Honeywell HERCULINE 2000 User Manual

HercuLine® 2000 Series Actuator

Installation, Operation and

Maintenance Manual

Doc. No.:	62-86-25-10
Revision:	7
Date:	7/08

Honeywell Field Solutions

Notices and Trademarks

Copyright 2008 by Honeywell

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

Palm is a trademark of Palm Inc.

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

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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		51-52-25-66
Modbus® RTU Serial Communications User Manual		51-52-25-103
Configuration/Remote Calibration Interfaces for HercuLine Actuators
HercuLink™ User Manual		62-86-25-11
HART Communications Installation and Operations Manual		62-86-25-12

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

Telephone

Contact us by telephone at the numbers listed below.

	Organization	Phone Number
United States and Canada	Honeywell	1-800-423-9883	Tech. Support
		1-800-525-7439	Service

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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.

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Contents

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
Actuator Mounting ......................................................................................................	13
Mechanical Installation ...............................................................................................	15
Electrical Installation...................................................................................................	17
Burner Control/Flame Safety.................................................................	23
Series 90 Control – HercuLine® 2001 model only......................................................	24
Split Range .................................................................................................................	26
Master/Slave Arrangement.........................................................................................	26
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

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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

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		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

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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 Connections (non-slidewire 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 Locations	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

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Introduction

Product Description

Introduction

Product Description

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

HercuLine® 2001, HercuLine® 2002, and HercuLine® 2003. All are low torque, precision electric rotary actuators incorporating all of the high quality and reliable features of the traditional HercuLine series actuators. These precision control and high reliability actuators ensure processes operate at maximum efficiency, with minimal downtime, and lowest lifetime cost.

Honeywell's HercuLine® 2000 series actuators are precision engineered for exceptional reliability, accurate positioning, and low maintenance (Figure 1). Designed for very precise positioning of dampers and quarter turn valves the HercuLine® 2000 series actuators perform especially well in extremely demanding environments requiring continuous-duty, high reliability, and low maintenance.

Model distinctions

HercuLine® 2000 series actuators are used in applications requiring on/off or power to open/close position proportional with 135 or 1000 ohm feedback.

HercuLine® 2001 and 2002 are smart actuators used in applications requiring current proportional control 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® Palm PDA software connected to the actuator via a 232/485 converter, via HART communications or through the optional local keypad and display.

HercuLine® 2002 smart actuators offer features and functions similar to the HercuLine® 2001 and are used for more severe service applications requiring features such as non-contact position sensing.

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

The keypad and display are available on the HercuLine® 2001 and HercuLine® 2002 products at additional charge.

HercuLink® Software

HercuLink® Computer software enables access to programming and communication functions available as standard with the HercuLine® 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® software, the computer may be used as a master device over a Modbus network to 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® 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 pack 5), Windows ME, Windows XP

•200 MHz Pentium with 64 Megs Ram

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Introduction

Product Description

Display and

keypad

Handwheel

Conduit entry

Shaft and position indicator

Auto/manual switch

Figure 1 HercuLine® 2000 Series Actuator

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Introduction

Product Description

Display

Keypad

PWA

TB3 Connector for customer input and output connection on CPU PWA

Wiring

Label

Mechanical Stops

Cams and limit switches

TB1 customer power connection

		Non-contact	External
			auto-manual
	Relay PWAs	sensor
			switch

Figure 2 HercuLine® 2002 Actuator Internal View

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Introduction

Product Description

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Specifications

Technical and Operating Specifications

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	2000: 25 lb. (11.36 kg)
	2001,2002: 27 lbs. (12.27 kg)
Enclosure	Precision-machined die cast aluminum housing, finished in light gray powder coat
	epoxy.
Gear Train	Alloy steel, high efficiency steel spur gear primary train. Precision ground, self-
	locking/self releasing worm gear final mesh.
Mechanical Stops	Factory set at 90° or 150° (+/-5°).
	Attention: Do not adjust the mechanical Stops. Adjusting the stops will void
	the warranty
Storage Temperature	–40 °C to +93 °C (–40 °C to +200 °F)
Relative Humidity	0 % to 99 % R.H. non-condensing over the full operating temperature range.
Scale	0 % to 100 % corresponding to full crank arm travel.
Crank Arm	Adjustable radii 1.0 in (25.4mm) to a maximum of 2.8 in (71.1mm). Position
	adjustable through 360° rotation.
Output Shaft	0.625+/-.005 in (15.88 +/-.13mm) diameter
Rotation	90° or 150° degrees between 0 % and 100 % on scale, limited by mechanical stops.
Manual Handwheel	Provides a means of positioning the actuator in the event of a power failure or set-
	up.
Lubrication	Texaco Starplex 2 EP Grease
Output Torque/Full	Torque lb-in (N		50 Hz (90°/150°)	60 Hz (90°/150°)
Travel Stroking Time	M)		4.5 / 7.5	4 / 6
	50 / (6.0)		9 / 15	7 / 12
	100 / (11.5)		18 / 30	15 / 25
	200 / (22.5)		36 / 60	30 / 50
			54 / 90
	400 / (45.0)			45 / 75
	400 / (45.0)

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Specifications

Technical and Operating Specifications

	Electrical
Mains Supply	100-130 Vac single phase, 50 Hz or 60 Hz
	200-240 Vac single phase, 50 Hz or 60 Hz
Motor	Instant start/stop, non-coasting, non-burnout, continuous duty, permanent
	magnet, synchronous induction motor. Can be stalled up to 100 hours without
	damage.
Motor Current	= No load = full load = locked rotor = 0.4 amp for 120Vac, 0.2 amp for 240 Vac
Loss of Power
	Stays in place on loss of power
Local Auto/Manual Switch	Optional – Allows local and automatic operation of the actuator.
End of travel Limit	Standard – adjustable to limit actuator travel to less than 90 or 150 degrees
Switches	respectively
Auxiliary Switches/Relays	Optional – Up to 4 additional SPDT switches rated at (10 A at 125 Vac, 5 A at 250
	Vac).
	Certifications
Approvals	CSA/UL (Standard)
	CE Compliant (optional)
Enclosure Rating	Type 4 (NEMA 4), IP66 (standard)
	Torque Settings of Crank Arm Bolts
Clamp Bolt	88 lb-in (10 N-m)

Electrical and Performance Specifications

	HercuLine® 2002	HercuLine® 2001	HercuLine® 2000/2003
Input Signals	Analog:	Analog:
	• 0/4 to 20 mA (With CPU	• 0/4 to 20 mA (With CPU	120 vac drive open/120 vac
	PWA jumper in current	PWA jumper in current	drive close
	position)	position)	240 vac drive open/240 vac
	• 0/1 to 5 Vdc	• 0/1 to 5 Vdc	drive close
	• 0 to 10 Vdc	• 0 to 10 Vdc
	Digital:	• Series 90 control
	• Modbus RTU (RS485)	Digital:
		• Modbus RTU (RS485)
Isolation	Input signal, output signal and power are isolated from each other.		NA
Load Requirement (4-20)	Current Out — 0 to 1000 ohms		NA
Input Impedance	0/4 to 20 mA	250 ohms	NA
	0/1 to 5 Vdc	10 K ohms
	0-10 vdc
Feedback	0 to 20 mA, 4 to 20 mA		Dual output 1000 ohms
	0 to 5 Vdc & 1 to 5 Vdc with 250 ohm resistor, (0 to 16 Vdc with 800		over 90 degrees (135 ohms
			with 158 resistor)
	ohm resistor)
			Dual output 1000 ohms
			over 150 degrees (135
			ohms with with 158 resistor)

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Specifications

Technical and Operating Specifications

			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		Modbus RTU or optional HART™			NA
	Operating Temperature		–40°C to +75 °C (–40°F to +170 °F)			-40°C to +85 °C (-40°F to
						+185 °F)
	Position sensing		Non-contact position sensor		1000 ohm film potentiometer	Dual 1000 ohm film
						potentiometers
						(not on 2003)
	Sensitivity		0.2 % to 5 % of 90° span, proportional to deadband			NA
	Hysteresis		Less than 0.4 % of full scale			NA
	Deadband		0.2 % to 5 % of 90° span, programmable. Shipped at 0.5 %			NA
	Repeatability		0.2 % of 90° span			NA
	Repositions
	(minimum @ 90 or 150
	degree stroke)
	Table 1 option –050-		160		120	500
	Table 1 option –100-		290		250
	Table 1 option –200-		450		400
	Table 1 option –400-		700		400
	Table 1 option –600-		900		400
	Voltage/ Supply		0.25 % of span with +10/–15 % voltage change			NA
	Stability
	Temperature		Less than ±0.030 % of span per degree C for 0 °C to 50 °C			NA
	Coefficient		Less than ±0.05 % of span per degree C for –40 °C to 75 °C
	Zero Suppression		90 % of span.			NA
	Input Filters		Selectable spike and low pass filters.			NA
	Solid State Motor		Two triac switches for clockwise or anti-clockwise motor operation.			NA
	Control		Transient voltage protection provided.
	Failsafe operation		If input signal exceeds configured input range. Selectable and			NA
			adjustable.
	Direction of Rotation		Field programmable			Wire swap
	Duty Cycle		Continuous

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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:
				1st row (Upper display) – four characters
				2nd row (Lower display) – six characters.
	LED indicators			Six single LEDs provide actuator status and alarm indications.
	Display Operating			-30 °C to +50 °C (-20 °F to +122 °F)
	Temperature			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.

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		Specifications
		Technical and Operating Specifications
		Specifications – Communications
		Communications
	Communications	RS 485 Serial Communication, Modbus RTU Protocol
	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
		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.

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Specifications

Model Selection Guide

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

I

II

III

IV

V

VI

VII

VIII

IX

_ _ _ _

-

_ _ _

-

_ _ _

-

_ _ _

-

_ _ _

-

_ _

-

_ _ _ _ _ _

-

_

-

_

-

_ _

KEY NUMBER - Motor Selection

Selection

Availability

Basic Motor Unit (no electronics)

2000

Basic Motor Unit plus Digital Electronics

2001

Enhanced Performance Motor Unit with Non-contact Position Sensing

2002

Unidirectional Motor (M640D Replacement)

2003

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

Torque, lb-in/(N-M)

50Hz

60Hz

50 / (6.0)

7.5 sec

6 sec

050

100 / (11.5)

15 sec

12 sec

100

200 / 22.5)

30 sec

25 sec

200

400 / (45.0)

60 sec

50 sec

400

400 / (45.0)

90 sec

75 sec

600

TABLE II - ROTATION

Travel

90 degrees

090

150 degrees

150

360 degrees

360

TABLE III - POWER SUPPLY

Single Phase

100 - 130 Vac, 60 Hz

126

100 - 130 Vac, 50 Hz

125

200 - 240 Vac, 60 Hz

246

200 - 240 Vac, 50 Hz

245

TABLE IV - ANALOG INPUT/OUTPUT SIGNALS

Input

3 Wire Drive up/down

0 _ _

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 _ _

Output

None

_ 00

(Note 1)

Dual 1000 Ohm (1000 ohms over 150 degrees)

_ 15

b

(Note 1)

Dual 1000 Ohm (1000 ohms over 90 degrees)

_ 19

c

Slidewire Emulation

_ 60

Slidewire Emulation

_ 65

0/4-20mAdc (0/1-5 Vdc, 0-16 Vdc)

_ 80

0/4-20mAdc (0/1-5 Vdc, 0-16 Vdc)

_ 85

TABLE V - SWITCH AND RELAY OUTPUTS (2 end-of-travel switches are standard)

Auxiliary Outputs

No Auxiliary Switches

0 _

2 Auxilliary Switches

2 _

4 Auxilliary Switches

4 _

Relay Outputs

No Relays

_ 0

2 Programmable Relay Outputs

_ 2

2 Programmable Relay Outputs

_ 3

4 Programmable Relay Outputs

_ 4

continued

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Specifications

Model Selection Guide

						2000 2001 2002 2003
TABLE VI - OPTIONS						Selection
Local keypad/	No local display interface supplied			(Note 2)		0_ _ _ _ _
display	Integrally mounted local display/keypad interface					1_ _ _ _ _
Local Auto/	No auto/manual switch					_ 0_ _ _ _
manual switch	Auto/manual switch with "Out of Auto Contact"					_ 1_ _ _ _
	Auto/manual switch with "Out of Auto Contact"					_ 2_ _ _ _
Handwheel	No Handwheel					_ _ 0_ _ _
Certificates	Handwheel					_ _ 1_ _ _
	None					_ _ _ 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					_ _ _ _ _0
	Clockwise shaft rotation on increasing signal					_ _ _ _ _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					00
Restrictions
Restriction	Available Only With		Not Available With
Letter	Table	Selection	Table	Selection
a	IV	_ 00	IV	_ 60, _ 80
b	II	150	II		090
c	II	090	II		150

ACCESSORIES

Mounting Hardware	Mounting plate adapter for Barber Colman Series MP495		51452354-501
	Mounting plate adapter for Landis & Staefa SQM53/56		51452354-502
	Direct Couple Valve Hardware		51452354-503
	North American Valve Retrofit Kit		51452354-511
Linkage Assembly	Ball joint for 5/16" dia. Pushrod		51452354-504
	Pushrod 12 in. (304,5 mm) long, 5/16 " dia.		51452354-505
	Pushrod 18 in. (457,2 mm) long, 5/16 " dia.		51452354-506
	Pushrod 24 in. 609,6 mm) long, 5/16 " dia.		51452354-507
	Pushrod 48 in. (1219,2 mm) long, 5/16 " dia.		51452354-508
HART	Turk Cable for Handheld Connection		51452352-501
Handheld Config.	HercuLinkTM Palm Software		51452354-509
(Note 3)	Battery powered 232/485 converter with cable		51452354-510
Remote Mount	Remote 4-20 mA requires 135 ohm fdbk, 120V 50/60Hz		R7195A1031
Control	Remote 4-20 mA requires 1000 ohm fdbk, 120V 50/60Hz		R7195A1056
	Remote 4-20 mA requires 135 ohm fdbk, 220V 50/60Hz		R7195A1064
	Remote 135 ohm input requires 135 ohm fdbk, 120V 50/60Hz		R7195B1021

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

2.HercuLinkTM software (pn 51452354-509), RS232/485 converter (pn 51452354-510), customer supplied PalmTM 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.

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Installation

Installation Overview

Installation

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.

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.

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Installation

Before Starting

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.

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 adjustable 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.

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Installation

Actuator Mounting

	CLEARANCE FOR TOP REMOVAL:
289	101,6
11.379	4.0

25.4

1.00

mm inches

Figure 3 Outline and Dimensions of HercuLine® 2000 Series Actuators

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Installation

Mechanical Installation

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

	Vertical		Vertical
	Centerline	Centerline
45°	45°	45°	45°
		Linkage
Start	Stop	Close	Open
Drive Unit		Horizontal Offset	Damper
Crank Arm			Crank Arm
			a/n 23199
	Figure 4 Constant Torque Linkage

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. Figure 5 shows a general 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.

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Installation

Mechanical Installation

Vertical		Vertical
Centerline		Centerline
		45°	45°
Actuator	Linkage
Crank Arm
	Close		Open
5°	Horizontal Offset		Damper

a/n 23200	Crank Arm

Figure 5 Variable Torque Linkage

Actuator Crank Arms

The HercuLine® 2000 Series Actuator comes standard with a crank arm with adjustable radius of 1.0 in (25.4mm) to 2.80 in (71.12mm). See Figure 6.

Figure 6 Standard crank arm

Figure 7 Crank arm with optional ball joint and push rod

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Installation

Electrical Installation

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.

	Table 2 Recommended Minimum Wire Size
AWG	Description
14	Earth ground wire to common power supply.

18Earth ground wire to single actuator. 120/240 V ac line leads. +24 V and common signal leads. Common signal leads, relays, and aux switches.

Safety Precautions

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.

Actuator Connections

ATTENTION

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.

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.

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.

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Installation

Electrical Installation

HercuLine® 2000 Terminal Connections

Table 3 Terminal Connections: HercuLine® 2000

Connection	Terminal Numbers	Descriptions
	and LABEL
	See Figure 8
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	3	Switch contact to indicate setting of actuator AUTO/MANUAL
Contact	4	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	7	Clockwise-End
	8	Slider
	9	Counterclockwise-End
Potentiometer #2	10	Clockwise-End
	11	Slider
	12	Counterclockwise-End
Protective Ground		Ground wire connection for mains supply

158 ohm 158 ohm	Install resistors to convert 1000 ohm
	potentiometer to 135 ohms
	1

1 REQUIRED ONLY IF AUTO/MANUAL SWITCH IS PRESENT

Figure 8 HercuLine® 2000 connections

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Installation

Electrical Installation

HercuLine® 2001/2002 with Auto/Manual Terminal Connections

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

Connection

Terminal Numbers

Descriptions

and LABEL

See Figure 9

TB1

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

4

Switch contact to indicate setting of actuator AUTO/MANUAL

Contact

5

switch.

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

6

TB3

4 to 20mA Output*

1

(+)

Analog signal output

2

(-)

Feedback

3

Feedback signal used in conjunction with 4 to 20mA OUTPUT

voltage when using Slidewire Emulation

4 to 20mA Input

4

(+)

Analog signal input

5

(-)

Modbus

6

(+)

Connection for RS485 Modbus loop wires

Communication

7

(-)

8

Shield

HART Communications

4

(+)

HART Communication is 4-20 mA only.

5

(-)

Digital Input

9

Com

Customer’s contact closure

10 Input

HART

Communications

Connection

+

_

HART connection using

external Turck connector

Auxiliary

Connector

_

+

Brown

Blue

Black

Black Wire Not Used

Figure 9 HercuLine® 2001/2002 connections

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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.

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Installation

Electrical Installation

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

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.

Step	Action

1Remove AC power to actuator.

2Loosen the 6 captive screws (use 5mm hex key) and remove the cover.

3Locate the terminals TB1-1, TB1-2 and ground screw.

4Loosen the screws at terminals TB1-1 and TB1-2. Remove screw used for ground.

5Install the appropriate MOV assembly as shown in Figure 11.

6All 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
	TB1-2	(slidewire
		emulation)
	TB1-1
		Communications
		and digital input

Figure 11 CE wiring part 1

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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

Relays 3 and 4

AC power connection

Figure 12 CE Wiring part 2

9 Install new gasket and top cover. Secure top cover with 6 captive screws.

10Reapply AC power to the actuator.

11Actuator 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 Figure 27 on page 68. Observing polarity, connect the signal input wires TB3–4(+) and TB3–5(-) on CPU terminal board.

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 Figure 27 on page 68. Observing polarity, connect the signal input wires to terminals TB3–4(+) and TB3–5(-) of the terminal block.

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