Use
appropriate lifting equipment.

WARNING

4 ACT2000 USER GUIDE

Connecting the Clevis

The ACT2000 features a clevis for securing the motor end of the actuator.
A high-strength shoulder bolt (0.375” diameter) is recommended to fasten
the actuator to a user-provided mount bracket.

The clevis can be rotated to any orientation to support installation. Loosen
the four retaining screws and rotate to the desired angle. The screw
pattern can be indexed ± 45 degrees to provide additional adjustment.
When adjustments are complete, torque the four retaining screws to
117-138 in-lbs.

WARNING

Explosion Hazard – Do not remove the clevis. Removing the clevis
violates the warranty.

Care should also be taken when rotating the clevis or indexing the
screw pattern to avoid scratching the flame path or introducing
particulates to the assembly.

Connecting the Flange (ACT2000-200F only)

The ACT2000-200F can be flange mounted to a valve or other device.
The ACT2000-200F features eight (8) unthreaded through-holes situated
along the length of the actuator chassis. Use ¼ - 20 x ⅞” bolts to pass
through both the actuator chassis and the valve flange to secure the
ACT2000-200F in place.

Connecting the Extension Rod

The extension rod has a 0.375-24 UNF-3B female thread for connecting
user-supplied end attachments with a 0.375-24 UNF-3A male thread. A
spherical rod-end bearing attachment that will minimize any non-axial
forces on the extension rod as it extends and retracts is preferred.

INSTALLING THE ACT2000 5

Note: It is important that user-supplied end attachments and

connecting hardware align properly with the axis of the
extension rod. Any misalignment will result in a side load on
the extension rod (force applied perpendicular to the axis of
extension rod) as it extends and retracts. Such a side load
will reduce the efficiency of the ACT2000, requiring more
electrical current to achieve a given amount of force or
torque. A side load will also increase the mechanical stress
and friction, increasing the rate of wear on the ACT2000.

The extension rod has wrench flats to counteract mounting hardware
installation torque.

WARNING

Property Damage Hazard – Always use the extension rod wrench
flats when installing mounting hardware. Failure to use the wrench
flats may damage or break the internal anti-rotation guide.

When no power is applied to the ACT2000, its extension rod can be
moved manually, if necessary. Approximately 60 to 100 lbf is required to
extend or retract the extension rod. A rod guide is provided internally to
prevent extension rod rotation.

WARNING

Property Damage Hazard – Do not attempt to rotate the extension
rod. This may damage the internal anti-rotation guide and void the
warranty.

6 ACT2000 USER GUIDE

Figure 1-1. ACT2000-590P Dimensions

INSTALLING THE ACT2000 7

Figure 1-2. ACT2000-200F Dimensions

8 ACT2000 USER GUIDE

Figure 1-3. ACT2000-590P Pin-Mounting Provisions

INSTALLING THE ACT2000 9

Figure 1-4. ACT2000-200F Flange-Mounting Provisions

10 ACT2000 USER GUIDE

1.4 Electrical Connections

The ACT2000 is suitable for use in hazardous locations. See the General
Specification Summary in Section 1.2 for certifications. Ensure compliance
with the factory recommendations, and that wiring is in accordance with
local requirements.

WARNING:

94/9/EC (ATEX) Compliance – Special Conditions for Safe Use:

Two special factory-sealed unions are mounted on the equipment to
ensure the electrical connection to the network and to provide the
feedback signal to the user.

The installation of these devices and the final connections to the
conduit shall comply with the requirements of the European
standards.

Ground Connection

The case of the ACT2000 features a threaded hole (0.250-20 UNC-2B
female thread) that is dedicated for the ground connection. This hole has
been left unpainted and uncoated to ensure a good electrical contact. On
the pin-mounted version (ACT2000-590P), this threaded hole is located
on the underside of the unit below the identification plate (see Figure 1-3).
On the flange-mounted version (ACT2000-200F), this threaded hole is
located on the clevis end of the unit (see Figure 1-2). Use a screw with a

0.250-20 UNC-2A thread to connect the case of the ACT2000 to the
same ground plane as the user’s controller.

Power Connections

The ACT2000 operates on a 120VDC (nominal), user-provided input
voltage, which is supplied to the unit through the integral four-wire power
harness. The length of the power harness is 90 inches. See Table 1-1 for
the wire list for the ACT2000 power harness. See Figure 1-5 for the
ACT2000 system power wiring diagram. See Figure 1-6 for a typical
power connection with a power supply. See Figure 1-7 for a typical power
connection with a battery.

WIRE COLOR FUNCTION AWG

RED Power 14

WHITE/RED Power (AUX) 14

GREEN Power Return 14

WHITE/GREEN Power Return (AUX) 14

Table 1-1. Wire List for ACT2000 Power Harness

INSTALLING THE ACT2000 11

Figure 1-5: ACT2000 System Power Wiring Diagram

POWER SUPPLY

120 VDC

ACT2000 120 VDC INPUT

PWR (RED)

+
_

50,000 µF

FUSE

PWR AUX (WHT/RED)

PWR AUX RTN (WHT/ GRN)

PWR RTN (GRN)

Figure 1-6. Typical Power Connection With Power Supply

Figure 1-7. Typical Power Connection With Battery

WARNING - Shock Hazard

Connect both the 120 VDC power and auxiliary wires. If only the
primary power wires are connected, the 120 VDC auxiliary power
wires are electrically live and must be insulated on the ends.

12 ACT2000 USER GUIDE

Note: A battery system is recommended for highest reliability.

Note: If a 120 VDC power supply is used rather than a battery,

ensure an output capacitance of at least 50,000 µF, which
can both sink and source electric current. See Power
Supply Requirements (Table 1-2).

Note: Use a separate conduit for the power wiring. This prevents

noise pickup and transmission from ancillary equipment,
which could cause instability in the actuator.

Power Supply Requirements

Table 1-2 below lists the power supply requirements for the ACT2000.

PARAMETER VALUE

Voltage

Nominal
Range

Max. Ripple

Current

Maximum
Continuous , Typical
Transient, Typical

*Output Capacitance

120 VDC
80 – 160 VDC

4 VAC RMS or 12 VAC p-p

20 Amps
<1 Amp
+20 A <60 ms
+10 A <600 ms

-5 A <100 ms

50,000 µF (typical)

Table 1-2. Power Supply Requirements

*The output capacitance applies for non-battery power systems and assumes full-stroke step
changes in actuator position at rated load. This value is typical. The actual value required is
dependent on the user’s specific DC power system design, including:

• Power sources used in the DC power system (their output impedance, transient response,
rating, diode decoupling [if any], topology, etc.)

• All electrical loads and components connected to each respective power bus branch

• Switching relationships of these electrical loads and components to each other (for example,

does a large motor and actuator turn off at about the same time, etc.)

• Bus branch conductor length and arrangement (flat bus bars, round cables, twisted, etc.)

INSTALLING THE ACT2000 13

Therefore, it is not possible to correctly state a single capacitance value that should be placed on
the bus. It may require no added bus capacitance or hundreds of thousands of microfarads of
capacitance. A typical output capacitance value used for non-battery power systems is 50,000uF,
but the actual value depends on the specific power system as discussed above.

It is best to test the power system for adequate capacitance by executing full-stroke step changes
with the actuator at the same time as all other devices on the bus are switched and measuring the
bus voltage at the actuator power input point to verify that it does not dip below the minimum or
exceed the maximum bus voltage specifications. This test should be performed at both the
minimum and maximum expected operating voltages

Also, the output capacitance should be carefully positioned so that it is never disconnected from
the ACT2000 power input during any contact or switching operations.

Recommended Wiring for System Power

The recommended wire for connecting to system power is a two­conductor shielded cable containing twisted-pair wires with individual
shields. Use a wire size large enough to accommodate the installation
and provide a maximum one (1) ohm loop resistance. See Table 1-3
(below) for recommended wire sizes.

DISTANCE TO
USER POWER

≤ 500 ft. AWG 10, stranded

> 500 ft. Consult Factory

RECOMMENDED WIRE SIZE

(Minimum)

Table 1-3. Wire Size for ACT2000 Power Harness

WARNING

Explosion Hazard – Do not connect or disconnect while circuit is
live. For US Group B hazardous locations, an explosion proof seal
must be placed within 18 inches.

CAUTION

Disconnect all ACT2000 connections prior to welding.

14 ACT2000 USER GUIDE