Honeywell HERCULINE 2000 User Manual

HercuLine® 2000 Series Actuator

Installation, Operation and

Maintenance Manual

Doc. No.: 62-86-25-10

Revision: 7

Date: 7/08

Honeywell Field Solutions

Notices and Trademarks

Revision 7 July 2008

Warranty/Remedy

Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a particular purpose. Specifications may change without notice. The information we supply is believed to be accurate and reliable as of this printing. However, we assume no responsibility for its use.

While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the customer to determine the suitability of the product in the application.

CE Conformity

This product conforms with the protection requirements of the following European Council Directive: 89/336/EEC, the EMC directive and 73/23/EEC, the Low Voltage Directive. Conformance of this product with any other “CE Mark” Directive(s) shall not be assumed.

Attention

The emission limits of EN 50081-2 are designed to provide reasonable protection against harmful interference when this equipment is operated in an industrial environment. Operation of this equipment in a residential area may cause harmful interference. This equipment generates, uses, and can radiate radio frequency energy and may cause interference to radio and television reception when the equipment is used closer than 30 m to the antenna(e). In special cases, when highly susceptible apparatus is used in close proximity, the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment.

Honeywell Process Solutions

512 Virginia Drive

Fort Washington, PA 19034

HercuLink® and HercuLine® are trademarks of Honeywell

Other brand or product names are trademarks of their respective owners.

Palm is a trademark of Palm Inc.

ii HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

About This Document

Abstract

This manual describes the installation, set up, operation, maintenance, and troubleshooting of the HercuLine 2000 series actuators.

References

The following list identifies all documents that may be sources of reference for material discussed in this publication.

Document Title Doc ID

HercuLine 2000 Series Actuator Specification 61-86-03-14

HercuLine 2000 Series Actuator Model Selection Guide 62-86-16-21

Modbus® RTU Serial Communications User Manual

Modbus Configuration/Remote Calibration Interfaces for HercuLine Actuators

HercuLink™ User Manual 62-86-25-11

HART Communications Installation and Operations Manual 62-86-25-12

RTU Serial Communications User Manual

51-52-25-66

51-52-25-103

Contacts

World Wide Web

The following lists Honeywell’s World Wide Web sites that will be of interest to our customers.

Honeywell Organization WWW Address (URL)

Corporate

Honeywell Process Solutions http://www.honeywell.com/ps

Telephone

United States and Canada Honeywell

Organization Phone Number

http://www.honeywell.com

1-800-423-9883 Tech. Support 1-800-525-7439 Service

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual iii 7/08

Symbol Definitions

The following table lists those symbols that may be used in this document to denote certain conditions.

Symbol Definition

This DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

This WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

This CAUTION symbol may be present on Control Product instrumentation

and literature. If present on a product, the user must consult the appropriate part of the accompanying product literature for more information.

This CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may result in property damage.

WARNING

PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a

potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms,

42.4 Vpeak, or 60 Vdc may be accessible. Failure to comply with these instructions could result in death or serious injury.

ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for handling electrostatic sensitive devices

Protective Earth (PE) terminal. Provided for connection of the protective earth (green or green/yellow) supply system conductor.

Functional earth terminal. Used for non-safety purposes such as noise immunity improvement. NOTE: This connection shall be bonded to protective earth at the source of supply in accordance with national local electrical code requirements.

Earth Ground. Functional earth connection. NOTE: This connection shall be bonded to Protective earth at the source of supply in accordance with national and local electrical code requirements.

Chassis Ground. Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements.

iv HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Contents

Introduction .............................................................................................1

Product Description ......................................................................................................1

Specifications .......................................................................................... 5

Technical and Operating Specifications.......................................................................5

Model Selection Guide ...............................................................................................10

Installation ............................................................................................. 12

Installation Overview ..................................................................................................12

Mechanical Stops .......................................................................................................12

Before Starting............................................................................................................13

Contents

Actuator Mounting ......................................................................................................13

Mechanical Installation ...............................................................................................15

Electrical Installation...................................................................................................17

Burner Control/Flame Safety................................................................. 23

Series 90 Control – HercuLine

Split Range .................................................................................................................26

Master/Slave Arrangement.........................................................................................26

2001 model only......................................................24

Set Up and Calibration Procedures....................................................... 31

Overview.....................................................................................................................31

Local Display and Keypad..........................................................................................31

Set Up Tips.................................................................................................................33

Set Up Groups............................................................................................................34

Set Up Procedure .......................................................................................................36

Configuration Prompt Hierarchy .................................................................................38

Input Set Up Group.....................................................................................................39

Relays Set Up Group..................................................................................................44

Current Out Set Up Group..........................................................................................49

Communications Set Up Group..................................................................................50

Digital Input Set Up Group .........................................................................................51

Display Set Up Group.................................................................................................52

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual v 7/08

Contents

Lock Set Up Group .....................................................................................................53

Read Status Set Up Group.........................................................................................55

Drive Set Up Group ....................................................................................................56

Maintenance Set Up Group........................................................................................59

Regions of Motor Travel .............................................................................................62

CAL POSOUT Group .................................................................................................63

Auto - Manual Drive Switch ........................................................................................64

Calibration ..................................................................................................................65

Setting End-of-Travel Limit Switches .........................................................................78

Setting Auxiliary Switches ..........................................................................................81

Start-Up/Operation ................................................................................ 83

Introduction.................................................................................................................83

Power-up Diagnostics.................................................................................................83

Operations Checklist ..................................................................................................83

Operating Displays .....................................................................................................84

Motor Stall ..................................................................................................................84

Position Sensor Operation .........................................................................................85

Remote Setpoint Operation........................................................................................85

Maintenance.......................................................................................... 87

Introduction.................................................................................................................87

Basic Maintenance .....................................................................................................87

Replacement Procedures...........................................................................................89

Replacement/Upgrade/Accessory Kits ..................................................91

Replacement Kits .......................................................................................................91

Upgrade Kits.............................................................................................................102

Accessory Kits ..........................................................................................................104

Troubleshooting .................................................................................. 105

Introduction...............................................................................................................105

Troubleshooting Procedures ....................................................................................106

Appendix A - HercuLine

2001/2002 Configuration Record Sheet...... 112

Index ...................................................................................................116

vi HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Contents

Tables

Table 1 Specifications - General.............................................................................................................................5

Table 2 Recommended Minimum Wire Size........................................................................................................17

Table 3 Terminal Connections: HercuLine® 2000...............................................................................................18

Table 4 Terminal Connections: HercuLine® 2001/2002 with auto/manual.........................................................19

Table 5 Split Range Set Up Procedure .................................................................................................................26

Table 6 Keypad Description.................................................................................................................................32

Table 7 Set Up Tips..............................................................................................................................................33

Table 8 Set Up Groups .........................................................................................................................................34

Table 9 Set Up Procedure Using Display and Keypad.............................................................................. ...........36

Table 10 Input Set Up Group Parameters.............................................................................................................39

Table 11 Equal Percentage Valve Characteristics................................................................................................42

Table 12 Quick Opening Valve Characteristic.....................................................................................................43

Table 13 Relay Set Up Group Parameters............................................................................................................44

Table 14 Relay Type Descriptions........................................................................................................................45

Table 15 Current Out Set Up Group Parameters..................................................................................................49

Table 16 Communications Set Up Group Parameters ..........................................................................................50

Table 17 Digital Input Set Up Group Parameters.................................................................................................51

Table 18 Display Set Up Group Parameters.........................................................................................................52

Table 19 Lock Set Up Group Parameters.............................................................................................................53

Table 20 Read Status Set Up Group Parameters ..................................................................................................55

Table 21 Drive Set Up Group Parameters............................................................................................................56

Table 22 Maintenance Set Up Group Parameters.................................................................................................59

Table 23 CAL POSOUT Group Parameters.........................................................................................................63

Table 24 Auto - Manual Switch Functions...........................................................................................................64

Table 25 Input Calibration Procedure...................................................................................................................69

Table 26 Motor Calibration Procedure.................................................................................................................70

Table 27 Output Calibration Procedure................................................................................................................ 71

Table 28 Slidewire Emulation Calibration Procedure..........................................................................................73

Table 29 NCS Position Sensor Calibration Procedure.........................................................................................74

Table 30 Potentiometer Position Sensor Calibration Procedure..........................................................................76

Table 31 Load Position Sensor Factory Calibration.............................................................................................77

Table 32 End-of-Travel Limit Switch Setting Procedure.....................................................................................79

Table 33 Auxiliary Switch Setting Procedure ...................................................................................................... 82

Table 34 Typical Operating Displays...................................................................................................................84

Table 35 Spur Gear Lubrication Procedure..........................................................................................................87

Table 36 Motor Drive Fuse Replacment Procedure .............................................................................................89

Table 37 Relay PWA Replacement Procedure.....................................................................................................90

Table 38 Replacement kits....................................................................................................................................96

Table 39 Observable Symptoms of Failure........................................................................................................105

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual vii 7/08

Contents

Figures

Figure 1 HercuLine® 2000 Series Actuator 2 Figure 2 HercuLine® 2002 Actuator Internal View 3 Figure 3 Outline and Dimensions of HercuLine® 2000 Series Actuators 14 Figure 4 Constant Torque Linkage 15 Figure 5 Variable Torque Linkage 16 Figure 6 Standard crank arm 16 Figure 7 Crank arm with optional ball joint and push rod 16 Figure 8 HercuLine® 2000 connections 18 Figure 9 HercuLine® 2001/2002 connections 19 Figure 10 HercuLine® 2003 connections 20 Figure 11 CE wiring part 1 21 Figure 12 CE Wiring part 2 22 Figure 13 Burner Control/Flame Safety Wiring 23 Figure 14 Series 90 connections 24 Figure 15 T775 Controller connections 25 Figure 16 Flow Diagram 27 Figure 17 Interconnection Diagram 27 Figure 18 Proportional Flow Using Multiple Actuators 28 Figure 19 Multiple Actuator Interconnection Diagrams 29 Figure 20 Interconnection Diagrams 30 Figure 21 HercuLine® 2000 Display and Keypad 31 Figure 22 Relay connectors 46 Figure 23 Regions of Motor Travel 62 Figure 24 Auto - Manual Switch 64 Figure 25 Calibration Wiring Connectio ns ( no n -sl i dewire emulation) 66 Figure 26 Calibration Wiring Connections (slidewire emulation) 67 Figure 27 Jumper Location on CPU PWA 68 Figure 28 Location of NCS Assembly 75 Figure 29 Location of potentiometer position sensor 77 Figure 30 End of Travel Limit Switch Settings 78 Figure 31 Location of End-of-Travel Limit and Auxiliary Switches 80 Figure 32 Auxiliary Switch Settings 81 Figure 33 Terminal Block Connections for Modbus Communications 86 Figure 34 Spur Gear Location 88 Figure 35 Power Distribution PWA and Relay PWA Locatio ns 89 Figure 36 Motor Drive Circuit Fuses 90 Figure 37 Replacement Kits 6, 7, 8, 11, 12, 14 91 Figure 38 Replacement Kit 10 92 Figure 39 Replacement Kits 1, 2, 3, 4, 5, 9, 15, 16, 19 93 Figure 40 Replacement Kit 13 94 Figure 41 Replacement Kits 17, 18 95 Figure 42 Test for Actuator Operation 107 Figure 43 Power Up Diagnostics 108 Figure 44 Test Power Distribution PWA 109 Figure 45 Test AUTO - MANUAL Switch 110 Figure 46 Test Relay Function 111

viii HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Product Description

Introduction

Product Description

Introduction

Honeywell’s HercuLine® 2000 series actuators are available in four versions: HercuLine® 2000, HercuLine

actuators incorporating all of the high quality and reliable features of the traditional HercuLine actuators. These precision control and high reliability actuators ensure processes operate at maximum efficiency, with minimal downtime, and lowest lifetime cost.

Honeywell's HercuLine accurate positioning, and low maintenance ( and quarter turn valves the HercuLine demanding environments requiring continuous-duty, high reliability, and low maintenance.

Model distinctions

HercuLine

proportional with 135 or 1000 ohm feedback.

HercuLine

or digital control. They offer digital electronics providing for precision positioning control, easy set-up and configuration, on board health monitoring, and network communications. Programming access is provided through our HercuLink communications or through the optional local keypad and display.

HercuLine

used for more severe service applications requiring features such as non-contact position sensing.

HercuLine

The keypad and display are available on the HercuLine additional charge.

2001, HercuLine® 2002, and HercuLine® 2003. All are low torque, precision electric rotary

2000 series actuators are precision engineered for exceptional reliability,

Figure 1). Designed for very precise positioning of dampers

2000 series actuators perform especially well in extremely

series

2000 series actuators are used in applications requiring on/off or power to open/close position

2001 and 2002 are smart actuators used in applications requiring current proportional control

Palm PDA software connected to the actuator via a 232/485 converter, via HART

2002 smart actuators offer features and functions similar to the HercuLine® 2001 and are

2003 actuators are unidirectional/ 360 degree rotation, special purpose actuators.

2001 and HercuLine® 2002 products at

HercuLink

Software

HercuLink standard with the HercuLine

Computer software enables access to programming and communication functions available as

2001 and 2002 actuators without the added expense of the keypad &

display HMI. Using a Palm™ PDA, laptop PC or desktop computer, HercuLink

software, and a RS232/485 converter users may configure, calibrate, and access maintenance information locally or remotely to the actuator.

Using HercuLink access information to/from the actuators and to control the device. Set-up configurations may also be stored on the computer for download to other HercuLine

software, the computer may be used as a master device over a Modbus network to

devices. Information may be stored on the users

PC in CSV format for use in preventative maintenance programs.

• Certified on Palm™ m125, m130, and m505.

• Compatible with Palm OS3.5 or higher.

• Compatible with Windows 2000 or XP operating systems

• Minimum system requirements:

• Windows 2000 (w/service pack 2), Windows NT (w/service p a ck 5), Windows ME, Windows XP

• 200 MHz Pentium with 64 Megs Ram

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 1 7/08

Introduction Product Description

Display and keypad

Handwheel

Conduit entry

Shaft and position indicator

Auto/manual switch

Figure 1 HercuLine

2000 Series Actuator

2 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Introduction

Product Description

Display

Display Keypad

Keypad PWA

PWA

TB3

TB3 Connector

Connector for customer

for customer input and

input and output

output connection

connection on CPU

on CPU PWA

PWA

Wiring

Wiring Label

Label

Mechanical Stops

Cams and

Cams and limit

limit switches

switches

TB1

TB1 customer

customer power

power connection

connection

External

External auto-manual

auto-manual switch

switch

Relay PWAs

Non-contact

Non-contact sensor

sensor

Figure 2 HercuLine

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 3 7/08

2002 Actuator Internal View

Introduction Product Description

4 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Specifications

Technical and Operating Specifications

This section provides you with the technical specifications and the model selection guide for the HercuLine

2000 Series Actuators.

Technical and Operating Specifications

Table 1 Specifications - General

Physical

Weight

Enclosure

Gear Train

Mechanical Stops

Storage Temperature Relative Humidity Scale

2000: 25 lb. (11.36 kg) 2001,2002: 27 lbs. (12.27 kg)

Precision-machined die cast aluminum housing, finished in light gray powder coat epoxy.

Alloy steel, high efficiency steel spur gear primary train. Precision ground, selflocking/self releasing worm gear final mesh.

Factory set at 90° or 150° (+/-5°).

Attention: Do not adjust the mechanical Stops. Adjusting the stops will void the warranty

–40 °C to +93 °C (–40 °C to +200 °F)

0 % to 99 % R.H. non-condensing over the full operating temperature range.

0 % to 100 % corresponding to full crank arm travel.

Crank Arm

Output Shaft Rotation Manual Handwheel

Lubrication

Output Torque/Full Travel Stroking Time

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 5 7/08

Adjustable radii 1.0 in (25.4mm) to a maximum of 2.8 in (71.1mm). Position adjustable through 360° rotation.

0.625+/-.005 in (15.88 +/-.13mm) diameter

90° or 150° degrees between 0 % and 100 % on scale, limited by mechanical stops.

Provides a means of positioning the actuator in the event of a power failure or setup.

Texaco Starplex 2 EP Grease

Torque lb-in (N M)

50 / (6.0) 100 / (11.5) 200 / (22.5) 400 / (45.0) 400 / (45.0)

4.5 / 7.5 9 / 15 18 / 30 36 / 60 54 / 90

50 Hz (90°/150°)

60 Hz (90°/150°)

4 / 6 7 / 12 15 / 25 30 / 50 45 / 75

Specifications Technical and Operating Specifications

Electrical

Mains Supply

Motor

Motor Current Loss of Power Local Auto/Manual Switch End of travel Limit

Switches Auxiliary Switches/Relays

Approvals

Enclosure Rating

Clamp Bolt

100-130 Vac single phase, 50 Hz or 60 Hz 200-240 Vac single phase, 50 Hz or 60 Hz

Instant start/stop, non-coasting, non-burnout, continuous duty, permanent magnet, synchronous induction motor. Can be stalled up to 100 hours without damage.

= No load = full load = locked rotor = 0.4 amp for 120Vac, 0.2 amp for 240 Vac

Stays in place on loss of power

Optional – Allows local and automatic operation of the actuator.

Standard – adjustable to limit actuator travel to less than 90 or 150 degrees respectively

Optional – Up to 4 additional SPDT switches rated at (10 A at 125 Vac, 5 A at 250 Vac).

Certifications

CSA/UL (Standard) CE Compliant (optional)

Type 4 (NEMA 4), IP66 (standard)

Torque Settings of Crank Arm Bolts

88 lb-in (10 N-m)

Electrical and Performance Specifications

HercuLine® 2002 HercuLine® 2001 HercuLine® 2000/2003

Input Signals

Isolation Load Requirement (4-20) Input Impedance

Feedback

Analog:

• 0/4 to 20 mA (With CPU

PWA jumper in current position)

• 0/1 to 5 Vdc

• 0 to 10 Vdc

Digital:

• Modbus RTU (RS485)

Analog:

• 0/4 to 20 mA (With CPU

PWA jumper in current position)

• 0/1 to 5 Vdc

• 0 to 10 Vdc

• Series 90 control

Digital:

• Modbus RTU (RS485)

120 vac drive open/120 vac drive close

240 vac drive open/240 vac drive close

Input signal, output signal and power are isolated from each other. NA Current Out — 0 to 1000 ohms NA

0/4 to 20 mA

0/1 to 5 Vdc

250 ohms

10 K ohms

0-10 vdc

0 to 20 mA, 4 to 20 mA

0 to 5 Vdc & 1 to 5 Vdc with 250 ohm resistor, (0 to 16 Vdc with 800 ohm resistor)

Dual output 1000 ohms over 90 degrees (135 ohms with 158 resistor)

Dual output 1000 ohms over 150 degrees (135

ohms with with 158 resistor)

6 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

HercuLine® 2002 HercuLine® 2001 HercuLine® 2000/2003

Feedback Slidewire emulation - Provides

output voltage ratiometric to shaft position and potentiometric to supply voltage (1 Vdc to 18 Vdc) without a slidewire. Emulates a 100 ohm to 1000 ohm slidewire. 10 mA output maximum.

Communications Operating Temperature

Position sensing

Sensitivity Hysteresis Deadband Repeatability Repositions

(minimum @ 90 or 150 degree stroke)

Table 1 option –050Table 1 option –100Table 1 option –200Table 1 option –400Table 1 option –600-

Modbus RTU or optional HART™

–40°C to +75 °C (–40°F to +170 °F)

Non-contact position sensor 1000 ohm film potentiometer

0.2 % to 5 % of 90° span, proportional to deadband NA Less than 0.4 % of full scale

0.2 % to 5 % of 90° span, programmable. Shipped at 0.5 % NA

0.2 % of 90° span NA

160

290 450 700

900

Specifications

Technical and Operating Specifications

120 250 400 400

400

-40°C to +85 °C (-40°F to +185 °F)

Dual 1000 ohm film potentiometers (not on 2003)

500

Voltage/ Supply Stability

Temperature Coefficient

Zero Suppression Input Filters Solid State Motor

Control Failsafe operation If input signal exceeds configured input range. Selectable and

Direction of Rotation Duty Cycle

0.25 % of span with +10/–15 % voltage change NA

Less than ± 0.030 % of span per degree C for 0 °C to 50 °C

Less than ± 0.05 % of span per degree C for –40 °C to 75 °C 90 % of span. NA Selectable spike and low pass filters. NA

Two triac switches for clockwise or anti-clockwise motor operation.

Transient voltage protection provided.

adjustable. Field programmable Wire swap

Continuous

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 7 7/08

Specifications Technical and Operating Specifications

HercuLine® 2002 HercuLine® 2001 HercuLine® 2000/2003

Programmable

Selectable and configurable operating parameters: NA

Functions

• Input range

• Input filtering

• Input characterization

• Security

• Digital Input action

• Deadband

• Failsafe on loss of input signal

• Failsafe on loss of position sensor

• Direction of rotation

• Relay closure action

• Communication parameters

• Split range operation

• Output range

• Alarms

Specifications – Local Display and Keypad

Display

Display Design

Multi-segment LED displays that provides up to ten alphanumeric characters. Display arrangement consists of two rows:

row (Upper display) – four characters

2nd row (Lower display) – six characters.

LED indicators Six single LEDs provide actuator status and alarm indications. Display Operating

Temperature

-30 °C to +50 °C (-20 °F to +122 °F) Automatically shuts off when operating temperature exceeds +50 °C

Storage Temperature -40 °C to +93 °C (-40 °F to +200 °F)

Keypad

Keys

Six single pushbutton keys allow access to all status displays and set up group parameters.

See Set Up and Calibration Procedures (page 31) for detailed information on display and keypad functions.

8 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Technical and Operating Specifications

Specifications – Communications

Communications

Specifications

Communications Option

Connection Twisted pair cable with shield Maximum loop length 600 meters (2000 feet) Communication Mode Half duplex Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19.2K

RS 485 Serial Communication, Modbus RTU Protocol

Required Specifications – PDA (customer provided)

PDA

Operating System Palm OS version 3.5 or greater RAM At least 8 MB Communications Serial port with RS232 compatible levels to drive external converter

Note: As of this writing only Palm devices have this feature. Honeywell has qualified the M105, M125, M130, and M505 devices with the HercuLink application.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 9 7/08

Specifications

)

Model Selection Guide

Instructions

Select the desired key number. The arrow to the right marks the selection available. Make the desired selections from Tables I thru VIII using the column below the arrow. A dot ( ) denotes unrestricted availability.

Key Number V VI VII VIII IX

- - - - - _ _ - _ _ _ _ _ _ - _

_ _ __ _ _ _

_ _ _

III

_ _ _ _ _ _

IVII

_ _

KEY NUMBER - Motor Selection Availability

Basic Motor Unit (no electronics) Basic Motor Unit plus Digital Electronics Enhanced Performance Motor Unit with Non-contact Position Sensing Unidirectional Motor (M640D Replacement)

TABLE I - TORQUE & SPEED SELECTION (speed per 150 degree rot ation)

Torque, lb-in/(N-M)

50 / (6.0) 7.5 sec 6 sec 100 / (11.5 200 / 22.5) 30 sec 25 sec 400 / (45.0 400 / (45.0) 90 sec 75 sec

TABLE II - ROTATION

Travel 90 degrees

TABLE III - POWER SUPPLY

Single Phase 100 - 130 Vac, 60 Hz

TABLE IV - ANALOG INPUT/OUTPUT SIGNALS

Input 3 Wire Drive up/down 0 _ _

Output None _ 00

TABLE V - SWITCH AND RELAY OUTPUTS

Auxiliary Outputs No Auxiliary Switches

Relay Outputs No Relays

15 sec 12 sec

60 sec 50 sec

150 degrees 360 degrees

100 - 130 Vac, 50 Hz 200 - 240 Vac, 60 Hz 200 - 240 Vac, 50 Hz

0/4-20 mA, 0/1-5 Vdc, 0-10 Vdc 2 _ _ 0/4-20 mA, 0/1-5 Vdc, 0-10 Vdc 3 _ _ 0 to 135 ohm input (Series 90 control) 4 _ _ a Contact Input for 2003 6 _ _

(Note 1) (Note 1)

Dual 1000 Ohm (1000 ohms over 150 degrees) _ 15 Dual 1000 Ohm (1000 ohms over 90 degrees) _ 19 Slidewire Emulation _ 60 Slidewire Emulation _ 65 0/4-20mAdc (0/1-5 Vdc, 0-16 Vdc) 0/4-20mAdc (0/1-5 Vdc, 0-16 Vdc)

2 Auxilliary Switches 4 Auxilliary Switches

2 Programmable Relay Outputs 2 Programmable Relay Outputs 4 Programmable Relay Outputs

50Hz 60Hz

(2 end-of-travel switc hes are standard)

Selection

2000 2001 2002 2003

050 100 200 400 600

090 150 360

126 125 246 245

b c

_ 80 _ 85

0 _ 2 _ 4 _ _ 0 _ 2 _ 3 _ 4

continued

10 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Specifications

Model Selection Guide

TABLE VI - OPTIONS Selection

Local keypad/ No local display interface supplied display Integrally mounted local display/keypad interface

(Note 2) 0_ _ _ _ _

1_ _ _ _ _ Local Auto/ No auto/manual switch _ 0_ _ _ _ manual switch Auto/manual switch with "Out of Auto Contact"

Auto/manual switch with "Out of Auto Contact"

_ 1_ _ _ _

_ 2_ _ _ _ Handwheel No Handwheel _ _ 0_ _ _

Handwheel

Certificates None

_ _ 1_ _ _

_ _ _ 0 _ _

Certificate of Conformance _ _ _ 1_ _

Approvals UL Type 4/IP66, CSA

(Note 4) _ _ _ _ 0_

CE _ _ _ _ 1_

Shipped Rotation Counter clockwise shaft rotation on increasing signal

Clockwise shaft rotation on increasing signal

_ _ _ _ _0

_ _ _ _ _1

TABLE VII - COMMUNICATIONS/PROTOCOL

None No communications option board or protocol 0 Modbus RTU RS485 RS-485 Modbus compliant - standard with EEU 1 HART 5 HART Communications Protocol 2

TABLE VIII - MANUALS

Standard English 0

TABLE IX - FACTORY OPTIONS

Factory Options None

Restrictions

Restriction

Letter

a b c

Available Only With

Table Selection

Not Available With

Table Selection

IV _ 00 IV _ 60, _ 80

II II II II

150 090

090 150

2000 2001

2002 2003

ACCESSORIES

Mounting Hardware Mounting plate adapter for Barber Colman Series MP495

Mounting plate adapter for Landis & Staefa SQM53/56 Direct Couple Valve Hardware North American Valve Retrofit Kit

Linkage Assembly Ball joint for 5/16" dia. Pushrod

Pushrod 12 in. (304,5 mm) long, 5/16 " dia. Pushrod 18 in. (457,2 mm) long, 5/16 " dia. Pushrod 24 in. 609,6 mm) long, 5/16 " dia. Pushrod 48 in. (1219,2 mm) long, 5/16 " dia.

51452354-501 51452354-502 51452354-503 51452354-511 51452354-504 51452354-505 51452354-506 51452354-507

51452354-508 HART Turk Cable for Handheld Connection 51452352-501 Handheld Config.

(Note 3)

HercuLink Battery powered 232/485 converter with cable

Remote Mount Remote 4-20 mA requires 135 ohm fdbk, 120V 50/60Hz

Control Remote 4-20 mA requires 1000 ohm fdbk, 120V 50/60Hz

Remote 4-20 mA requires 135 ohm fdbk, 220V 50/60Hz Remote 135 ohm input requires 135 ohm fdbk, 120V 50/60Hz

Notes:

1. 135 ohm available by parallelling 1K potentiometer with 158 Ohm resistor (supplied).

2. HercuLink

customer supplied Palm

Palm Software

51452354-509

51452354-510

R7195A1031

R7195A1056

R7195A1064

R7195B1021

software (pn 51452354-509), RS232/485 converter (pn 51452354-510),

PDA running OS3.5 or higher and Palm serial cable are required

for the 2001 and 2002 actuators if no display is selected.

3. Requires PDA manufacturer's serial interface cable.

4. CSA approval is good for 75°C and a maximum relay load of 3.5 amps or 70°C with a relay load of 5 amps.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 11 7/08

Installation Installation Overview

Installation Overview

The procedures to install the HercuLine® 2000 Series actuator and place it in service require that you:

• Select a suitable location for installation. (See Installation Considerations below.)

• Mount the actuator securely.

• Install mechanical connections or linkage between control arm and final control element. Use HAL software

application to aid in mechanical installation.

• Make all electrical connections for actuator according to local and national electrical codes.

• Power up actuator.

• Enter, verify and adjust set up parameters for proper operation.

• Adjust control arm linkage for accurate operation of final control element.

Installation

This section provides you with mechanical and electrical installation information required to mount and connect the HercuLine

2000 Series Actuator to your specific application. Unpacking instructions, installation

consisderations, electrical and safety precautions also included in this section should be observed.

Mechanical Stops

Factory set at 90° or 150° (+/-5°).

See Figure 2 for location.

Attention: Do not adjust the mechanical stops. Adjusting the stops will void the warranty.

12 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Before Starting

Unpacking

If there are visible signs of damage to the shipping container, notify the carrier and Honeywell immediately. If there is no visible damage, compare the contents with the packing list. Notify the carrier and Honeywell

immediately if there is equipment damage or shortage. Please do not return goods without contacting Honeywell Applications Center in advance. The contact number

is 1-800-423-9883.

Installation Considerations

Mount the actuator in a location where it will be easily accessible for maintenance and for manual operation by means of the handwheel. The exact location must be determined in accordance with the linkage used.

It is important that the actuator be mounted securely to a solid foundation commensurate with the maximum torque developed. Use studs or bolts that are as large as the foot mounting holes.

Allocate sufficient clearance around the actuator for the removal of all covers to permit inspection of internal parts and to provide access to the handwheel.

Installation

Before Starting

Actuator Mounting

Firmly bolt the actuator to a mounting surface that will not distort when subjected to the torque stresses generated by the actuator. The output shaft of the actuator should be parallel to the output shaft of the driven device. The output shaft crank arm is fully adjustab le through 360°.

Mounting holes (bottom and side) and location of shaft/crank arm duplicate mounting for Honeywell Actionators M640A, 740A, 940A for drop-in replacement. Optional adaptor plates available for replacing Landis and Staefa SQM53/56 and Barber Coleman series MP495 models.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 13 7/08

Installation Actuator Mounting

289

11.379

25.4

1.00

CLEARANCE FOR TOP REMOVAL:

CLEARANCE FOR TOP REMOVAL: 101,6

101,6

4.0

mm inches

Figure 3 Outline and Dimensions of HercuLine® 2000 Series Actuators

14 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Mechanical Installation

Linkage Set-up

Many applications require the use of a linkage assembly and often the final control element does not have a linear torque curve. The actuator linkage can be set up to achieve an optimal delivered torque distribution for specific applications. To assist with linkage design, Honeywell offers a linkage analysis software application (HAL). The software can be ordered as P/N 51197910-001.

Constant Torque Linkage (typical)

A constant torque linkage is employed when it is desired to provide a linear torque profile throughout the full range of final control element travel. In this situation, the actuator and driven crank arms will be set-up proportionally with respect to each other. profile.

Installation

Mechanical Installation

Figure 4 shows a general linkage setup to achieve a linear torque

Start Stop Close Open

Drive Unit Crank Arm

Variable Torque Linkage

A variable torque linkage is employed when it is desired to provide a non-linear torque profile throughout the full range of final control element travel. In this general situation, the actuator and driven crank arms will be set up to provide a higher torque for seating or unseating the final control element. linkage setup to achieve a non-linear torque profile. Note that this linkage can be characterized in many different ways by varying start angles and rotation requirements of both the Actuator Crank Arm and the Driven Arm.

Vertical

Centerline

45° 45°

Horizontal Offset

Figure 4 Constant Torque Linkage

Linkage

Vertical

Centerline

45° 45°

Damper Crank Arm

a/n 23199

Figure 5 shows a general

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 15 7/08

Installation Mechanical Installation

Actuator Crank Arms

The HercuLine (25.4mm) to 2.80 in (71.12mm). See

Vertical Centerline

45° 45°

Actuator

Linkage

Crank Arm

Close Open

5°

a/n 23200

Horizontal Offset

Damper Crank Arm

Figure 5 Variable Torque Linkage

2000 Series Actuator comes standard with a crank arm with adjustable radius of 1.0 in

Figure 6.

Figure 6 Standard crank arm

Figure 7 Crank arm with optional ball joint and push rod

16 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Electrical Installation

General Wiring Recommendations

Only qualified personnel should perform wiring.

Wiring must conform to national and local electrical codes.

In general, copper wire used. Unless locally applicable codes dictate otherwise, the recommended minimum wire sizes in

Table 2 should be observed.

AWG Description

14 Earth ground wire to common power supply.

Installation

Electrical Installation

Table 2 Recommended Minimum Wire Size

Safety Precautions

Actuator Connections

ATTENTION

The actuator terminal connections for the field wiring are located behind the cover on the actuator case as shown in

Figure 2. Power and field wiring is brought into the actuator through two access holes located on the

side of the actuator case.

Earth ground wire to single actuator. 120/240 V ac line leads. +24 V and common signal leads. Common signal leads, relays, and aux switches.

An external disconnect switch must be installed to break all current carrying conductors connected to the actuator. Turn off power before working on conductors. Failure to observe this precaution may result in serious personal injury.

The ground terminal must be connected to a reliable earth ground.

While the unit is powered, a potentially lethal shock hazard exists inside the case. Do not open the case while the unit is powered. Do not access the terminals while the unit is powered.

Use both openings: one for low level wiring (control signal) and the other for high level wiring (120Vac).

Do not run both the High Level and Low Level wiring through the same opening.

The screw terminals, locations, and descriptions for all customer connections are identified in the tables and figures that follow.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 17 7/08

Installation Electrical Installation

HercuLine® 2000 Terminal Connections

Table 3 Terminal Connections: HercuLine

Connection

Terminal Numbers

and LABEL

See Figure 8

2000

Descriptions

Hot 1

Hot wire for 120/240VAC mains supply. Use only if Auto/Manual switch is present.

Neutral 2 Neutral wire for 120/240VAC mains supply

Auto/Manual Switch Contact

3 4

Switch contact to indicate setting of actuator AUTO/MANUAL switch.

Switch is closed when actuator is “NOT-IN-AUTO”

CW from Controller 5 CW motor drive

CCW from Controller 6 CCW motor drive

Potentiometer #1

Potentiometer #2

7 8 9

10 11 12

Clockwise-End Slider Counterclockwise-End

Protective Ground Ground wire connection for mains supply

158 ohm 158 ohm Install resistors to convert 1000 ohm

potentiometer to 135 ohms

REQUIRED ONLY IF AUTO/MANUAL

SWITCH IS PRESENT

Figure 8 HercuLine

2000 connections

18 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

HercuLine® 2001/2002 with Auto/Manual Terminal Connections

Table 4 Terminal Connections: HercuLine

2001/2002 with auto/manual

Connection

Hot 1 Hot wire for 120/240VAC mains supply

Neutral 2 Neutral wire for 120/240VAC mains supply

Protective Ground 3 Ground wire connection for mains supply

Auto/Manual Switch Contact

4 to 20mA Output*

Feedback 3

4 to 20mA Input

Modbus Communication

HART Communications

Digital Input

Terminal Numbers

and LABEL

See Figure 9

TB1

4 5

TB3

1 (+) 2 (-)

4 (+) 5 (-)

6 (+) 7 (-) 8 Shield

4 (+) 5 (-)

9 Com 10 Input

Descriptions

Switch contact to indicate setting of actuator AUTO/MANUAL switch.

Switch is closed when actuator is “NOT-IN-AUTO”

Analog signal output

Feedback signal used in conjunction with 4 to 20mA OUTPUT voltage when using Slidewire Emulation

Analog signal input

Connection for RS485 Modbus loop wires

HART Communication is 4-20 mA only.

Customer’s contact closure

Installation

Electrical Installation

HART

Communications

Connection

HART connection using

HART connection using external Turck connector

external Turck connector

Auxiliary

Connector

Brown

Black Wire Not Used

Black

Blue

Figure 9 HercuLine

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 19 7/08

2001/2002 connections

Installation Electrical Installation

HercuLine® 2003 Wiring Connections and Operation (Actionator 640D Replacement)

Wiring

Figure 10 HercuLine

2003 connections

Operation

The 2003 actuator is uni-directional (it does not reverse rotation with a reversal in control action).

Figure 10 illustrates the internal wiring and the external connections.

The smaller insert of the figure describes the limit switch action for one complete cycle. When the two-position controller detects a sufficient fall in temperature in a heating application, the switch portion between the “4” and “5” terminals will close.

The motor then rotates for 180º or until the opening switch breaks (stops are adjustable, factory set at 180º), and stops in full open position.

A subsequent rise in temperature causes the controller to close the switch between the “4” and “6” terminals when the motor will start to rotate (in the same direction) for 180º or until the closing switch breaks.

The motor stops in the closed position and completes one cycle.

20 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

Power Connections

Depending on which power supply selection is ordered for your actuator, wire the power input (MAINS POWER) as described in the previous tables and figures. Wiring must conform to national and local electrical codes.

CE Wiring

When wiring the actuator power input for CE approved units, you must also install a MOV and ferrite beads supplied with the CE unit.

You need the following tools:

• 5mm hex key

• small flat blade screwdriver

• small needle nose pliers

Step Action

Electrical Installation

While the unit is powered, a potentially lethal shock hazard exists inside the case. Do not open the case while the unit is powered. Do not access the terminals while the unit is powered.

Installation

1 Remove AC power to actuator. 2 Loosen the 6 captive screws (use 5mm hex key) and remove the cover. 3 Locate the terminals TB1-1, TB1-2 and ground screw. 4 Loosen the screws at terminals TB1-1 and TB1-2. Remove screw used for ground. 5 Install the appropriate MOV assembly as shown in Figure 11. 6 All ferrites require 1 loop of wire per ferrite. Connect as shown in following steps. 7 • Current input and output (slidewire emulation) connection

• Communications and digital input connection

Ground screw

Current input and output (slidewire

TB1-2

emulation)

TB1-1

Communications and digital input

Figure 11 CE wiring part 1

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 21 7/08

Installation Electrical Installation

Step Action

8 • AC power connection

• Auxiliary switches connection

• Relay contact connection

Aux switches 1 and 2 (SW3 and SW4)

Aux switches 3 and 4 (SW5 and SW6)

Relays 1 and 2

9 Install new gasket and top cover. Secure top cover with 6 captive screws. 10 Reapply AC power to the actuator. 11 Actuator is ready for use.

Input Signal Connections

ATTENTION

Shielded and grounded cables are recommended.

0/4-20 mA Input Signals

For current signal input, ensure jumper W2 on the CPU PWA is in the “Current” position. See

68. Observing polarity, connect the signal input wires TB3–4(+) and TB3–5(-) on CPU terminal board.

page

Relays 3 and 4

AC power connection

Figure 12 CE Wiring part 2

Figure 27 on

0/1-5 Vdc and 0 to 10 Vdc Input Signals

For voltage signal input, ensure jumper W2 on the CPU PWA is in the “Voltage” position. See

68. Observing polarity, connect the signal input wires to terminals TB3–4(+) and TB3–5(-) of the terminal

page

Figure 27 on

block.

22 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08

+ 98 hidden pages