Honeywell HERCULINE 2000 User Manual

Download

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

Output Signal Connections

0/4-20 mA, 0/1-5 Vdc Feedback Signal Connections

ATTENTION

Shielded and grounded cables are recommended.

Actuator output is a 4 to 20 mA analog signal. If a voltage input is required for custo mer devices, a range resistor is needed at the device input. Refer to (page

Slidewire Emulator Connections

ATTENTION

Shielded and grounded cables are recommended.

If you ordered the Slidewire output option for your actuator, it is set at the factory to provide an output that emulates 100 to 1000 ohm slidewires. Refer to (page

Burner Control/Flame Safety

Electrical Installation

19) for more information.

Burner Control/Flame Safety

Introduction

Often, Gas Fired control applications use a Fl ame Safety System that drives the gas valve to full closed and full open during the start-up sequencefor the burner. HercuLine® 2000 Series actuators have been designed to be compatible with the Flame Safety Systems and to perform the required operations.

Configuration

39), configure the parameter FSTYPL to Down .

51), configure the parameter DIG INP to Up.

To TB3 #10

•

To TB3 #5

•

Wiring

In the Input Set Up Group (Page In the Digital Input Set Up group (Page

Figure 13 Burner Control/Flame Safety Wiring shows a Typical Flame Safety Module wiring diagram.

High Fire

Common

Low Filter

HercuLine TB3

–

Add Jumper

1 2 3 4 5 6 7 8 9 10

11 22 33 44 55 66 77 88 99 10

11 22 33

1 2 3 4 5 6 7 8 9 10

11 22 33 44 55 66 77 88 99 10

11 22 33

1 2 3 4 5 6 7 8 9 10

11 22 33 44 55 66 77 88 99 10

11 22 33

1 2 3 4 5 6 7 8 9 10

11 22 33 44 55 66 77 88 99 10

11 22 33

1 2 3 4 5 6 7 8 9 10

11 22 33 44 55 66 77 88 99 10

1 2 3 4 5 6 7 8 9 10

11 22 33 44 55 66 77 88 99 10

11 22 33

+ 4 to 20 Output from Controller

Modulate

Typical Flame

Safety Module

•

+ 4 to 20 Output from Controller

– 4 to 20 Output from Controller

Figure 13 Burner Control/Flame Safety Wiring

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 23 7/08

Burner Control/Flame Safety Series 90 Control – HercuLine® 2001 model only

Series 90 Control – HercuLine® 2001 model only

Series 90 Controls are commonly used in building environmental systems and flame safeguard systems to provide modulating control. The control is affected by balancing a 135 ohm potentiometer. The HercuLine 2001 provides an emulation of this system as follows. The current output is used to excite the potentiometer in the controller. To do this it is set permanently at 11 ma. This produces a 1.5 volt span. The wiper is then connected to the HercuLine 2001 input, which is operating in voltage mode. The returns from both the input and the output are tied together.

Series 90 terminals are typically color coded white, red and blue. Conventionally, red is the wiper and white and blue are the two ends of the potentiometer. On a drop in temperature, the wiper moves toward the blue terminal.

Connections

TB3

Considerations

This connection performs an emulation of a series 90 motor. If the controller being used is also an

1. emulation of a Series 90, the connections required may be different. Shown in connections found necessary to connect a T775 controller through an S443A S9 0 Auto/Manual Control. If the controller has the capability to provide a 4/20 or voltage output, it is easier to use that mode. It will require only two wires and it will allow the independent use of the 4/20 output. If help is required, contact Honeywell.

Due to variations in the definition of rotation directions, it may be necessary to reverse the action of the

2. actuator from CCW to CW or vice versa.

4-20mA output

4-20mA input

Figure 14 Series 90 connections

White

Red

Blue

Figure 15 are the

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

Burner Control/Flame Safety

Series 90 Control – HercuLine® 2001 model only

I out from

uto

T775 B 3

HercuLine2001

T775 W 1 + Signal to HercuLine2001

Man

GND to HercuLine2001 (2)

T775 R 2

Figure 15 T775 Controller connections

In the T775 controller manual there are several examples of using resistances or potentiometers as high and

3. low limit controls. Because of the mode of emulation of Series 90, it is likely that these connections will not work as intended. Instead, use the output or input limits which are programmable in the HercuLine

2001.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 25 7/08

Burner Control/Flame Safety Split Range

Split Range

The HercuLine® 2001/2002 actuators can be set up to operate within a narrow input range (for example, 4 to 12mA input) in certain applications. The procedure in to operate as part of a split valve configuration.

Step Action

To Set Actuator span to operate from 4 to 12 mA input.

1 Enter Set Up mode by pressing SET UP key 2 Select SET INPUT group 3 Press FUNCTION key until INP HI (on lower display) is selected. 4 Set INP HI value to 50.0

Table 5 describes how to set up an actuator

Table 5 Split Range Set Up Procedure

5 Press FUNCTION key to select INP LO and set value to 0.0 6 Press DISPLAY key to exit Set Up mode.

To Set Actuator span to operate from 12 to 20 mA input.

1 Enter Set Up mode by pressing SET UP key 2 Select SET INPUT group 3 Press FUNCTION key until INP HI (on lower display) is selected. 4 Set INP HI value to 100.0 5 Press FUNCTION key to select INP LO and set value to 50.0 6 Press DISPLAY key to exit Set Up mode.

ATTENTION

Be sure to review failsafe strategy for your process application.

Master/Slave Arrangement

Introduction

With the motor positioner, the controlling signal for the actuator is a 4 to 20mA from a current output controller as shown in the flow diagram in

Figure 16.

Unlike the position output controller, the current output controller must produce a continuous analog signal or the actuator will revert to one of its failsafe states. Signal failure is not a problem since the available failsafe settings allow you to set the actuator position on signal loss.

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

Basic Flow Control

When the process variable signal is below set point, the controller increases current (4 to 20mA) to the actuator input and opens the valve. Controller set point governs valve position to obtain desired flow rate.

Burner Control/Flame Safety

Master/Slave Arrangement

Positioner & Actuator

Controller

FIC

4 to 20 mA

Position

Linkage

Orifice Plate

Valve

Figure 16 Flow Diagram

Current Output Controller

4 to 20 mA

Actuator

See Figure 27 for jumper location

Jumper W2 = Current

250 Ohms 1 to 5 VDC

Hot Neutral Ground

120/240

VAC

Figure 17 Interconnection Diagram

Proportional Flow using Multiple Actuators

Refer to flow diagram in flow rate in one burner. Only that

Figure 18 and interconnection diagrams in Figure 19. The controller governs

flow is measured. Since #2 and #3 motor positions receive the same signal as #1 motor positioned, valves #2 and #3 will deliver the same amount of fuel. This is true when the span and zero adjustment are all set the same as in curve 2 of the graph. Other relationships between units exist if the span adjustment (3) for ratio or if the zero adjustment is changed (1) for bias.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 27 7/08

Burner Control/Flame Safety Master/Slave Arrangement

Position

FIC

with Bias

Controller

4 to 20 mA

Proportional

Ratio

Positioner & Actuator

MP #1

MP #2

Linkage

Orifice Plate

Linkage

MP #3

Valve

Linkage

Valve

Figure 18 Proportional Flow Using Multiple Actuators

Current Output Controller

4 to 20 mA

Note: Controller must be capable of sourcing the impedance.

See Figure 27 for jumper location

Preferred Wiring

NOTE: If using HART® communications, for this application HART®must be configured for Multi-drop operation.

Actuator #1

10260S Series Actuator #1

Jumper W2 = Current

250 Ohms 1 to 5 VDC

Actuator #2

10260S Series Actuator #2

Jumper W2 = Current

250 Ohms 1 to 5 VDC

Actuator #3

10260S Series Actuator #3

Jumper W2 = Current

250 Ohms 1 to 5 VDC

Hot Neutral Ground

120/240

VAC

120/240

VAC

120/240

VAC

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

Burner Control/Flame Safety

Master/Slave Arrangement

Current Output Controller

4 to 20 mA

See Figure

10260S Series Actuator #1

Actuator #1

Jumper W2 = Current

250 Ohms 1 to 5 VDC

10260S Series Actuator #2

Actuator #2

Jumper W2 = Voltage

Hot Neutral Ground

Hot Neutral

Ground

120/240

VAC

120/240

VAC

27 for jumper location

10260S Series Actuator #3

Actuator #3

Alternate Wiring

Jumper W2 = Voltage

Hot

Neutral

Ground

120/240

VAC

Figure 19 Multiple Actuator Interconnection Diagrams

NOTE: If using HART® communications, for this application HART® must be configured for Multi-drop operation.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 29 7/08

Burner Control/Flame Safety Master/Slave Arrangement

Split Valve Configuration

A common heat or cool type process requires two valves. In this case the controller has only one output. The two motor positioners are calibrated differently, one responds to 4 to 12mA and the other responds to 12 to 20mA. At 12mA, both valves are closed; one opening below 12mA and th e other above 12mA. Refer to

Figure 20 for an interconnection diagram for split valve operation using two actuators.

Current Output Controller

4 to 20 mA

Note: Controller must be capable of sourcing the impedance.

Preferred Wiring

NOTE: If using HART® communications, for this application HART® must be configured for Multi-drop operation.

Current Output Controller

4 to 20 mA

10260S Series Actuator #1

Actuator #1

Jumper W2 = Current

250 Ohms 1 to 5 VDC

Actuator #2

10260S Series Actuator #2

Jumper W2 = Current

250 Ohms 1 to 5 VDC

Actuator #1

10260S Series Actuator #1

Jumper W2 = Current

250 Ohms 1 to 5 VDC

Actuator #2

10260S Series Actuator #2

Hot

Neutral

Ground

Hot

Neutral

Ground

Hot

Neutral Ground

120/240

VAC

See Figure 27 for jumper location

120/240

VAC

120/240

VAC

See Figure 27 for jumper location

Alternate Wiring

Jumper W2 = Voltage

Hot

Neutral

Ground

120/240

VAC

Figure 20 Interconnection Diagrams

NOTE: If using HART® communications, for this application HART® must be configured for Multi-drop operation.

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

Overview

Set Up and Calibration Procedures

Overview

Set Up and Calibration Procedures

Once you have installed the actuator, you can verify, set or change certain operating parameters. Set up is accomplished through use of the local display and keypad interface through your PDA with HercuLink software (see HercuLink® manual 62-86-25-11) or via the HART® communication option. Please keep in mind that the unit is calibrated at the factory for your application and can be placed into service right out of the box. Changing operating parameters may require recalibration of the actuator. This section details the various operating parameters and functions of the actuator available using the local display and keypad interface, and calibration procedures.

Local Display and Keypad

The alphanumeric display and keys on the keypad are the local operator interface for con t rol, monitoring, and configuration of the actuator. The display consists of a four character upper display and a six character lower display. Six LEDs of various colors indicate actuator-operating status. Directly below the display are six keys that allow you to setup, monitor, and control the actuator locally, as well as call up various operating parameters and configuration values on the display. display and keypad. descriptions of the status indicators.

Upper Display (Four Characters)

Table 6 summarizes the various functions you can perform using the keys as well as

Figure 21 shows the physical features of the

STALLED ALARM

MANUAL AUTO

Lower Display (Six Characters)

FUNCTIONSET UP

MAN/AUTO

DISPLAY

Figure 21 HercuLine

2000 Display and Keypad

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 31 7/08

Set Up and Calibration Procedures Local Display and Keypad

Key or

LED Indicator

SET UP

FUNCTION

MAN/AUTO Alternately selects:

DISPLAY

INCREMENT

DECREMENT

☼

☼ ☼ STALLED ☼ ALARM ☼ MANUAL ☼ AUTO

Places the actuator in the set up group select mode. Sequentially displays the set up groups and allows the FUNCTION key to display function parameters within the set up group.

See Set Up and Calibration Procedures (page 31)Error! Reference source not found. for descriptions of the various options available in the set up groups.

Used in conjunction with the SET UP key to select the individual functions of a selected configuration set up group.

Used during field calibration procedure.

MAN - Actuator is in Manual mode. AUTO - Actuator is in Automatic mode.

NOTE: When in Manual mode the POS display is automatically selected so you can use the up and down arrow keys to drive actuator motor manually.

NOTE: This button is disabled if MAENAB is set to DIS. See

Pressing this key repeatedly cycles through the operating parameters that can be shown on the lower display.

INP – Input. Shows the value of the actuator input. OP – Output. Shows the value of the actuator output DE – Deviation. Shows deviation between input value and actuator position. POS – Position. Shows current actuator position.

Increases the configuration values shown on the display. Also shown as

In manual mode and POSition display selected, pressing this key will drive actuator motor in direction of increasing signal input.

Decreases the configuration values shown on the display. Also shown as

In manual mode and POSition display selected, pressing this key will drive actuator motor in direction of decreasing signal input.

Indicates the movement of the actuator arm in the counterclockwise direction.

NOTE: Actuator rotation is the direction of the output shaft when facing the end of the shaft and refers to the direction of rotation on increasing signal.

Indicates the movement of the actuator arm in the clockwise direction.

NOTE: Actuator rotation is the direction of the output shaft when facing the end of the shaft and refers to the direction of rotation on increasing signal.

Indicates that the actuator has detected a motor stall condition.

Indicates a programmed alarm condition exists.

Indicates actuator is in manual mode

Indicates actuator is in automatic mode.

Table 6 Keypad Description

Function

Table 19 (page 53).

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

Set Up Tips

Table 7 contains tips that will help you view, verify and enter the operating parameters more quickly. If you cannot change the parameters, check the status of the “SET LOCK” parameter. Also some parameters require that you enter a security password before you access or change the parameter value.

Set Up and Calibration Procedures

Set Up Tips

Table 7 Set Up Tips

Function Tip

Displaying Groups

Displaying Functions

Scrolling

Changing values quickly

Exiting Set Up mode

Timing out from Set Up mode

Use the SET UP key to display and scroll through the set up groups. The group titles are listed in the order that they appear on the actuator display.

Use the FUNCTION key to display the individual function parameters under each set up group. The prompts are listed in the order of their appearance in each group. See Tables 8 through 19.

Pressing and holding the SET UP key will scroll through the set up groups. However, when any set up group is displayed, you can scroll

through the set up groups twice as fast using the any set up group, hold the FUNCTION key in to scroll through the prompts within that group.

When changing the value of a parameter, you can adjust a more significant digit in the upper display by holding in one key pressing the other

• The adjustment will move one digit to the left.

• Press the key again and you will move one more digit to the left.

To exit Set Up mode, press the DISPLAY key. This returns the display to the same state it was in immediately preceding entry into the Set Up mode.

If you are in Set Up (configuration) mode and do not press any keys for thirty seconds, the actuator display will time out and revert to the mode and display that was being used prior to entry into Set Up mode.

or at the same time.

or key. When in

or and

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 33 7/08

Set Up and Calibration Procedures Set Up Groups

Set Up Groups

Pressing the SET UP key on the keypad provides access to the various set up groups and allows you to set up operating parameters, (such as input types and alarms), calibrate the actuator’s inputs and outputs, set communications, and check actuator status. available by using the SET UP and FUNCTION keys on the keypad.

Set Up Group Title Pressing the FUNCTION Key Allows You to… For Details, See

Table 8 on the next page lists the set up groups that are

Table 8 Set Up Groups

SET

INPUT

SET

RELAYn

n = 1, 2, 3, or 4

SET

CUROUT

SET

COMM

SET

DIGINP

SET

DISPLA

CAL

INPUT

CAL

MOTOR

Select and set various parameters associated with the input signal to the actuator.

Select relay functions. NOTE: Set Relay groups will show on display only if relays are installed in the actuator.

Select the output signal type of the actuator.

Select communication parameters for remote control of actuator when connected to a SCADA system.

Select the parameters for external digital input states.

Select and set parameters for the local display.

Calibrate input zero and span values.

Calibrate zero and span values for motor operation.

ATTENTION

When calibrating the motor to a short stroke range, you must reset the end-of-travel limit switches. See

Setting End-of-Travel Limit Switches.

Table 10

Table 13

Table 15

Table 16

Table 17

Table 18

Calibration Procedure,

Table 25

Calibration Procedure,

Table 26

CAL

CURENT

SET

LOCK

READ

STATUS

SET

DRVINF

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

Calibrate actuator output. Calibration

Procedure,

Table 27

Set or change security password. Enable or disable security access to set up parameters and calibration set up.

Display operating and alarm status. Display self-test diagnostic results.

Display and/or set various parameters specific to the actuator.

Table 19

Table 20

Table 21

Set Up and Calibration Procedures

Set Up Groups

SET

MAINT

CAL

POSOUT

Display various operating statistics. Reset accumulated operating statistics

Use the display as an indicator, (in this case a voltmeter) so you can verify that the position sensor is operating properly.

Table 22

Table 23

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 35 7/08

Set Up and Calibration Procedures Set Up Procedure

Set Up Procedure

Each of the set up groups and their functions are either pre-configured at the factor y or set to their default values. Tables 8 through 19 list and describe the options available in each set up group. The following procedure shows you the key press sequence to access any set up group or any associated Function parameter. Make sure lock set up group “LOCK” function is set to “NONE” or “CAL.” Also some parameters require that you enter a security password before you access or change the parameter.

You can use this procedure to access the set up groups and select all parameters.

Table 9 Set Up Procedure Using Display and Keypad

Step Operation Press Result

1 Enter Set Up Mode

Select any Set Up Group

Select a Function Parameter

SET UP

FUNCTION

Upper Display = SET

Lets you know you are in the set up mode and a set up group title is being displayed in the lower display.

Lower Display = INPUT

This is the first set up group you see when you press SET UP.

Successive presses of the SET UP key will display the other set up group titles as listed in

found..

You can also use the groups in both directions.

Stop at the set up group title that describes the group of parameters you want to configure. Then proceed to the next step.

Upper Display

4-20

function prompt in the selected set up group.

Lower Display

IN TYP

set up group.

Shows the current value or selection for the

Shows the first function prompt within the selected

Table 8Error! Reference source not

or keys to scroll through the set up

Example display shows Input group function prompt “IN TYP” and the selection.

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

Select other function parameters

FUNCTION

Successive presses of the FUNCTION key will sequentially display the other function prompts of the selected set up group.

Stop at the function prompt that you want to change, and then proceed to the next step.

Set Up and Calibration Procedures

Step Operation Press Result

Set Up Procedure

Change the Value or Selection

Enter Value or Selection

FUNCTION

SET UP

7 Exit Set Up mode DISPLAY

These keys increase or decrease the value, or display the next available selection for the selected function prompt.

See Table 7, Set Up Tips for instructions to increase or decrease

a value quickly.

Change the value or selection to meet your needs.

NOTE: If the display flashes, you are trying to make an unacceptable entry, or the value on the display is at its range limit. The display may also show “KEYERR” (Key error).

This key selects another function prompt.

This key selects another set up group.

NOTE: Pressing either key will cause the previously selected value or selection to be entered into memory.

Exits set up mode and returns actuator to the same state it was in immediately preceding entry into the set up mode. Any changes you have made are stored in memory.

If you do not press any keys for 30 seconds, the display times out and reverts to the mode and display shown prior to entering the set up mode.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 37 7/08

Set Up and Calibration Procedures Configuration Prompt Hierarchy

Configuration Prompt Hierarchy

Setup Groups

Function Prompts

INPUT

RELAYn

CUROUT

COMM

DIGINP

DISPLA

LOCK

STATUS

IN TYP INP HI INP LO FILTYP Direct Dband FSTYPH

FSTYPL FsVALL

Y0 VAL

RTYPny Rny VAL Rny E* Rny HL RTYPny Rny VAL Rny E*

Rny HL RLYnHY

CUROUT

COMM ADDRES BAUD XmtDLY DBLBYT

DIGINP EndPos

DECMAL EUNITS UNITS

LOCKID LOCK MAENAB

FAILSF RAMTST SEETST CFGTST CALTST

…

CHAR CUSTOM X0 VAL X20 VAL

Y20 VAL

n = 1,2,3 or 4 y = 1 or 2

…

FsVALH

VERSON SPEED POWER ROTATE TAG MFGDAT

DRVINF

MAINT

VERSON SPEED POWER ROTATE TAG MFGDAT

LREP LCAL REPTYP

TEMP TEMPHI TEMPLO ACSTAL STARTS RL1CNT

RL2CNT RL3CNT RL4CNT REGN0 REGN9 TOTDEG

DATSAV PASSWD MANRST LD CAL LD CFG RESTRT

…

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

Input Set Up Group

Table 10 lists the parameters and selections available when the SET INPUT group is selected. On the keypad and local display:

•

Press the SET UP key to enter the Input Set Up group. Press the FUNCTION key to scroll through the prompts listed in the set up group.

•

Press the or keys to view selections or change range settings.

•

Set Up and Calibration Procedures

Input Set Up Group

Table 10 Input Set Up Group Parameters

Actuator Lower

Display Prompt

IN TYP

Note: If input

type from model

selection guide

is:

0/4-20mA, 0/1-

5Vdc, 0-10Vdc

IN TYP

INP HI 10.0 to 100

Selections or

Range of Setting

default = 100

Parameter Definition/PDA HercuLink Prompt

4-20

0-20 1-5V 0-5V

0-10

R_SP

S_90 Series 90 – 0 to 135 ohms.

INPUT ACTUATION TYPE— This selection specifies the

signal type and range you are going to use for the actuator input. Be sure that the values configured for the high and low range, alarm setpoint, etc. are within the measuring range for the selected signal range.

4 to 20 mA 0 to 20 mA 1 to 5 Volts dc 0 to 5 Volts dc 0 to 10 Volts dc Remote Setpoint (via communications)

NOTE: Changing the Input Actuation Type will restore the actuator calibration to its factory values.

Note: If input type from model selection guide is: Series 90 control

INPUT HIGH RANGE VALUE in % is displayed.

NOTE: When Input Type (R_SP or S_90) is selected, Input

Hi is not configurable.

INP LO 0.0 to 90.0

default = 0.0

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 39 7/08

INPUT LOW RANGE VALUE in % is displayed.

NOTE: When Input Type (R_SP or S_90) is selected, Input Hi is not configurable.

Set Up and Calibration Procedures Input Set Up Group

Actuator Lower

Display Prompt

FILTYP

LPFILT *

Direct

Selections or

Range of Setting

NONE

SPIK

S+LP

LPAS

default = LPAS

0 to 50.00

(in seconds)

default = 0.5

CCW

default = CCW

Parameter Definition/PDA HercuLink Prompt

INPUT FILTER TYPE— Allows the selection of a software

digital input filter to smooth the input signal.

Spike— Selects spike filter to remove transients in the input

signal when actuator is installed in noisy environments.

Spike plus Low Pass— Selects spike and low pass filtering. * Allows setting of lag time constant for low pass filter.

Low Pass— Selects low pass filter. * Allows setting of lag time constant.

NOTE: When Input Type (R_SP or S_90) is selected, Input Filter Type = NONE.

LAG TIME CONSTANT— (Filter Type S+LP or LPAS only)

Allows you to set the first order lag time constant of the low pass filter when selected. Range is from 0 to 50 seconds.

NOTE: When Input Type (R_SP or S_90) is selected, Low

Pass Filter Value is not configurable. ACTUATOR ROTATION—This selection determines the

direction of rotation of the actuator shaft.

Counterclockwise rotation Clockwise rotation

NOTE: Actuator rotation is the direction of the output shaft when facing the end of the shaft and refers to the direction of rotation on increasing signal.

Dband

0.2 to 5.0

(in percent of

span)

INPUT DEADBAND— Specifies an adjustable gap that is the

difference between the setpoint value and the value at which the motor energizes. Deadband is set in percent of full span.

default = 0.5

FSFTYPH

LAST

DOWN

USER

default = UP

FsFVALH *

0 to 100%

default = 100

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

FAILSAFEHI TYPE—Selects the motor position you want

the actuator to go to when input signal is above the high end range value.

NOTE: Failsafe condition occurs when the input exceeds its

high end range value by 3%,

Last Position—Actuator motor remains at last position. Up—Actuator motor moves to full scale value. Down—Actuator motor moves to zero value. User selected value—Actuator motor moves to a customer-

defined value.

* Allows setting of failsafehi input value. FAILSAFEHI INPUT VALUE—(FailsafeHI Type USER only)

Selects the motor position you want the actuator to go to when input signal is above the high end range value.

Range is from 0 to 100%.

Set Up and Calibration Procedures

Input Set Up Group

Actuator Lower

Display Prompt

FSFTYPL

FsFVALL *

CHAR

CUSTOM

Xn VAL

n = 1 - 20

Selections or

Range of Setting

LAST

DOWN

USER

default = DOWN

0 to 100%

default = 0

LINR

SQRT CUST

default = LINR

EQUL

QUIK

USER

default = EQUL

0 to 100 %

Parameter Definition/PDA HercuLink Prompt

FAILSAFELO TYPE—Selects the motor position you want

the actuator to go to when input signal is below the low end range value or on loss of input signal.

NOTE: Failsafe condition occurs when the input exceeds its low end range value by 3%, or when the input signal goes to zero. For input types 0 to 20mA, 0 to 5 V, and 0 to 10 V

there is no failsafe condition at the zero value.

defined value.

* Allows setting of failsafelo input value. FAILSAFELO INPUT VALUE—(FailsafeLO Type USER

only) Selects the motor position you want the actuator to go to when input signal is below the low end range value or on loss of input.

Range is from 0 to 100%.

INPUT CHARACTERIZATION— Selects a characterization

type that causes the actuator to characterize a linear input

signal to represent a non-linear input.

Linear— Provides linear characterization of the input signal. Square Root— Provides square root characterizations of

the input signal. Custom— Custom characterization. Selecting custom

allows you to create a twentieth order characterization of input value (x) and associated shaft position (y).

NOTE: Selecting CUST input characterization causes the

following prompt CUSTOM to be displayed. Equal percentage – Sets the characterization as explained

in Equal Percentage Valve Characteristic on page 42. Values are read-only.

Quick opening - Sets the characterization as explained in

Quick Opening Valve Characteristic on page 43. Values are read-only.

User-configurable – Lets you create your own

characterization using the following Xn VAL and Yn VAL

prompts. Input Value— as a percentage of input range. Defaults are

in increments of 5%.

Yn VAL

n = 1 - 20

0 to 100 %

Shaft Position Value— as a percentage of position range.

Defaults are in increments of 5%.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 41 7/08

Set Up and Calibration Procedures Input Set Up Group

Equal Percentage Valve Characteristic

Table 11 contains values that approximate an equal percentage valve characteristic in the actuator. When the EQUL custom characterization type is selected, the values in actuator configuration to produce the characteristic as presented in the graph. The Xn VAL is the input value as a percentage of range and Yn VAL is the characterized output (actuator shaft position) as a percentage of range.

Table 11 Equal Percentage Valve Characteristics

Table 11 are automatically loaded into the

Order

Xn VAL

% of

Range

Yn Val

% of

Range

0 0 0

1 5 0.8

2 10 2.1

3 15 3.2

4 20 4.9

5 25 6.5

6 30 8.4

7 35 10.7

8 40 13.2

9 45 15.7

10 50 18.7

11 55 22.6

12 60 27.2

13 65 33.4

14 70 40

15 75 46

16 80 53.8

17 85 63.2

Equal Percentage Valve Characterization

100

95 90 85 80

u p

u O

d e

t c

r a

h C

A V

n Y

25 20 15 10

5 0

10 20 30 40 50 60 70 80 90 100

Xn VAL - Actua l Input

18 90 73.7

19 95 86.2

20 100 100

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

Quick Opening Valve Characteristic

Table 12 contains values that approximate the characteristic of a quick opening control valve. When the QUIK custom characterization type is selected, the values in actuator configuration to produce the characteristic as presented in the graph. The Xn VAL is the input value as a percentage of range and Yn VAL is the characterized output (actuator shaft position) as a percentage of range.

Table 12 Quick Opening Valve Characteristic

Set Up and Calibration Procedures

Input Set Up Group

Table 12 are automatically loaded into the

Xn VAL

Yn Val

Order

% of

Range

0 0 0

1 5 10

2 10 20

3 15 30

4 20 40

5 25 50

6 30 60

7 35 70

8 40 77

9 45 82

10 50 86

11 55 88

12 60 90

13 65 92

14 70 94

15 75 95

16 80 96

17 85 97.5

18 90 98.5

% of

Range

Quick Opening Valve Characteristic

100

95 90 85 80

25 20 15 10

5 0

10 20 30 40 50 60 70 80 90 100

Xn VAL - Actual Input

19 95 99.5

20 100 100

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 43 7/08

Set Up and Calibration Procedures Relays Set Up Group

Relays Set Up Group

ATTENTION

The Relay set up group parameters are accessible only if relay PWAs are installed in the actuator. HercuLine relays. Using the Relay set up groups you can program the installed relays to operate in response to various operating conditions.

Table 13 lists the parameters and selections available when the SET RELAYn group is selected.

2001 actuators can be equipped with one PWA –for a total of two SPDT

Table 13 Relay Set Up Group Parameters

Actuator Lower

Display Prompt

RTYPny

n = 1, 2, 3, or 4

y = 1 or 2

RnyE*

RnyVAL

n = 1, 2, 3, or 4

y = 1 or 2

Rny HL

n = 1, 2, 3, or 4

y = 1 or 2

RLYnHY

n = 1, 2, 3, or 4

n is the relay number, y is the relay contact.

Selections or

Range of Setting

NONE

InPR

PosR

DEV

ULim

LLim

T Hi

T Lo

STRT STAL

MAN

PWRF

FsFA PosF

DiGI

TDEG

default = InPR and

NONE

X10k

default = X1

0.0 to 100.0

0.0 to 100.0 (in percent)

Parameter Definition/PDA HercuLink® Prompt

RELAY TYPE— Selects the relay number and the relay

activation type. See

Input Range— Upper / lower limits of input signal exceeded Position Range— Upper / lower limits of motor position exceeded Deviation— Deviation from input exceeded Upper Limit Travel— Same as PosR for upper limit Lower Limit Travel— Same as PosR for lower limit Temperature High— High temperature limit exceeded Temperature Low— Low temperature limit exceeded Starts— Motor starts limit exceeded. Allows setting of multiplier value. Stalled— Motor position does not follow input Manual— Actuator is set to manual mode Power Up Test Failure— Failure of any power up diagnostic Failsafe Alarm— Failsafe condition detected Position Sensor Signal Failure— position output out of valid range Digital Input— Digital input closure

Total Degrees— total degrees traveled. Allows setting of

multiplier value.

MULTIPLIER— (Relay Types STRT and TDEG only)

Selects the multiplier for the number limit of motor starts and total degrees traveled before the relay is activated. Multiplier specifies the value on display as times one (X1) or times ten

thousand (X10k). RELAY VALUE— Sets numerical value of limit where relay

trips (energizes). Units are determined by the relay type selection. See

RELAY HIGH/LOW— Sets relay trip point to high or low limit.

RELAY HYSTERESIS— 0.0 to 100.0% of span or full output.

NOTE: Relay Hysteresis parameter is accessible only if appropriate relay type is selected.

Table 14 Relay Type Descriptions.

Table 14 Relay Type Descriptions for units.

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

Table 14 Relay Type Descriptions

Set Up and Calibration Procedures

Relays Set Up Group

When this Relay Type is

selected…

(RTYP)

Input Range

Position Range

Deviation

Upper Limit Travel

Lower Limit Travel

Temperature High

The Relay can be set up to indicate …

The upper / lower limits of the input signal have been exceeded. Relay value parameter defines range limits and units are in percent of full span.

Upper / lower limits of motor position have been exceeded. Relay value parameter defines range limits and units are in either percent of

span or degrees of rotation. See “Relay Examples “for setting range limits.

Motor position has exceeded deviation limit from input. (Deviation is defined as: setpoint – motor position = Deviation) Relay value parameter defines limits and units are in percent of span.

See “Relay Examples” for setting deviation limit.

The motor position has exceeded the upper limit of travel. (Same as Position Range.) Relay value parameter defines limits and units are in degrees of rotation or

percent of span. See “Relay Examples” for setting upper limit with hysteresis.

The motor position has exceeded the lower limit of travel. (Same as Position Range.) Relay value parameter defines limits and units are in degrees of rotation or percent of span.

The high temperature limit of the actuator has been exceeded. Relay value parameter defines temperature limits and units are in either degrees C or degrees F.

Temperature Low

Starts

Stall Manual Mode Power Up Test Failure

Failsafe Position Sensor Failure Digital Input Total Degrees

(Temperature units are defined in the UNITS setting of the DISPLA set up group.)

The low temperature limit of the actuator has been exceeded. Relay value parameter defines temperature limits and units are in either degrees C or degrees F.

(Temperature units are defined in the UNITS setting of the DISPLA set up group.)

The accumulated motor starts have exceeded the limit. Relay value parameter

defines the limit. See “Relay Examples” for setting motor starts limit. Range is

from 10 to 99,990,000.

The motor is in a stall condition.

The actuator is in manual mode.

A failure of any one of the power up test diagnostics. See READ STATUS set up group.

The actuator is in failsafe. (input signal loss or input signal out of valid range)

The potentiometer or non-contact sensor output is out of range or has failed.

The digital input closure.

The total degrees traveled.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 45 7/08

Set Up and Calibration Procedures Relays Set Up Group

Relay connector #1

Relay connector #2

Relay connector #3

Relay connector #4

Figure 22 Relay connectors

Relay Examples

Relay Type - Position Range

Selecting PosR relay type, you can cause the relay to energize when the actuator motor travels below 20% of range and above 80% of range. Note in the example below that Relay 1 is set up to provide two trip points. The first trip point (R11VAL) causes the relay to energize when the motor travels above 80%, the second trip point (R12VAL) is set so the relay energizes when the motor travels below 20%.

Set Up Group Parameter Value

SET RELAY1 RTYP11 PosR

R11VAL 80.0

R11HL HI

RTYP12 PosR

R12VAL 20.0

R12HL LO

RLY1HY 0.0

The figure below shows the resulting action.

Motor Position

Closed

20%

Open

80%

100%

Closed

RELAY 1

Normally Open

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

Relay Type - Deviation

Setting up a relay to alarm (energize) when the motor position deviates 10% (+ or -) from the actuator setpoint can be set up as follows.

The resulting action is shown below.

Set Up and Calibration Procedures

Relays Set Up Group

Set Up Group Parameter Value

SET RELAY1 RTYP11 DEV

R11VAL 10.00

R11HL HI

RTYP12 DEV

R12VAL -10.00

R12HL LO

RLY1HY 0.0

Motor Position

Closed

Input

50%

-10%

Normally Open

+10%

Open

RELAY n

100%

Closed

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 47 7/08

Set Up and Calibration Procedures Relays Set Up Group

Relay Type – Upper Limit Travel with Hysteresis

Selecting relay type

ULim will cause the relay to energize when the motor position exceeds the upper limit

trip point, and can be set up as follows. Note that relay hysteresis parameter (RLY1HY) value is set to 10, which is 10% of range. This means that when the relay is energized, due to the motor position exceeding the upper limit value, the relay will not de-energize until the motor moves to 10% below the trip point.

Set Up Group Parameter Value

SET RELAY2 RTYP21 ULim

R21VAL 70.0

R21HL HI

RTYP22 NONE

RLY2HY 10.0

Motor Position

Open

RELAY n

Normally Open

60%

70%

H y s t e r e s I s

Closed

100%

Motor Position

Relay Type – Motor Starts

Selecting relay type STRT will cause the relay to trip when the number of motor starts exceeds the selected limit. The motor starts value is stored as one of the maintenance group statistics. This example sets the motor starts limit at 200,000 for Relay 1.

Set Up Group Parameter Value

SET RELAY1 RTYP11 STRT

R11 E* X10K

R11VAL 20

R11HL HI

RTYP12 NONE

The resulting action is that Relay 1 will trip when the number of accumulated motor starts in the maintenance group exceeds 200,000.

Open

RELAY n

Normally Open

60%

H y s t e r e s I s

70%

100%

Closed

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

Current Out Set Up Group

Table 15 lists the parameters and selections available for the SET CUROUT group.

Table 15 Current Out Set Up Group Parameters

Set Up and Calibration Procedures

Current Out Set Up Group

Actuator Lower

Display Prompt

CUROUT

: If output

Note

type from model

selection guide

is:

0/4-20mA, 0/1-

5Vdc

CUROUT

: If output

Note

type from model

selection guide

is:

Slidewire

Emulation

CUROUT

Note

type from model

selection guide

None

: If output

is:

Selections or

Range of Setting

4 – 20

0 – 20 1 – 5V 0 – 5V

SW E Slidewire Emulation

NONE No current output configured.

Parameter Definition/PDA HercuLink Prompt

OUTPUT SIGNAL RANGE

range.

4 to 20 mA 0 to 20 mA 1 to 5 Volts (250 ohm resistor required) 0 to 5 Volts (250 ohm resistor required)

— Selects the signal output

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 49 7/08

Set Up and Calibration Procedures Communications Set Up Group

Communications Set Up Group

Table 16 lists the parameters and selections available for the SET COMM group.

Table 16 Communications Set Up Group Parameters

Actuator Lower

Display Prompt

COMM

ADDRES 1 to 99

BAUD

XmtDLY

Selections or

Range of Setting

default = 19.2k

DIS

MODB

HART

default = 1

2400 4800 9600

19.2k

NONE

10ms 20ms 30ms 40ms 50ms

Parameter Definition/PDA HercuLink Prompt

COMMUNICATONS PARAMETERS— Disables or enables

parameter displays for Modbus communciations set up.

Disabled— Locks out access to communications displays

and parameters.

Modbus— Allows access to the communication displays

and settings for the parameters listed below.

HART – selects HART as the communications protocol DEVICE ADDRESS

a Modbus communications loop. Select an address that is unique to other devices on the communications link.

BAUD RATE

equipment on the link must be set to match the host setting.

RESPONSE DELAY

milliseconds) before a response to a query is transmitted.

— Selects device address when used in

— Selects the speed of data transfer. All

— Selects the time delay (in

default = 20ms

DBLBYT

FP B FPBB

FP L

FPLB

default = FP B

FLOATING POINT DATA FORMAT

transferring floating point data.

Byte Order Floating Point Big Endian format— 0 1 2 3

Floating Point Big Endian format Floating Point Little Endian format

Floating Point Little Endian format

with byte-swapped— 1 0 3 2

with byte-swapped— 2 3 0 1

— Selects the format for

— 3 2 1 0

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

Digital Input Set Up Group

Table 17 lists the parameters and selections availible for the SET DIGINP group.

Table 17 Digital Input Set Up Group Parameters

Set Up and Calibration Procedures

Digital Input Set Up Group

Actuator Lower

Display Prompt

DIGINP

EndPos

Selections or

Range of Setting

NONE

DOWN

USER

default = UP

0 – 100

(in percent)

Parameter Definition/PDA HercuLink® Prompt

Digital Input State

response to a digital input signal (contact closure).

None— No action by the actuator. Up— Actuator motor moves to full scale value. Down— Actuator motor moves to zero value. User selected value— Actuator motor moves to a

customer-selected value. * Allows setting of End Position Value.

END POSITION VALUE

motor position you want the actuator to go to when digital input signal present (contact closure).

— Selects the position of the actuator in

— (DIGINP USER only) Selects the

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 51 7/08

Set Up and Calibration Procedures Display Set Up Group

Display Set Up Group

Table 18 lists the parameters and selections availible for the SET DISPLAY group.

Table 18 Display Set Up Group Parameters

Actuator Lower

Display Prompt

DECMAL

EUNITS

UNITS

Range of Setting

Selections or

8888

888.8

default = 8888

PCNT

DEG

default = PCNT

Parameter Definition/PDA HercuLink® Prompt

DECIMAL POINT LOCATION— This selection determines

where the decimal point appears in the display.

None

One Place

Note: Be sure the selection agrees with the value to be displayed. If display value requires 4 whole digits, the decimal will not show.

UNITS DISPLAY— Selects the units of the position display. Percent— Shows actuator position as a percentage of span.

(0 to 100%)

Degrees— Shows the actuator position in degrees of

rotation. (0 to 150

DISPLAY UNITS— Selects standard for unit values for the

local display.

SI— Display will show unit values in international (metric)

units. (Temperature in degrees C, Date format: ddmmyy)

°) (90°)

ENGL

default = ENGL

English— Display will show unit values in U.S. units.

(Temperature in degrees F, Date format: mmddyy)

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

Lock Set Up Group

Table 19 lists the parameters and selections available for the SET LOCK group.

Set Up and Calibration Procedures

Lock Set Up Group

Table 19 Lock Set Up Group Parameters

Actuator Lower

Display Prompt

LOCKID

LOCK

MAENAB

Selections or

Range of Setting

0 to 4095

default = 0

NONE

CONF

FULL

default = NONE

CAL

Parameter Definition/PDA HercuLink® Prompt

PASSWORD LOCK

provide security access to calibration information, set up parameters and supervisory functions. Password can be a number from 0 to 4095.

LOCK OUT FEATURE

calibration and supervisory functions, and set up groups.

None— No lockout of any calibration or set up groups. You

select and change set up group values, and perform field calibration.

Calibration— Lockout for calibration groups SET CALINP,

SET CALMTR, SET CALOUT and CAL POSOUT only. You can select and change set up group values.

Configuration— Lockout for calibration groups and set up

group configuration. You can only scroll through and view set up group values.

Full— Lockout for calibration and all set up group values.

Only SET LOCK and READ STATUS groups are accessible.

Manual / Auto

from the front panel.

— 4-digit password can be selected to

— Selects lockout security for

— Allows the ability to lockout mode changes

DIS

ENAB

default = ENAB

Disabled

functionality.

Enabled— Enables the front panel auto / manual switch

functionality.

— Disables the front panel auto / manual switch

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 53 7/08

Set Up and Calibration Procedures Lock Set Up Group

Set/Change Password

A password is required to disable the ability to readily change features of the actuator. Lock out of calibration capability and other supervisory functions can be controlled by using a password. The password can be any number from 0 to 4095. The password is set and/or changed by using the keys on the kepad and the local display. Follow the steps below to change the password.

NOTE: The LOCK parameter must be set to NONE in order to change the password.

Step Action

1 Press SET UP key until the display reads SET LOCK. 2 Press the FUNCTION key until the lower display reads LOCK.

If the prompt in the upper display is flashing, a password is required to change the LOCK type, proceed to step 3.

If the upper display is not flashing and you want to change the LOCK type, proceed to step 5.

If the upper display is not flashing and you want to change the password proceed to step 3.

3 Press the FUNCTION key until the lower display reads LOCKID. 4

The upper display will show 0 (zero). Use the or keys to increment the number to the correct password. See NOTE below on use of keys.

Note: If the password can not be recovered to allow user access, a universal password can be obtained by calling the Honeywell Tactical Assistance center.

Press the FUNCTION key, the lower display should read LOCK. The upper display should not be flashing. If it is repeat steps 3 & 4.

Use the or keys to change the LOCK type to the desired selection.

If your not changing the password proceed to step 9.

If your changing the password set the LOCK type to NONE and proceed to step 7.

7 Press the FUNCTION key until the lower display reads LOCKID. 8

The upper display will show 0 (zero). Use the or keys to increment the number to the new password. See NOTE below on use of keys.

9 Press FUNCTION key to view next parameter. Press DISPLAY to exit set up mode.

(LOCK type has now been changed or Password is now set to new value).

NOTE:

When changing the value of the number, you can adjust a more significant digit in the upper display by holding in one key

The adjustment will move one digit to the left.

Press the key again and you will move one more digit to the left.

or and pressing the other or at the same time.

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

Read Status Set Up Group

Table 20 lists the parameters and selections available for the READ STATUS group.

Table 20 Read Status Set Up Group Parameters

Set Up and Calibration Procedures

Read Status Set Up Group

Actuator Lower

Display Prompt

FAILSF

RAMTST

SEETST

Selections or

Range of Setting

YES

PASS

FAIL

PASS

FAIL

Parameter Definition/PDA HercuLink® Prompt

FAILSAFE

failsafe.

No— Actuator not in failsafe.

— Read Only. Shows whether actuator in

Yes— Actuator in failsafe, see

Troubleshooting (page 105)

RAM TEST DIAGNOSTIC

RAM test diagnostic.

Pass— Test passed, no errors

— Read Only. Shows status of

Fail— Test failed, see see

Troubleshooting (page 105)

SERIAL EEPROM TEST DIAGNOSTIC

Shows status of serial electrically eraseable PROM test diagnostic.

Pass— Test passed, no errors

— Read Only.

Fail— Test failed, see

Troubleshooting (page 105)

CFGTST

CALTST

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 55 7/08

PASS

FAIL

PASS

FAIL

CONFIGURATION TEST DIAGNOSTIC

Shows status of Configuration test diagnostic.

Pass— Test passed, no errors

Fail— Test failed, see

Troubleshooting (page 105)

CALIBRATION TEST DIAGNOSTIC

status of Calibration test diagnostic.

Pass— Test passed, no errors

Fail— Test failed, see

Troubleshooting (page 105)

— Read Only.

— Read Only. Shows

Set Up and Calibration Procedures Drive Set Up Group

Drive Set Up Group

Table 21 lists the parameters and selections available for the SET DRVINF group.

Table 21 Drive Set Up Group Parameters

Actuator Lower

Display Prompt

VERSON

SPEED

(150° @ 60hz)

SPEED

(90° @ 60hz)

SPEED

(150° @ 50hz)

SPEED

(90° @ 50hz)

Selections or

Range of Setting

nnnn FIRMWARE VERSION

6 S 12 S 25 S 50 S 75 S

3.2 S

7.2 S 15 S 30 S 45 S

7.5 S

15 S

30 S 60 S 90 S

4.5 S 9 S 18 S 36 S 54 S

Parameter Definition/PDA HercuLink® Prompt

version currently in use by the actuator’s CPU.

STROKE SPEED

seconds it takes for the actuator shaft to move its full range of travel.

STROKE SPEED

seconds it takes for the actuator shaft to move its full range of travel.

STROKE SPEED

seconds it takes for the actuator shaft to move its full range of travel.

STROKE SPEED— Read Only. The speed is the number of

seconds it takes for the actuator shaft to move its full range of travel.

— Read Only. Displays the firmware

— Read Only. The speed is the number of

POWER

ROTATE

TAG

DMFG

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

1206 1205 2206 2205

150

nnnnnn TAG NAME

mmddyy *

ddmmyy

POWER INPUT VOLTAGE AND FREQUENCY

Only. Selects the power input voltage and line frequency of

the actuator.

1206— 120Volts, 60Hz 1205— 120Volts, 50Hz 2206— 220Volts, 60Hz 2205— 220Volts, 50Hz

ROTATION

rotation.

90— Factory calibrated for 90 degrees of rotation. 150— Factory calibrated for 150 degrees of rotation.

actuator. Up to 6 alphanumeric characters. See “Set Tag Name” on next page.

MANUFACTURING DATE— Read Only. Displays date

code of manufacture for actuator.

— Indicates the factory calibrated degrees of

— Selects the tag name or identifier of the

— Read

Set Up and Calibration Procedures

Drive Set Up Group

Actuator Lower

Display Prompt

LREP

LCAL

REPTYP

Selections or

Range of Setting

mmddyy *

ddmmyy

mmddyy *

ddmmyy

NONE

01 02 03 04 05 06 07 08 09 10 11 12 13

Parameter Definition/PDA HercuLink® Prompt

DATE OF LAST REPAIR

— Factory set only. Displays date

of last repair.

DATE OF LAST FACTORY CALIBRATION— Factory set

only. Displays date of last factory calibration

REPAIR TYPE

— Factory set only. Displays a repair code to

identify the type of repair service previously performed.

None

Future

Non-contact Sensor Main CPU PWA repair Motor service Power Distribution PWA service Switch repair Relay service Gear service Service to repair water damage Service to repair damage caused by heat Service to repair due to over-voltage damage Actuator reconfigured Warranty Repair

* NOTE: Date format is set by the UNITS parameter. See SET DISPLA set up group.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 57 7/08

Set Up and Calibration Procedures Drive Set Up Group

Set Tag Name

The actuator tag name can be an alphanumeric name up to six characters. The tag name is set by using the keys on the keypad and the local display. Follow the steps below to set the tag name.

Step Action

1 Press SET UP key until the display reads SET DRVINF. 2 Press the FUNCTION key until the upper display reads TAG. 3

The lower display contains six digits. A decimal point will be flashing at the leftmost digit for approximately three seconds. Then the decimal point shifts to the right and flashes for three seconds before shifting again to the right. This pattern repeats continuously.

Set the digit to the left of the flashing decimal point. Use the or keys to scroll through the character set of 0 through 9, the letters ‘a’ through ‘z’ and the letters ‘A’ through ‘Z’ . Scroll through until the desired character is displayed.

Wait for the decimal point to shift to the right and then scroll through using the or keys until the next character is displayed.

6 Repeat for each character of the tag until the complete tag name is displayed. 7 Press the FUNCTION key to go to the next parameter, or press DISPLAY to exit set up mode.

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

Maintenance Set Up Group

The Maintenance set up group consists of information about actuator operation accumulated through time. This information (or maintenance statistics) can be used to evaluate actuator operation and determine predicted or scheduled maintenance periods. SET MAINTENANCE group.

Please note that maintenance statistics are written to the EEPROM every 8 hours. Therefore the statistics are saved in the event of a power interruption.

Table 22 Maintenance Set Up Group Parameters

Set Up and Calibration Procedures

Maintenance Set Up Group

Table 22 lists the parameters and selections available for the

Actuator Lower

Display

Selections or

Range of Setting

Prompt

TEMP nnnn F *

TEMPHI

TEMPLO nnnn F *

hh:mm:ss †

STARTS

RLnCNT

n = 1, 2, 3 or 4

Parameter Definition/PDA HercuLink® Prompt

PDA users: The prompts are organized differently on your PDA’s HercuLink®

nnnn F *

software. Grayed prompts are under Configuration, Maintenance. Non-grayed

ACTUATOR TEMPERATURE

current internal temperature of the actuator.

HIGH TEMPERATURE LIMIT

temperature limit of the internal actuator temperature since it

prompts are under Maintenance.

— Read Only. Displays the

— Displays the high

was last reset.

LOW TEMPERATURE LIMIT

— Displays the low temperature limit of the internal actuator temperature since it was last reset.

ACST †

nnnn

ACCUMULATED STALL TIME

stall time of the actuator motor since it was last reset.

ACCUMULATED MOTOR STARTS— Displays the

accumulated motor starts since it was last reset. Multiply displayed value times 10 999,900,000.

— Displays the accumulated

to get actual value. Range is 0 to

nnnn RELAY CYCLE COUNTS— Displays the accumulated cycle

counts of a relay since it was last reset. One relay cycle is when a relay is energized and deenergized. displayed value times 10 999,900,000.

to get actual value. Range is 0 to

Multiply

REGNn

n = 0 to 9

TOTDEG

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 59 7/08

nnnn ACCUMULATED MOTOR STARTS— Displays the

accumulated motor starts in the 1 it was last reset. See

Regions of Motor Travel (page times 10

to get actual value. Range is 0 to 999,900,000.

nnnn TOTAL DEGREES OF MOTOR TRAVEL

total number of degrees of motor travel since it was last

Multiply displayed value times 10

reset. Range is 0 to 999,900,000.

10% of motor span since

62). Multiply displayed value

— Displays the

to get actual value.

Set Up and Calibration Procedures Maintenance Set Up Group

Actuator Lower

Display Prompt

DATSAV

PASSWRD

MANRST

Selections or

Range of Setting

DIS

ENAB

nnnn

NONE

STAL STRT

REGNn

n = 0 to 9

Parameter Definition/PDA HercuLink® Prompt

PDA users: The prompts are organized differently on your PDA’s HercuLink®

software. Grayed prompts are under Configuration, Maintenance. Non-grayed

prompts are under Maintenance.

MAINTENANCE DATA FORCED SAVE— Allows you to

manually force a save of the current maintenance data values.

DISABLE— Forced data save is disabled. ENABLE— Forced data save is enabled. PASSWORD— If a password has been activated, then a 4-

digit password is required to enable any of the functions below.

NOTE: Password is set (or changed) from the Lock set up group.

MAINTENANCE STATISTIC RESET— Allows reset of the

following maintenance statistics:

— No reset of maintenance statisitics

None Stall— Resets accumulated stall time to zero. Motor Starts— Resets the accumulated motor start counter

to zero.

Motor Starts in the Region— Resets the selected motor

span region counter to zero.

TEMP

TDEG

RELn

n = 1, 2, 3 or 4

ALL

SYST

default = NONE

Temperature Statistics— Resets the high / low

temperature limit statistics.

Total Degrees— Resets the total degrees of motor travel to

zero.

Relay Counts

— Resets the selected accumulated relay

cycle counter to zero.

All— Resets all maintenance statistics to zero. SYST— Enables the system restart function.

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

Set Up and Calibration Procedures

Actuator Lower

Display Prompt

LD CAL NONE

LD CFG DIS

Selections or

Range of Setting

default = NONE

INP

MTR

COUT

ALL

POS

ENAB

default = DIS

Parameter Definition/PDA HercuLink® Prompt

PDA users: The prompts are organized differently on your PDA’s HercuLink®

software. Grayed prompts are under Configuration, Maintenance. Non-grayed

prompts are under Maintenance.

RESTORE CALIBRATION TYPE— Allows you to restore a

calbration value to its factory calibration.

Input — Restores input calibration to the factory calibration

for the current configured input type.

Motor— Restores motor calibration to the factory calibration. Output — Restores actuator output calibration to the factory

calibration for the current configured output type.

All — Restores input (for the type configured), motor and

output (for the type configured) calibration to the factory calibration.

POS — Allows a position sensor field calibration to be stored

as a factory calibration. This is to be used when a sensor is

replaced in the field. See “Calibrate POS Output”.

RESTORE DEFAULT FACTORY CONFIGURATION—

Allows you to restore the factory default configuration.

DIS — Restore disabled. ENAB— Restore enabled.

RESTRT DIS

ENAB

default = DIS

* Temperature units are displayed in degrees C or F, and are set by the UNITS parameter. See SET DISPLA set up group.

† Note that the upper display contains the parameter name and the lower display contains the value.

This is to allow for the display of hours: minutes: seconds.

SYSTEM RESTART— Allows you to force the system to

restart.

DIS — Restart disabled. ENAB— Restart enabled.

Note: The

MANRST function must be set to SYST.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 61 7/08

Set Up and Calibration Procedures Regions of Motor Travel

Regions of Motor Travel

The full span of motor travel can be 90° or 150° rotation. The span is divided into 10 regions of motor travel as shown in on the total number of motor starts, as well as the total number of motor starts that occur in each region of travel. The statistics can be accessed in the maintenance set up group. The counts can also be reset to zero if desired. See the Maintenance Set Up Group for more information. The regions of travel are determined by the full span motor travel (90° or 150° rotation). If the actuator is set up to operate in a smaller range, for example between 40% and 80% of full span, the maintenance statistics will show motor starts only in regions 4 through 7.

Figure 23 (regions are numbered 0 through 9). Maintenance statistics are accumulated

Percent of Span

0% 20% 40% 60% 80% 100%

Region of Travel

0 1 2 3 4 5 6 7 8 9

0o 30o 60o 90o

Degrees of Rotation

Regio n of Trave l

Pe rc en t of S pa n

0% 20% 4 0% 60% 8 0% 100%

0 1 2 3 4 5 6 7 8 9

Degrees of R otation

150

Figure 23 Regions of Motor Travel

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

CAL POSOUT Group

The CAL POSOUT group is used to verify that the position sensor is operating and adjusted properly. This group allows the local display to indicate the output voltage of the position sensor. This display is used when verifying the POS sensor is operating and that it is properly calibrated. available for the CAL POSOUT group.

Set Up and Calibration Procedures

CAL POSOUT Group

Table 23 shows the selections

Table 23 CAL POSOUT Group Parameters

Actuator Lower

Display Prompt

CALPOS

Selections or

Range of Setting

n.nnn POSITION SENSOR OUTPUT

Parameter Definition/PDA HercuLink Prompt

output voltage of the position sensor

To access the display…

FUNCTION Upper Display = DIS

FUNCTION

Press Result

SETUP

until you see

or key

Upper Display = Lower Display =

Lower Display = Upper Display =

Lower Display =

— Read Only. Displays the

CAL

POSOUT

CALPOS

BEGN

CALPOS

n.nnn (sensor output in volts)

POSOUT

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 63 7/08

Set Up and Calibration Procedures Auto - Manual Drive Switch

Auto - Manual Drive Switch

The Auto - Manual switch is located on the side of the actuator case below the handwheel. The switch allows manual mode control of the actuator motor for set up, calibration and troubleshooting. Figure 24 shows an illustration of the Auto - Manual switch and Table 24 describes the switch settings. The Auto - Manual Drive switch setting overrides all input signals (analog signal and remote setpoint) and local display mode settings. When not in auto the manual LED will flash every second.

OFF

A U T O

MANUAL

OFF

CWCCW

AUTO - MANUAL DRIVE

Figure 24 Auto - Manual Switch

Table 24 Auto - Manual Switch Functions

Switch Setting Motor Drive Control

AUTO Actuator moves according to signal input and set up configuration.

CCW Actuator moves to the fully counterclockwise position.

CW Actuator moves to the fully clockwise position.

OFF Actuator is idle.

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

Calibration

Calibration of the HercuLine® 2000 Series Actuator may consist of calibrating the motor circuit that positions the actuator with 0/4-20mA input signal, calibrating the potentiometer or non-con tact sensor, and calibrating the slidewire emulation output or the 0/4-20mA output signal. Typically, only a motor calibration is required for installation.

Calibration is performed by connecting test equipment to the input terminals or output terminals and then using the keypad and display to step through the calibration group functions .

Set Up and Calibration Procedures

Calibration

ATTENTION

Input calibration and output calibrations are performed at the factory and may not be necessary. Normally, you may only need to perform Calibrate Motor.

Only qualified personnel should perform calibration.

High voltages exist inside the actuator case. Do not touch the powered wires inside. Death or serious injury can occur.

Equipment Needed

The table below lists the equipment you will need to calibrate the HercuLine circuits.

Input Calibration

Output Calibration

• A 250 ohm resistor 0.01% tolerance.

2000 input and output

Procedure Equipment Needed

• A calibrated signal source which can provide current (4 to 20

mA) or voltage (0 to 10 V) with an accuracy of 0.02% or better.

• Two insulated copper leads for connecting the current source

to the actuator.

• A digital voltmeter with an accuracy of 0.01% or better.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 65 7/08

Set Up and Calibration Procedures Calibration

Calibration Set up

Follow the steps below to set up the test equipment and actuator to verify calibration or perform calibration procedures.

Step Action

1 Determine input type (current or voltage). 2

Set jumper W2 on main CPU board according to type of signal source. See Figure 27 on page 68 for jumper location.

Connect the copper leads from the signal source to the input terminals of the actuator as shown in

4 Place signal source output at zero and switch power on. 5

Connect a 250 ohm resistor across the Output terminals of the actuator and connect the DVM leads to the terminals.

Figure 25.

Actuator

Calibrated Signal Source

Internal 250 ohm resistor

settable through

Jumper W2

Terminal Block

Input

5 4

Output

2 1

250 ohm resistor (supplied)

Digital Voltmeter

+ -

Current

Voltage

Figure 25 Calibration Wiring Connections (non-slidewire emulation)

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

Calibrated Signal Source

Set Up and Calibration Procedures

Calibration

Actuator

Digital Voltmeter

+ -

Terminal Block

Input

5 4

Output

2 1 3

Power Supply 1-18 VDC

Internal 250 ohm resistor

settable through

Jumper W2

Current

Voltage

Figure 26 Calibration Wiring Connections (slidewire emulation)

+ -

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 67 7/08

Set Up and Calibration Procedures Calibration

Jumper W2

Calibrate Input

The HercuLine

0 to 20 mA, or 4 to 20 mA

0 to 5 Volts,1 to 5 Volts, or 0 to 10 Volts

The input type is selected through th e Input set up group using the local keypad. Refer to

circuit of the HercuLine

Figure 27 Jumper Location on CPU PWA

2001/2002 actuator accepts a variety of signal inputs.

Figure 25 for the wiring connections and follow the procedure in Table 25 to calibrate the input

ATTENTION

For an input calibration to be saved, you must complete the procedure. The calibration will not be saved if you exit without completing the steps of the procedure.

To exit calibation mode, press DISPLAY or SETUP keys.

2001/2002 actuator.

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

Set Up and Calibration Procedures

Table 25 Input Calibration Procedure

Step Operation Press Result

Calibration

Enter Calibration Mode

SETUP

until you see

Upper Display = Lower Display =

CAL

INPUT

FUNCTION Upper Display = DIS

CAL IN

BEGN

CAL IN

or key

Lower Display = Upper Display =

Lower Display =

2 Calibrate Zero (0%) FUNCTION Upper Display = APLY

Lower Display =

• Adjust the signal source to an output value equal to 0% range

value.

• Wait 5 seconds, then go to step 3.

Calibrate Span (100%)

4 FUNCTION

FUNCTION Upper Display =

Lower Display =

• Adjust the signal source to an output value equal to 100%

range value.

• Wait 5 seconds, then go to step 4.

Calibration for zero and span input values are now saved. Input calibration is complete.

NOTE: The display will automatically go to the CAL MOTOR set up display. See pressing the DISPLAY or SETUP keys.

Table 26. You may also exit calibation mode by

INZERO

APLY INSPAN

ATTENTION:

When calibrating the motor to a short stroke range, you must

reset the end-of-travel limit switches. See Setting End-of-Travel Limit Switches.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 69 7/08

Set Up and Calibration Procedures Calibration

Calibrate Motor

Use the procedure in

Table 26 to calibrate the actuator motor for 0% and 100% input signal

ATTENTION

For a motor calibration to be saved, you must complete the procedure. The calibration will not be saved if you exit without completing the steps of the procedure.

ATTENTION

When calibrating the motor to a short stroke range, you must reset the end-of-travel limit

switches. See Setting End-of-Travel Limit Switches.

Table 26 Motor Calibration Procedure

Step Operation Press Result

Enter Calibration Mode

SETUP

until you see

Upper Display = Lower Display =

CAL MOTOR

FUNCTION Upper Display = DIS

or key

Lower Display = Upper Display =

Lower Display =

CALMTR BEGN

CALMTR

2 Calibrate Zero (0%) FUNCTION Upper Display = APLY

Lower Display =

MTR LO

• Use the Handwheeel or AUTO/MANUAL switch to manually

drive the actuator motor to its low position.

• Wait 5 seconds, then go to step 3.

Calibrate Span (100%)

4 FUNCTION

FUNCTION Upper Display =

Lower Display =

• Use the Handwheeel or AUTO/MANUAL switch to manually

drive the actuator motor to its high position.

• Wait 5 seconds, then go to step 4.

Calibration for zero and span motor positions are now saved. Motor calibration is complete.

NOTE: The display will automatically go to the CAL CURENT set up display. See mode by pressing the DISPLAY or SETUP keys.

APLY MTR HI

Table 27. You may also exit calibation

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

Calibrate Output

HercuLine

0 to 20 mA, or 4 to 20 mA output

0 to 5 Volts, or 1 to 5 Volts with 250 ohm range resistor

Slidewire emulation.

The output signal range is selected through the Current Out set up group using the keypad and local display.

0/4-20 mA Output

The HercuLine do a calibration in the field, adjust the output using the procedure in diagram to connect a signal source to the actuator input and a DVM to measure actuator output signal.

This procedure provides the steps to calibrate the actuator for a 4 to 20mA output. If you are using another output type, change the procedure accordingly.

For an output calibration to be saved, you must complete the procedure. The calibration will not be saved if you exit without completing the steps of the procedure.

Set Up and Calibration Procedures

2001/2002 actuator can be one of three output types:

2001/2002 Actuator comes already calibrated from the factory. If it becomes necessary to

Table 27. Refer to Figure 25 for a

ATTENTION

Calibration

To exit calibation mode, press DISPLAY or SETUP keys.

Table 27 Output Calibration Procedure

Step Operation Press Result

Enter Calibration Mode

SETUP

until you see

Upper Display = Lower Display =

CAL CUR OUT

FUNCTION Upper Display = DIS

CALOUT

BEGN CALOUT

or key

Lower Display =

Upper Display = Lower Display =

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 71 7/08

Set Up and Calibration Procedures Calibration

Step Operation Press Result

2 Calibrate Zero (0%) FUNCTION Upper Display = xxx

Lower Display =

• Read meter connected to actuator output.

ZERO

Calibrate Span (100%)

or key

FUNCTION Upper Display =

or key

4 FUNCTION

• Adjust actuator output to a value equal to 0% output as read

from the DVM.

NOTE: Typically for a 4 mA output, the display will show a value of approximately 382. A lower limit value is imposed on the zero output. If the value is 357 or lower, the actuator will not allow you to calibrate the zero output. The value must be larger than 357 for a valid calibration.

Lower Display =

• Read meter connected to actuator output.

• Adjust actuator output to a value equal to 100% output as read

from the DVM.

• NOTE: Typically for a 20 mA output, the display will show a

value of approximately 1887.

Calibration for zero and span output values are now stored. Output calibration is complete.

Slidewire Emulation

The HercuLine

2001/2002 Actuator comes already calibrated from the factory. If it becomes necessary to do a calibrationin the field, adjust the output using the procedure in diagram to connect a signal source to the actuator input and a DVM to measur e actuator output signal.

ATTENTION

For a slidewire emulation output calibration to be saved, you must complete the procedure. The calibration will not be saved if you exit without completing the steps of the procedure.

xxxx SPAN

Table 28. Refer to Figure 26 for a

To exit calibration mode, press DISPLAY or SETUP keys.

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

Set Up and Calibration Procedures

Table 28 Slidewire Emulation Calibration Procedure

Step Operation Press Result

Calibration

Enter Calibration Mode

SETUP

until you see

Upper Display = Lower Display =

CAL OUTPUT

FUNCTION Upper Display = DIS

CALOUT

BEGN CALOUT

or key

Lower Display =

Upper Display = Lower Display =

2 Calibrate Zero (0%) FUNCTION Upper Display = xxx

Calibrate Span (100%)

Lower Display =

xxx = arbitrary number assigned by software

or key

FUNCTION Upper Display =

or key

Adjust actuator output voltage using down key until value on DVM ceases to change, then press up key until value on DVM moves up one digit

Lower Display =

xxx = arbitrary number assigned by software

Adjust actuator output voltage using ceases to change, then press

moves down one digit

ZERO

xxxx SPAN

key until value on DVM

down key until value on DVM

FUNCTION Calibration for zero and span output values are now stored.

Slidewire Emulation Output Calibration is complete. Read meter connected to actuator output.

Calibrate Position Sensor

ATTENTION The Position Sensor is factory calibrated. Under normal operation it does not require

calibration.

Sensor calibration may be necessary due to any of the following conditions:

• The sensor output is incorrect,

• The position sensor in the actuator has been replaced,

• The position sensor adjustment has been disturbed.

When the position sensor has been replaced (or serviced), you should perform a calibration of the position sensor circuit and then store it as the motor factory calibration. Please note that performing this procedure will destroy any previously stored motor factory calibration values.

Table 29 outlines the steps to perform a

calibration to the position sensor circuit.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 73 7/08

Set Up and Calibration Procedures Calibration

While the unit is powered, a potentially lethal shock hazard exists inside the case.

Table 29 NCS Position Sensor Calibration Procedure

Step Action

1 Remove AC power to the actuator. 2

Remove the six screws and the top cover from the actuator case. See Figure 2. Lay extended cover assembly on a flat surface. Remove relay cards if present.

3 Reapply AC power to the actuator. 4 Press SET UP key to access the INPUT set up group.

Press FUNCTION key until the lower display reads Direct.

Press the

NOTE: Actuator direction must be set to CCW for this procedure. Direction can be changed after calibration is complete.

Drive the actuator to the 50% position (this refers to the position on the actuator scale for CCW rotation). This should be done manually with the handwheel or with the AUTO - MANUAL switch.

or keys to set Actuator Rotation direction to CCW.

6 Press SET UP key until the display reads CAL POSOUT.

Press the FUNCTION key until the dispaly reads DIS CALPOS.

Press the

Press FUNCTION key.

The upper display now shows the output of the position sensor in Volts.

Loosen the allen screw in the hub of the NCS spoiler just enough to be able to rotate the spoiler. See

Adjust the NCS spoiler so that the voltage in the local display is 2.500 ± 0.010 volts dc. The allen screw should be almost in a vertical position. The bottom edge of the spoiler should almost be horizontal in relation to the NCS PWA. See

Tighten NCS spoiler set screw with an allen wrench, holding spoilers located on each side of the NCS PWA in position.

IMPORTANT: Spoilers need to be held in position both rotationally and longitudinally along

the drive shaft extension. An air gap must be maintained between the surface of the PWA and each spoiler. (Any plastic or paper insulating material may be used to create this gap while positioning the spoilers). Make sure that neither spoiler is touching the sensor PWA when the adjustment is complete.

or keys until the lower display reads BEGN CALPOS.

Figure 28.

10 Press DISPLAY key to exit calibration mode. 11 Remove AC power to the actuator. Reinstall relay cards If present. 12 Install a new gasket and replace extended cover. Secure to actuator with screws. 13 Continue with calibration procedure in Table 31.

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

Set Up and Calibration Procedures

Calibration

NCS set screw

NCS PWA

Relay PWA card guides (relay PWAs removed)

NCS Spoiler (shown at full 150 degree travel CCW)

Figure 28 Location of NCS Assembly

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 75 7/08

Set Up and Calibration Procedures Calibration

Table 30 Potentiometer Position Sensor Calibration Procedure

Step Action

1 Remove AC power to the actuator. 2

Remove the six screws and the top cover from the actuator case. See Figure 2. Lay extended cover assembly on a flat surface. Remove relay cards if present.

3 Reapply AC power to the actuator. 4 Press SET UP key to access the INPUT set up group.

Press FUNCTION key until the lower display reads Direct.

Press the

NOTE: Actuator direction must be set to CCW for this procedure. Direction can be changed after calibration is complete.

Drive the actuator to the 50% position (this refers to the position on the actuator scale for CCW rotation). This should be done manually with the handwheel or with the AUTO - MANUAL switch.

or keys to set Actuator Rotation direction to CCW.

6 Press SET UP key until the display reads CAL POSOUT.

Press the FUNCTION key until the dispaly reads DIS CALPOS.

Press the

Press FUNCTION key.

The upper display now shows the output of the position sensor in Volts.

Loosen the set screw at the end of the switch camshaft where the potentiometer connects to the shaft.

Using pliers, adjust the white plastic knob on the back side of the potentiometer so the voltage in the local display is 2.500 ± 0.010 volts dc.

or keys until the lower display reads BEGN CALPOS.

9 Tighten set screw with an allen wrench. 10 Press DISPLAY key to exit calibration mode. 11 Remove AC power to the actuator. Reinstall relay cards If present. 12 Install a new gasket and replace extended cover. Secure to actuator with screws. 13 Continue with calibration procedure in Table 31.

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

Set Up and Calibration Procedures

Calibration

Potentiometer position sensor Mounting bracket

Figure 29 Location of potentiometer position sensor

Table 31 Load Position Sensor Factory Calibration

Step Action

1 Reapply AC power to the actuator. 2

Press SET UP key to access the MAINT set up group. Press the FUNCTION key until the display reads LD CAL.

Press the

Perform the Calibrate Motor procedure exactly as in Table 26 Motor calibration must be performed for the factory configured full span range (0-100%).

ATTENTION

When calibrating the motor to a short stroke range, you must reset the end-of-travel limit

switches. See Setting End-of-Travel Limit Switches.

When motor calibration is complete, the calibration is now stored as the factory calibration of the actuator motor.

or keys until the display reads POS.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 77 7/08

Set Up and Calibration Procedures

Setting End-of-Travel Limit Switches

ATTENTION Referring to

100% limit switches (Switch #1 and Switch #2) and should not need any adju stments as they are factory set to stop the drive at 0% and 100%. See Figure 30 for limit switch settings.

Figure 31. The first two cams (starting from the front) are for the 0% and

LEFT HAND POINTER SCALE

SW# 1

SW#2

END OF TR

(FACTORY SET AT 0% AND 100%)

Clockwise and counterclockwise rotation is the direction of the output shaft when

Clockwise and counterclockwise rotation is the direction of t he output shaft

facing the end of the shaft. As shown, full clockwise rotation of the output shaft

when facing the end of the shaft. As shown, clockwise rotation of the output

activates SW1 and CCW rotation activates SW2.

shaft activates SW 1 (at 0% on the left hand pointer scale) and CCW rotation activates SW 2 (at 100% on the left hand pointer scale). Terminal numbers are next to the ci rcles.

8 (SW 1 COM)

VEL LIMIT SWITCH S ETTINGS

Clockwise Rotation

Counterclockwise Rotation

100%

9 (SW 2 COM)

155

Figure 30 End of Travel Limit Switch Settings

REFERENCE

An unactuated switch will have its normally closed (NC) contacts closed and its normally open (NO) contacts open.

An actuated switch will have its NC contacts become open and its NO contacts become closed. Both NC and NO contacts are available at the terminal block. See

Figure 9 (page 19).

and

Figure 8 (page 18)

An unactuated switch has its roller arm in the up position when adjacent to the reduced diameter portion of the cam.

If it becomes necessary to do adjust the limit switch cams in the field, use the procedure given in

While the unit is powered, a potentially lethal shock hazard exists inside the case.

Table 32.

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

Set Up and Calibration Procedures

Setting End-of-Travel Limit Switches

Table 32 End-of-Travel Limit Switch Setting Procedure

Step Action

1 Remove AC power to the actuator. 2

Remove the six screws and the cover from the actuator case. See Figure 2. Lay cover assembly on a flat surface.

Using a flat blade screwdriver in the slots at the edge of the cams, or your finger, rotate the cams until the switches are set. (See

• Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the 0%

position (this is the 0% for CCW operation using the bottom scale or 100% for CW operation using the top scale). If the actuator is installed on a damper or valve, also make sure that this position is synchronized with the travel of the final control element.

• Rotate the #1 limit switch operating cam to activate at this position. The switch roller arm

should go from being in an up, not depressed state, to a depressed state as the cam is rotated in the direction of the shaft rotation going toward the limit position. This will cause the switch to go from NC to NO and turn off the power to the motor when the switch activates. Switch activation may be detected by the clicking sound or with a continuity tester connected to the terminals.

Figure 31).

• Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the

100% position (this is 100% for CCW operation using the bottom scale or 0% for CW operation using the top scale). If the actuator is installed on a damper or valve, also make sure that this position is synchronized with the travel of the final control element.

• Rotate the #2 limit switch operating cam to activate at this position. The switch roller arm

• If optional auxiliary switches were ordered, these switches may also be set at this time. (See

Setting Auxiliary Switches (page 81).

Double check limit switch actuation by first manually driving the actuator to each end of travel and hearing the switch click or by detecting it with a continuity tester. Secondly, drive the actuator to both ends of travel (using the auto/manual switch or by providing minimum and full input signal) and make sure the switches activate and turn off the motor.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 79 7/08

Set Up and Calibration Procedures

Setting End-of-Travel Limit Switches

ATTENTION

Make sure you do not to set the switches too close to the hard stop.

Relay PWAs

Relay #1 Relay #2 Relay #3 Relay #4

Aux switch #1 Aux switch #2 Aux switch #3

ux switch #4

End of travel switch #1 (stops CW rotation) End of travel switch #2 (stops CCW rotation)

Figure 31 Location of End-of-Travel Limit and Auxiliary Switches

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

Setting Auxiliary Switches

ATTENTION Referring to

100% end of travel limit switches (Switches #1 and #2) and should not need any adjustments as they are factory set to stop the actuator precisely at 0% and 100%. See

Setting End-of-Travel Limit Switches (page 78).

Additional switch settings should be set so that switch #3 operates in synchronism with switch #1 (i.e., both activating when the actuator is going in the same direction) and switch #4 to operates in synchronism with switch #2, etc. See

LEFT HAND POINTER SCALE

SW #3

Figure 31. The first two cams (starting from the front) are for the 0% and

17 (SW3 COM)

23 (SW5 COM)

(SW 6 CO M) 26

Set Up and Calibration Procedures

Setting Auxiliary Switches

Figure 32 for auxiliary switch settings.

100%

20 (SW4 COM)

SW #4

SW #5

SW #6

Figure 32 Auxiliary Switch Settings

If it becomes necessary to do adjust the auxillary switch cams in the field, use the procedure given in

Table

33.

While the unit is powered, a potentially lethal shock hazard exists inside the case.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 81 7/08

Set Up and Calibration Procedures Setting Auxiliary Switches

Step Action

1 Remove AC power to the actuator.

Remove the six screws and the cover from the actuator case. See Figure 2. Lay cover assembly on a flat surface.

Using a flat blade screwdriver on the slots on edge of cams, or your fingers, rotate the cams until the switches are set. (See

• The auxiliary switches should be set so switches #3 and #5 operate in synchronism with

switch #1 (i.e., both activating when the drive is going in the same direction) and set switches #4 and #6 to operate in synchronism with switch #2. See switch settings.

4 For Switches #3 and #5:

• Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the

desired low scale position.

• Rotate the #3 switch operating cam to activate at this position. The switch roller arm should

go from being in an up, not depressed state, to a depressed state as the cam is rotated in the direction of the shaft rotation going toward the limit position. This will cause the switch to go from NC to NO and turn off the power to the motor when the switch activates. Switch activation may be detected by the clicking sound or with a continuity tester connected to the terminals.

Table 33 Auxiliary Switch Setting Procedure

Figure 31)

Figure 32 for auxiliary

• Repeat for Switch #5 if applicable.

5 For Switches #4 and #6:

• Rotate the actuator shaft, using the manual handwheel or the auto-manual switch, to the

desired up scale position.

• Rotate the #4 switch operating cam to activate at this position. The switch roller arm should

• Repeat for Switch #6 if applicable.

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

Introduction

After the actuator is completely installed, wired, and the preliminary adjustments made, it is advisable to check the operation of the actuator and controlled device before placing it in service. In other words, operate the controlled device and check its direction of travel in response to an increase of the input signal and make sure it is correct for the process. Actuators having the optional auto-manual switch must have the knob set in the AUTO position.

This section provides a checklist that can be used to do a walk-through with the actuator before it is actually used for control. Other features which may be helpful in understanding actuator operation are also provided.

Power-up Diagnostics

When power is applied to the actuator, the actuator electronics performs a diagnostic routine on various device components. These tests include a:

Start-Up/Operation

Introduction

Start-Up/Operation

• RAM diagnostic (RAMTST),

• Check of the electrically eraseable PROM (SEETST),

• Verification that valid parameter values are in the actuator configuration (CFGTST),

• Verification of valid calibration values (CALTST)

• Test of the local display and LED indicators (all display segments and LED indicators light simultaneously).

The local display shows the status of the diagno stics as they are completed during power up. TEST DONE is shown on the display when diagnostics are complete and actuator should be in AUTO mode. See more information on the power up diagnostics.

Operations Checklist

To make sure that the actuator is properly installed and set up for your particular application, you should check and verify the following:

• Verify that the configuration is correct for your application by stepping through all set up groups and

checking the setting of all set up parameters.

• Verify operation of end-of-travel limit switches.

• Verify operation of auxiliary switches or relay function (if installed).

• Check operation of AUTO - MANUAL DRIVE switch (if present), by setting the knob to the CW and CCW

- MANUAL positions. The output shaft should rotate in the direction indicated by the knob. The LED indicator on the local display should also indicate the actuator is in manual mode.

Table 20 for

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 83 7/08

Start-Up/Operation Operating Displays

Operating Displays

Pressing the DISPLAY key cycles the display through a number of operating parameters. Table 34 shows a number of sample displays that can be shown during operation.

Display Description

Table 34 Typical Operating Displays

NOTE: When the AUTO/MANUAL key is pressed, placing the actuator in manual mode, the local display mode is forced to the Position display (POS). The Manual L.E.D. indicator should be lit. When the AUTO/MANUAL key is pressed again, placing the actuator in auto mode, the local display mode is forced to the Output display (OP). The Auto L.E.D. indicator should be lit. Set up parameters can still be accessed.

Motor Stall

The actuator is equipped with a low current motor that prevents against burnout if the motor becomes stalled. A stall condition occurs when the motor position does not follow the input, or if the motor does not reach setpoint within a given period of time.

0.0 INP

OP 0.5

100.0

DE 99.9

0.6 POS

— Upper Disp lay = Shows input value

Input

Lower Display = prompt

Output— Upper Display = Shows input value

Lower Display = Shows output value

Deviation

Lower Display = Shows value of deviation of sensor from input.

Position— Upper Display = Shows value of position sensor.

Lower Display = prompt

NOTE: Position display will show negative values, if appropriate.

— Upper Display = Shows input value

When the stall condition occurs, a stall alarm is indicated. The actuator sets the STALLED LED indicator ON and also any other alarms or relay contacts that are programmed to close whenever a stall condition is detected.

The motor drive for the indicated direction is shut off approximately 3 minutes after the stall alarm is indicated. Also, the appropriate CW/CCW LED direction indicator is turned OFF.

The maintenance statistic for accumulated stall time gets updated during the stalled condition. To reactivate the drive in the stalled direction, change the position of the drive to the opposite direction and set

at a point below where the stall originally occurred, then start the drive in the stalled direction. Note: A stall condition is not detected if a limit end of travel limit switch is activated while the motor is moving

toward the setpoint, or if the motor position is within 0.5% of calibrated motor 0% and 100% end points.”

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

Position Sensor Operation

Start-Up/Operation

Position Sensor Operation

On HercuLine® 2000 and HercuLine® 2001 the potentiometer position sensor is a sealed film pot that is directly coupled to the output shaft. On HercuLine

2002 the non-contact sensor (NCS) is inductively coupled to the output shaft of the actuator so that the sensor detects shaft position. The sensor is adjusted at the factory and under normal conditions and requires no adjustment. A simple check can verify that the sensor working properly and that it is in adjustment. Verification of the output is performed by setting the drive motor to its zero, midpoint and 100% positions and observing the output voltage of the sensor. The actuator has a feature that the sensor output voltage can be read from the local display.

Step Action

Drive the motor to 50% position.

Press SET UP key on the keyboard until the display reads CAL POSOUT.

Press FUNCTION key until the display reads DIS CALPOS.

Press the

Press the FUNCTION key.

Upper Display = Lower Display =

The display should read 2.500 +/– 0.012 Volts for both 90° and 150° operation.

Press DISPLAY key and then drive the motor to zero position. Repeat Step 2.

The display should read 1.600 +/– 0.060 Volts for 90° operation; 1.000 +/- 0.060 volts for 150° operation.

or keys until the display reads BEGN CALPOS.

n.nnn (Output voltage of the sensor)

POSOUT

Press DISPLAY key and then drive the motor to 100% position. Repeat Step 2.

The display should read 3.400 +/– 0.060 Volts for 90° operation; 4.000 +/- 0.060 volts for 150° operation.

If the sensor needs adjustment, refer to the “Calibrate Non-Contact Sensor” procedure in Table

29 (page

74).

Remote Setpoint Operation

The HercuLine® 2001/2002 actuator can be set up to receive a digital input from a remote source. The actuator uses RS485 communications that supports digital Modbus RTU protocol. Press the SET UP key to select the Input set up group. Change the Input Type to Remote Setpoint (R_SP). Make the necessary connections to terminals 6, 7, 8 on the actuato r terminal block. See same values as the host device. The actuator communication parameters are accessed in the Communications Set Up group.

There are some restrictions to actuator operation when remote setpoint inpu t is active. In order to provide a bumpless transfer when switching from one input signal type to remote setpoint, the actuator will use the last known analog input value as its setpoint when switching to remote setpoint input operation. No input filtering is active on the input signal to the actuator.

Figure 33. Communicaton parameters should be set to the

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 85 7/08

Start-Up/Operation Remote Setpoint Operation

Actuator Terminal Block

COMMUNICATION

Figure 33 Terminal Block Connections for Modbus Communications

867

SHIELD

COM

DIGITAL INPUT

INP

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

Introduction

There is some basic maintenance that is recommended for the HercuLine® 2000 Series Actuators. The electronic PWAs within the actuator require no maintenance or servicing under normal conditions.

Maintenance

Introduction

Maintenance

If there is a problem, refer to information in this section or to

Basic Maintenance

Position Sensor

Under normal conditions the position sensor does not require maintenance.

Main Gear Lubrication

Under normal operating conditions, the main worm gear should not require maintenance.

Spur Gear Lubrication

Honeywell recommends that during major shutdown periods the spur gears should be inspected and lubricated. Follow the steps in necessary.

Disconnect power before opening the actuator case to inspect the actuator gears. A potentially dangerous pinch hazard exists inside the case if the unit is open while powered.

Step Action

Troubleshooting (page 105) .

Table 35 to access the spur gear compartment and lubricate the gears if

Table 35 Spur Gear Lubrication Procedure

1 Remove AC power from actuator. 2 Remove the six screws and the bottom cover of the actuator case. See Figure 34. 3

Inspect the final spur gear, the idler gear and motor pinion for excessive wear and adequate lubrication. See

If needed, use Texaco Starplex 2 EP grease, or equivalent and apply lubricant to assure that the gears are adequately protected.

Figure 34.

5 Install a new gasket and replace side cover. Secure to actuator with screws. 6 Restore actuator to service.

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 87 7/08

Maintenance Basic Maintenance

Bottom cover Gears

Idler spur gear

Final output spur gear

Motor pinion gear

Figure 34 Spur Gear Location

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

Replacement Procedures

Fuse Replacement

The motor drive circuit contains two fuses. They are located on the power distribution PWA. If it becomes necessary to replace these fuses, follow the procedure in

Disconnect power before opening the actuator case to replace the fuse(s). A potentially lethal shock hazard exists inside the case if the unit is opened while powered.

Table 36 Motor Drive Fuse Replacment Procedure

Step Action

1 Remove AC power from actuator. 2 Remove the 6 screws and the extended cover of the actuator case. See Figure 35. 3 Lay assembly down on a flat surface. 4 Remove connectors from CPU and power distribution PWA.

Maintenance

Replacement Procedures

Table 36 and refer to Figure 36 for fuse location.

5 Remove power distribution PWA. 6

Locate the two fuses on the power distribution PWA. See Figure 36. Carefully remove and replace fuse(s) with Wickmann T1 type 6A 250V, or equivalent (not available from Honeywell).

7 Reinstall power distribution PWA. 8 Reconnect connectors to CPU and power distribution PWA. 9 Install a new gasket and replace extended cover. Secure to actuator with screws.

Relay connector #1 Relay connector #2 Relay connector #3 Relay connector #4

}

Relay PWA#1

}

Relay PWA#2

Power distribution PWA

CPU connections

Figure 35 Power Distribution PWA and Relay PWA Locations

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 89 7/08

Maintenance Replacement Procedures

Relay PWA Replacement

Fuses for Motor Drive Circuit

Power Distribution PWA

Figure 36 Motor Drive Circuit Fuses

If a relay PWA needs to be replaced, follow the procedure in

Table 37 to access and replace the PWA.

Disconnect power before opening the actuator case. A potentially lethal shock hazard exists inside the case if the unit is opened while powered.

Table 37 Relay PWA Replacement Procedure

Step Action

1 Remove AC power from actuator. 2 Remove the six screws and the cover of the actuator case. See Figure 35. 3 Lay assembly down on a flat surface. 4 Disconnect the wire connector from the relay PWA. 5

Carefully remove the relay PWA. Pry the locking tabs of the card guides away to unlock the PWA and slide it out from the card guides.

Install the replacement relay PWA by sliding it into the card guides until it mates with the backplane board. Locking tabs on the card guides will engage to secure the PWA in place.

7 Plug in wire connector to relay PWA. 8 Install a new gasket if needed and replace cover. Secure to actuator with screws.

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

Replacement/Upgrade/Accessory Kits

Replacement Kits

This section provides you with a complete list of all the spare parts that may be needed for the HercuLine® 2000 Series Actuators and optional equipment.

Replacement/Upgrade/Accessory Kits

Replacement Kits

To determine which kit you need, cross-reference Each kit contains replacement parts accessories and instructions for component replacement.

Figure 37 through Figure 41 with Table 38 on page 96.

6,7 ,8

Figure 37 Replacement Kits 6, 7, 8, 11, 12, 14

Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 91 7/08

Replacement/Upgrade/Accessory Kits Replacement Kits

Figure 38 Replacement Kit 10

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

Honeywell HERCULINE 2000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual