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1. 1 etso Sot Mig End Plate Mowing ri SM5M4000 Switch End Mtg Plate Mowing 2 sr108e82 005 Plat Waser M CECI 2 5H00050 Machine ScrewPan Head Sted 3s oss ETT EIC O ooo o EE fSWamr O La SH567620 SorwHexHead 632x125lg 1 st4s2046 002 ToCoeGmie LL LLL em esa o A Pi esso Bonom Cover Gasket S E emaon StfSm O OOOO 1 erua ORmg2MAWXOUUUBmaN ri esso Top Comer asker a erua ORmBuaN ri SM9x4600 Display Gastet A 0O O 0O O NININ a 92 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Replacement Upgrade Accessory Kits Replacement Kits SusmsQi DisplayGasket S stomsooi Overlay Display 51800289001 lemDwiy 1800291001 GaxeAdweskeDe Ou 51800743001 Display MigColarMachinng 51800287001 Keypad 6 Poston sususoi Uma z000 SemM4oXS gRyh 4 30754244 001 ScewMemcPanh QrssFec 4 onoz SpkWamer 51800628001 Sleeve Keyra __ 51452190 002 Displaykeyoa Cable __ 51452045 002 Top Cover Gastet O LLL LC Qty Unit Part Number Description Figure ID susmdss ROCK o Susmio02 Cmadon2zsMd S 51451604008 Resistor 200 Orm25u Susteso0 Capacitor 75 Ma 400v stor OS NENNEN NENNEN 51452045 002 Top Cov
2. n 1 2 3 or4 SET CUROUT SET COMM SET DIGINP SET DISPLA CAL INPUT CAL MOTOR CAL CURENT SET LOCK READ STATUS SET DRVINF SET MAINT CAL POSOUT Table 7 Set Up Groups Pressing the FUNCTION Key Allows You to 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 Calibrate actuator output 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 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 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual For Details See Table 9 Table 12 Table 14 Table 15 Table 16
3. 2096 8096 100 Position Closed Closed RELAY 1 Normally Open 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 SET RELAY1 RTYP11 D EV R11VAL 10 00 mw w The resulting action is shown below Relay Type Deviation continued Input Motor 0 50 100 Position 10 10 Closed Closed Open RELAY n Normally Open 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 RLY 1H Y value is set to 10 34 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Relays Set Up Group 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 RELAY2 RTYP21 RTYP22 NONE Motor 0 6076 70 100 Position Closed Open RELAY n Normally Open Motor J 9 0 60 0 100 Position Closed vn 0o00 lb THK I RELAY n Normally Open Relay Type Motor Starts
4. MANUAL DRIVE Figure 40 Test AUTO MANUAL Switch Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 7 02 103 Troubleshooting Troubleshooting Procedures Test Relay Function Press SET UP button on keypad to enter Set up mode Set suspect Relay Set AUTO MANUAL switch type to MAN to MAN Place onmmeter across associated relay contacts at Actuator terminal Yes block See below NEN Does Relay No operate Replace Relay PWA or Wire harness from Relay PWA to terminal block ok See Relay replacement in Maintenance Section 7 Figure 41 Test Relay Function Relay Associated Contacts RELAY 1 RELAY2 RELAY3 RELAY4 104 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Appendix A HercuLine 2001 2002 Configuration Record Sheet Appendix A HercuLine 2001 2002 Configuration Record Sheet Enter the value or selection for each set up parameter on this sheet so you will have a record of how your actuator 1s configured Set Up Group Parameter Prompt SET INPUT IN TYP Input Actuation Type See Note 1 INP HI Input High Range Value 100 INP LO Input Low Range Value 0 0 FILTYP Input Filter Type NONE LPFILT Low Pass Filter Time Constant 0 Direct Actuator Rotation CCW Dband Input Deadband 0 5 FsTYP Failsafe Type LAST FsVAL Failsafe Input Value 0 C
5. TB3 Connector for customer ic us es switches outpu connection s 51 on CPU A i PWA n A s ON TBI E customer 0 power connection Non contact External Relay PWAs sensor auto manual switch Figure 2 HercuLine 2002 Actuator Internal View HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 3 Introduction Product Description 4 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 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 2000 25 Ib 11 36 kg 2001 2002 27 lbs 12 27 kg 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 adjustable 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 96 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 S
6. Table 8 Set Up Procedure Using Display and Keypad oooooooonoooooooonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnss 23 Table 9 Input SU Group Eee 26 Table 10 Equal Percentage Valve Characteristics ot 29 Table 11 Ouick Opening Valve Chatacteristo sureties ies aeui dE aA Oe N SA A N MEE 30 Table 12 Reb Set Up Group Parameter rio enaA so Son a tuis e NSA n hena Aa SOAS AA 31 AR a Aa ha Ae aoa e Aa a tuis eeu eN 32 Table I4 Current Out Set Up Group Parameters uarie soies a eoe enoi a eo fa ASA er 36 Table 15 C mmunications Set Up Group Parameters i e enai beslote in eraai Selaa rn 37 Table To Disttal Input Sec Up Group Parameters sisara braia a eo a aA aE EA S r 38 Table I7 Display Set Up Group Parametros EE 39 Table tS Lock Set Up Group Para meteis diia 40 Table 19 Read Status Set Up Group Para meters citadino iia 42 Table 20 Drive Set Up Group Parameters sai a a Sir easet iu Pe eu ton s deus 43 Table 21 Maintenance Set Up Group Parameters critica ENa 46 Table 22 CALZPOS OU Group Parameter Sessera oa a a a es buttons dotes 50 Table 23 Auto Manual Switch Functions ssssssessssseeeereoessssssssssssseeeeeecessssssssssssoreeereooesssssssssssoreeereooesssssssssesorereees 51 Table 24 Tnput Calibration ProceQune yss lt ac5 252 scsadhenansendsadassnenakossencde aces 55 Table 25 Motor Calibration Procedure cccccccnnnnnoooooononnnnnnnncncnnnnnnnnnnnno nono rnnnnnnnnnnnnnnnnnnnnn nn nn nn nnnnnnnnnnnnnnnnnnnnnnnn
7. Voltmeter Internal 250 ohm resistor Mu PE settable through Jumper W2 supplied Current Voltage Figure 14 Calibration Wiring Connections Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 53 7 02 Set Up and Calibration Procedures Calibration Jumper W2 m D JEN oie j AN eem IT Ae SGY TTA J ten EU EL UM m 2 Figure 15 Jumper Location on CPU PWA Calibrate Input The HercuLine 2001 2002 actuator accepts a variety of signal inputs 1 0to20 mA or 4 to 20 mA 2 Oto 5 Volts 1 to 5 Volts or 0 to 10 Volts The input type is selected through the Input set up group using the local keypad Refer to Figure 14 for the wiring connections and follow the procedure in Table 24 to calibrate the input circuit of the HercuLine 2001 2002 actuator 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 54 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Step Release 1 7 02 Set Up and Calibration Procedures Calibration Table 24 Input Calibration Procedure Operation Press Result Enter Calibration SETUP Upper Display CAL Mode until you see Lower Display INPUT FUNCTION Upper Display DIS Lower Display CAL IN A or Y key
8. with Bias Linkage Valve 1 2 3 Ratio Position mA Figure 24 Proportional Flow Using Multiple Actuators 74 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Control Applications Master Slave Arrangement Actuator 1 Current Output Controller Jumper W2 Hot Current Neutral 120 240 Ground VAC 4to 20 mA Note Controller must Actuator 2 be capable of sourcing the impedance Jumper W2 Hot See Figure Current Neutral 120 240 15 for jumper Ground VAC location Actuator 3 Jumper W2 Hot Preferred Current Neutral 120 240 Ground VAC Wiring Actuator 1 Current Output Controller Jumper W2 Hot Current Neutral 120 240 41020mA Ground VAC Actuator 2 Jumper W2 Hot See Figure Voltage Neutral 120 240 15 for jumper Ground VAC location Actuator 3 Jumper W2 Hot Voltage 120 240 Alternate Neutral Ground VAC Wiring Figure 25 Multiple Actuator Interconnection Diagrams Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 15 7 02 Control Applications 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 a
9. 10 to 99 990 000 Stall The motor is in a stall condition Manual Mode The actuator is in manual mode Power Up Test Failure 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 Position Sensor Failure The potentiometer or non contact sensor output is out of range or has failed Digital Input The digital input closure Total Degrees The total degrees traveled 32 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Relays Set Up Group Relay connector 1 Relay connector 2 Relay connector 3 Relay connector 4 Figure 11 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 R11 VAL 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 RTYP12 mew o Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 33 7 02 Set Up and Calibration Procedures Relays Set Up Group The figure below shows the resulting action Motor 0
10. 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 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 Industrial Measurement and Control http www honeywell com imc Telephone Contact us by telephone at the numbers listed below Organization Phone Number United States and Canada Honeywell 1 800 423 9883 Tech Support 1 888 423 9883 Q amp A Faxback TACFAQS 1 800 525 7439 Service Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual iii 7 02 Symbol Definitions The following table lists those symbols that may be used in this document to denote certain conditions Symbol A WARNING A CAUTION CAUTION A iF D D Rv 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 CA
11. 7 02 Set Up and Calibration Procedures Communications Set Up Group Communications Set Up Group Table 15 lists the parameters and selections available for the SET COMM group Table 15 Communications Set Up Group Parameters Actuator Lower Selections or Display Prompt COMM ADDRES default 1 BAUD 2400 4800 9600 19 2k default 19 2k 1 to 99 XmtDLY NONE 10ms 20ms 30ms 40ms 50ms default 20ms DBLBYT FP B FPBB FP L FPLB default FP B HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 37 Release 1 7 02 Range of Setting 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 DEVICE ADDRESS Selects device address when used in a Modbus communications loop Select an address that is unique to other devices on the communications link BAUD RATE Selects the speed of data transfer All equipment on the link must be set to match the host setting RESPONSE DELAY Selects the time delay in milliseconds before a response to a query is transmitted FLOATING POINT DATA FORMAT Selects the format for transferring floating point data Byte Order Floating Point Big Endian format 0123 Floati
12. 85 86 87 88 100 102 103 104 Introduction Product Description Introduction Product Description Honeywell s HercuLine 2000 series actuators are available in three versions HercuLine 2000 HercuLine 2001 and HercuLine 2002 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 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
13. Actuator Statistics Accumulated motor starts 46 Failsafe 27 Motor starts 46 Failsafe Input Value 28 Relay cycle counts 46 Fuses Reset 47 Replacement 82 Temperature limits 46 Total degrees of motor travel 46 H Applications 72 Basic flow control 73 Hysteresis 31 Proportional flow with multiple actuators 74 Split range 72 76 Auto Manual Switch I Testing 103 Auto Manual Switch 51 Input Calibration J M Input Characterization 28 Auxiliary Switches 66 Setting 66 Input Filters 27 Input High Range 26 Input Low Range 26 B Input Set Up Group 26 Inputs 26 Baud Rate 37 Installation Considerations 11 C K Calibration 52 Ke ad 8 19 Set up 53 a 20 Calibration Values Restore 48 CE Wiring 18 L Change Password LOCKID parameter 40 s a E gear Display 20 R Limit Switches 63 Communications 9 Setting 63 Floating point data transfer 37 ET Linkage Kits 89 Configuration Tips 21 C Linkage Set up 13 onnections Output 18 Constant torque 13 Crank arms 14 Slidewire emulation 18 Variable torque 13 Crank Arms 14 Local Display 8 19 Customer Connections 15 Description 19 CW and CCW Direction See Actuator Rotation LEDs descriptioti 2 Operating displays 69 D Set up 39 LOCK ter 21 23 Decimal Point Location 39 Main Worm gear 80 Deviation 32 Spur gear 80 Relay type 34 Device Address 37 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 10
14. 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 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Start Up Operation Operating Displays Operating Displays Pressing the DISPLAY key cycles the display through a number of operating parameters Table 32 shows a number of sample displays that can be shown during operation Table 32 Typical Operating Displays Display Description Input Upper Display Shows input value 0 0 Lower Display prompt INP Output Upper Display Shows input value 00 Lower Display Shows output value OP 0 5 Deviation Upper Display Shows input value 100 0 Lower Display Shows value of deviation of DE 99 9 sensor from input Position Upper Display Shows value of position sensor 0 6 Lower Display prompt POS NOTE Position display will show negative values if appropriate 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
15. 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 Table 13 Relay Type Descriptions for units 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 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 31 Set Up and Calibration Procedures Relays Set Up Group Table 13 Relay Type Descriptions When this Relay Type is selected The Relay can be set up to indicate RTYP Input Range 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 Position Range 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 rota
16. Figure 38 Power Up Diagnostics 100 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Troubleshooting Troubleshooting Procedures Test Non Contact Sensor PWA See page 70 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 101 7 02 Troubleshooting Troubleshooting Procedures Test Power Distribution PWA Remove top cover of actuator Check Fuses F1 and F2 on the power distribution PWA NES Are fuses good EN Replace fuses with same type and rating Is correct Yes voltage present No at test points See below Replace CPU Replace Power assembly Distribution PWA Figure 39 Test Power Distribution PWA Power Distribution PWA Test Points Test Points Pins Voltage Pins 5 6 to pins 7 8 24 V J3 Pins 1 2 to pins 3 4 8 5V Pins 3 4 to pin 7 9 V Pins 1 2 to pins 7 8 28V or 3V 102 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Troubleshooting Troubleshooting Procedures Test AUTO MANUAL DRIVE Switch Turn switch to Manual CCW setting Does motor drive in the CCW direction Yes No Turn switch to Manual CW setting Does motor drive in the CW direction Yes Possible trouble spots Auto Manual switch Power Supply PWA See D Limit switches MANUAL Motor CCW ud R C networks etc Others AUTO
17. Observable Symptoms of Failure Symptom Procedure No Actuator current output Replace CPU Assembly No Actuator slidewire output Replace CPU Assembly Local display does not light See Figure 37 Actuator fails one or more power up diagnostics See Figure 38 Actuator motor does not drive in response to input signal Perform input calibration See Figure 37 Actuator motor does not drive to proper position Perform motor calibration Position sensor position is not correct See page 70 Auto Manual Switch does not operate correctly See Figure 40 Relay s does not operate See Figure 41 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 97 7 02 Troubleshooting Troubleshooting Procedures Troubleshooting Procedures Overview Follow the procedure or flow chart to test for and determine actuator component operation When using the flow charts for troubleshooting you may be instructed to go to another flow chart in order to identify the faulty component Instruction for replacing actuator components can be found either in Maintenance page 79 or in the kit with the replacement components Equipment needed You will need the following equipment in order to troubleshoot the symptoms listed in the tables that follow DC Milliammeter mA DC Calibration source Volt mA etc Digital Voltmeter Safety precautions Exercise appropriate safety precautions when troubleshooting the actuator
18. RS232 compatible levels to drive external converter Note As of this writing only Palm devices have this feature Honeywell has qualified the M105 M125 and M505 devices with the HercuLink application Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 9 7 02 Installation Installation Overview Installation Installation Overview 10 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 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Installation Before
19. 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 RELAY1 RTYP11 STRT R11 E X10K R11HL H 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 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 35 7 02 Set Up and Calibration Procedures Current Out Set Up Group Current Out Set Up Group 36 Actuator Lower Display Prompt CUROUT Note If output type from model selection guide IS 0 4 20mA 0 1 5Vdc CUROUT Note If output type from model selection guide IS Slidewire Emulation CUROUT Note If output type from model selection guide IS None HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Table 14 lists the parameters and selections available for the SET CUROUT group Table 14 Current Out Set Up Group Parameters Selections or Range of Setting Parameter Definition PDA HercuLink Prompt OUTPUT SIGNAL RANGE Selects the signal output 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 Slidewire Emulation No current output configured Release 1
20. Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Release 1 7 02 Set Up and Calibration Procedures Lock Set Up Group Step Action 1 2 NOTE Press SET UP key until the display reads SET LOCK 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 Press the FUNCTION key until the lower display reads LOCKID The upper display will show O zero Use the A or V 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 amp 4 Use the A or V 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 Press the FUNCTION key until the lower display reads LOCKID The upper display will show O zero Use the A or V keys to increment the number to the new password See
21. Upper Display BEGN Lower Display CAL IN Calibrate Zero 0 FUNCTION Upper Display APLY Lower Display INZERO e Adjust the signal source to an output value equal to 0 range value e Wait 5 seconds then go to step 3 Calibrate Span FUNCTION Upper Display APLY 100 Lower Display INSPAN e Adjust the signal source to an output value equal to 100 range value e Wait 5 seconds then go to step 4 FUNCTION 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 Table 25 You may also exit calibation mode by pressing the DISPLAY or SETUP keys HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 55 Set Up and Calibration Procedures Calibration Calibrate Motor Use the procedure in Table 25 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 Table 25 Motor Calibration Procedure Step Operation Press Result 1 Enter Calibration SETUP Upper Display CAL Mode until you see Lower Display MOTOR FUNCTION Upper Display DIS Lower Display CALMTR A or Y key Upper Display BEGN Lower Display CALMTR 2 Calibrate Zero 0 FUNCTION Upper Display APLY Lower Display MTR LO e Use the Handwheeel or AUTO MANUA
22. 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 4 20mA output 4 20mA input Figure 27 Series 90 connections Considerations 1 This connection performs an emulation of a series 90 motor If the controller being used is also an emulation of a Series 90 the connections required may be different Shown below in Figure 28 are the connections found necessary to connect a T775 controller through an S443A S90 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 2 Dueto variations in the definition of rotation directions it may be necessary to reverse the action of the actuator from CCW to CW or vice versa Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 17 7 02 Control Applications Considerations out from HercuLine2001 LR 1775 W 1 Signal to HercuLine2001 GND to HercuLine2001 2 l 3 Inthe T775 controller manual there are several examples of using resistances or potentiometers as high and low limit controls Because o
23. 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 The actuator sets the STALLED LED indicator on along with any other alarms or relay contacts that are programmed to close when a stall condition 1s detected The maintenance statistic for accumulated stall time 1s incremented A stall condition is not detected if a limit end of travel limit switch is activated while the motor is moving toward setpoint or if the motor position is within 0 5 of calibrated motor 0 and 100 endpoints Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 69 7 02 Start Up Operation Position Sensor Operation Position Sensor Operation On HercuLine 2000 and HercuLine 2001 the potentiometer position sensor is a sealed film pot that 1s 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
24. diet 37 Digital Input Set UD OroUp dsnednedieee tese sie ov eee desse a dle leal lec uas 38 Bitzel e RR eECiieodet rH cc 39 Moe SE r UPGrOUD ieramen ead ieee eo nckieueca ieee 40 Seu Change P aSSwOr sox secs do coi tones 40 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 7 02 Contents Contents Read Status et UD rol ica ci 42 Dre Set Up rol ta is 43 HE A EN 45 Maintenance Sel Up GOUD cocoa 46 Ixeglons orMotoF ave eo LOS 48 CAL TOSOUTSSEUD lt td e tu uu ti e o d 50 Auto Manual Drive SwitCh ooccccocnccccncoccnconcncnnnnononcnncnonncnnonnnonnnnonnnonnnnnnncnnnaninos 51 Cal anO ae ld doi 52 Setting End of Travel Limit SwitCh8S cooonccccnccccnoconnocanncconccnnnocannonannonancnnanonanoss 63 Seting AUXIlary SWINGS AA o a m s T 66 Starr W O OCT ALON nimodo 68 INTFOQUCIO Narra rad does 68 POWer WO DIAGMOSUCS iid siete id ia a 68 Operations Checklist seinen io is 68 Operating DISPO uid s I IS is I da ILI re 69 pleno eel Mee 69 Position Sensor OP Chat iseni dla 70 Remote Setpoint Operation ooccccocccccnccccnccncnononnonannononcnnnnonannonannonannonnnnnnnnnnaninnans 70 GONTOlAPPDICAMON Siria 72 MOUE UO tic ce scant ke II IN A A O S 12 SPIERana Permanece 72 Master Slave Arrangement ccccsecccesccceeeccececeucecaueecaeeecueeceucessueesaeeeeueeseueessueenaaes 73 Series 90 Control H
25. example 4 to 12mA input in certain applications The procedure in Table 33 describes how to set up an actuator to operate as part of a split valve configuration Table 33 Split Range Set Up Procedure Step Action To Set Actuator span to operate from 4 to 12 mA input 1 Enter Set Up mode by pressing SET UP key Select SET INPUT group Press FUNCTION key until INP HI on lower display is selected 2 3 4 Set INP HI value to 50 0 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 Select SET INPUT group Press FUNCTION key until INP HI on lower display is selected 2 3 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 72 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Control Applications Master Slave Arrangement 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 22 Unlike the position output controller the current output controller must produce a continuous analog signal or the actuator will revert to one of its failsa
26. exem 6 st4st496 001 Comm s srasrasro01 Camrigermoiing rs orsa Bowdwmhr D E S MEEMRMEMMNMKHMNNMMN 94 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Replacement Upgrade Accessory Kits staszaaa soz Display and keypad kit no HW re fao Sem4ox3igpphs rs sts00629 001 Seeve xey OO O O o 51aszaaa sos Display and keypad upgrade kit HW CON E IESO T CET TN rs sooo Seeve keyp amm Se E Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 7 02 Upgrade Kits 95 Replacement Upgrade Accessory Kits Accessory Kits Accessory Kits 51197910 001 HAL Linkage Analysis software 51452354 509 HercuLink PDA software 51452354 510 Battery powered R232 485 converter w cables 96 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Troubleshooting Introduction Troubleshooting Introduction Troubleshooting procedures can be followed when inaccurate or faulty actuator operation is detected In this section troubleshooting procedures consist of a few simple flow charts to test for proper function of various actuator components Component replacement is at the PWA or assembly level Table 38 indicates some of the observable symptoms of failure that can be identified by noting the faulty actuator operation Table 38
27. off the power to the motor when the switch activates e f optional auxiliary switches were ordered these switches may also be set at this time See Setting Auxiliary Switches page 66 4 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 64 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Release 1 7 02 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 D amp TOTTE j i r Relay PWAs Relay 1 m pu sviton 1 End of avol aton 2a Aux switch 2 Relay 4 Aube switch 353 End of travel switch 2 Aux switch 4 stops CCW rotation Figure 19 Location of End of Travel Limit and Auxiliary Switches HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 65 Set Up and Calibration Procedures Setting Auxiliary Switches Setting Auxiliary Switches n ATTENTION Referring to Figure 19 The first two cams starting from the front are for the 0 and 100 end of travel limit switches Switches 1 and 2 and should not need any adjustm
28. to exit set up mode HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 45 Set Up and Calibration Procedures Maintenance Set Up Group 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 Table 21 lists the parameters and selections available for the 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 21 Maintenance Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting PDA users The prompts are organized differently on your PDA s HercuLink Prompt software Grayed prompts are under Configuration Maintenance Non grayed prompts are under Maintenance TEMP nnnn F ACTUATOR TEMPERATURE Read Only Displays the current internal temperature of the actuator TEMPHI nnnn F HIGH TEMPERATURE LIMIT Displays the high temperature limit of the internal actuator temperature since it was last reset TEMPLO nnnn F LOW TEMPERATURE LIMIT Displays the low temperature limit of the internal actuator temperature since it was last reset hh mm ss t ACST t ACCUMULATED STALL TIME Displays the accum
29. to the actuator via a 232 485 converter 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 The keypad and display are available on the HercuLine 2001 and HercuLine 2002 products at additional charge HercuLink Palm software Release 1 7 02 HercuLink Palm Software is an innovative and easy means to access configuration calibration and maintenance information in the HercuLine 2001 and HercuLine 2002 actutators This feature eliminates the need for the keyboard and display resulting in reduced cost for the customer The software may be ordered from the model selection guide The HercuLink software runs on your Palm with OS3 5 or higher connected to the actuator via the Palm serial cable RS232 485 converter and cable A battery powered 232 485 converter and cable assembly is available as an accessory in the model selection guide HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 1 Introduction Product Description Display and keypad Handwheel Shaft and position indicator Figure 1 HercuLine 2000 Series Actuator 2 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Release 1 7 02 Introduction Product Description a Wiring ol Label PWA
30. 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 e 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 e 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 e Rotate the 2 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
31. 0 00 GERMANY HONEYWELL AG Kaiserleistrasse 39 D 63067 OFFENBACH GERMANY Tel 49 69 80 64444 HUNGARY HONEYWELL Kft Gogol u 13 H 1133 BUDAPEST HUNGARY Tel 36 1 451 43 00 ICELAND HONEYWELL Hataekni hf Armuli 26 PO Box 8336 128 reykjavik Iceland Tel 354 588 5000 ITALY HONEYWELL S p A Via P Gobetti 2 b 20063 Cernusco Sul Naviglio ITALY Tel 39 02 92146 1 MEXICO HONEYWELL S A DE CV AV CONSTITUYENTES 900 COL LOMAS ALTAS 11950 MEXICO CITY MEXICO Tel 52 5 259 1966 THE NETHERLANDS HONEYWELL BV Laaderhoogtweg 18 1101 EA AMSTERDAM ZO THE NETHERLANDS Tel 31 20 56 56 911 NORWAY HONEYWELL A S Askerveien 61 PO Box 263 N 1371 ASKER NORWAY Tel 47 66 76 20 00 POLAND HONEYWELL Sp z o o UI Domainewksa 41 02 672 WARSAW POLAND Tel 48 22 606 09 00 PORTUGAL HONEYWELL PORTUGAL LDA Edificio Suecia II Av do Forte nr 3 Piso 3 2795 CARNAXIDE PORTUGAL Tel 351 1 424 50 00 REPUBLIC OF IRELAND HONEYWELL Unit 1 Robinhood Business Park Robinhood Road DUBLIN 22 Republic of Ireland Tel 353 1 4565944 REPUBLIC OF SINGAPORE HONEYWELL PTE LTD BLOCK 750E CHAI CHEE ROAD 06 01 CHAI CHEE IND PARK 1646 SINGAPORE REP OF SINGAPORE Tel 65 2490 100 REPUBLIC OF SOUTH AFRICA HONEYWELL Southern Africa PO BOX 138 Milnerton 7435 REPUBLIC OF SOUTH AFRICA Tel 27 11 805 12 01 ROMANIA HONEYWELL Office Bucharest 147 Aurel Vlaicu Str Sc
32. 1 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 Industrial Measurement and Control Honeywell 1100 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 ii HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 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
33. 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 1 Drive the motor to 50 position 2 Press SET UP key on the keyboard until the display reads CAL POSOUT Press FUNCTION key until the display reads DIS CALPOS Press the A or V keys until the display reads BEGN CALPOS Press the FUNCTION key Upper Display n nnn Output voltage of the sensor Lower Display POSOUT 3 The display should read 2 500 0 012 Volts for both 90 and 150 operation 4 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 5 Press DISPLAY key and then drive the motor to 10096 position Repeat Step 2 The display should read 3 400 0 060 Volts for 90 operation 4 000 0 060 volts for 150 operation 6 If the sensor needs adjustment refer to the Calibrate Non Contact Sensor procedure in Table 27 page 59 Remote Setpoint Operation 70 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 actuator terminal
34. 9 Index Main Gear Lubrication 80 Mechanical Installation 13 Modbus communications 37 70 Motor Calibration 56 Motor Speed 43 Motor Stall 69 Motor Starts 32 Relay type 35 Mounting 11 Non Contact Sensor 80 Checking 101 REGN parameter 46 Relay Function Testing 104 Relay PWA Replacement 83 Relay Type 31 32 Remote Setpoint Operation 70 Restore Factory Calibration Values 48 S Scrolling through Set Up Groups 21 Self test Diagnostics 42 68 100 Set Up Groups Communications 37 Current out 36 Digital input 38 Operation 70 Display 39 Non Contact Sensor Output Calibration 58 Drive 43 Input 26 O Maintenance 46 Read status 42 Output Calibration 57 Relays 31 Output Type 36 Short Stroke Outputs 36 Motor calibration 56 Slidewire Emulation 18 Split Range 72 P Spur Gear Lubrication 80 Stall 69 SEED 40 Start Up Checklist 68 Change 40 Stroke Speed 43 Position Range Relay type 33 T Power Supply PWA Checking 102 Tag Name 45 Pushbuttons TAG parameter 43 Description 20 Terminal Connections 16 17 Total Degrees of Motor Travel TOTDEG parameter 46 R Troubleshooting 97 Regions of Motor Travel 48 Equipment 98 110 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Sales and Service For application assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below ARGE
35. Actuator reconfigured Warranty Repair NOTE Date format is set by the UNITS parameter See SET DISPLA set up group 44 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Tag Name Release 1 7 02 Set Up and Calibration Procedures Drive Set Up Group 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 2 3 Press SET UP key until the display reads SET DRVINF Press the FUNCTION key until the upper display reads TAG 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 A or Y keys to scroll through the character set of O 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 A or VW keys until the next character is displayed Repeat for each character of the tag until the complete tag name is displayed Press the FUNCTION key to go to the next parameter or press DISPLAY
36. Cover Basket pL Qty Unit Part Number Description Figure ID sususn BakpaeKt E 1 swswmop Hereuline Backplane ey susmesQ CauGudewy ssar caac SuoR92005 SpiWater S SiOBGOS1 MachineScewfanHeatSbted 30 95995008 Screw Triob Phipn 4 20 98 SusmMsQ TopCwerGmke o ttt 51451656 505 1000 Ohm Potentiometer Kit 90 Degrees HercuLine 2000 51451656 005 Pot 1 K Double 90 Degree DEBERI 003218 46 32 Hex Nut N A 51109827 003 6 Washer DEBER 51109828 003 6 Lock Washer MEE p 51108436 312 Machine Screw Pan Hd Cross Rec I 51452045 002 Top Cover Gasket Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 89 7 02 Replacement Upgrade Accessory Kits Replacement Kits 51451656 506 1000 Ohm Potentiometer Kit 150 Degrees HercuLine 2000 2 st10se2e 008 f lokWae ri sMem4sop Top CoverGasket S a NN an O ra IES IES AN Qty Unit Part Number Description Figure ID SMSHNSW as Meter CA EEC TO ri _ stas2r10 002 Cemotr225Md SOO P s145t604 004 Resistor 200 Ohm 25w ra SH0930612 Machine Screw Pan Head Sted SY ra enoo SpltWaser M8 s1108992 003 SpitLoekWasner La SH0e30305 Machine ScrewPan Head Sted SY 1 S550 CapactorHoldown Sid ri s1452046 002 Top Cover Gasket o ri SM834500 BotomCoerGeke TT 90 HercuLine 2000 Series Actuator Installa
37. DEG default PCNT SI ENGL default ENGL 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 10096 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 English Display will show unit values in U S units Temperature in degrees F Date format mmddyy Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 39 7 02 Set Up and Calibration Procedures Lock Set Up Group Lock Set Up Group Table 18 lists the parameters and selections available for the SET LOCK group Table 18 Lock Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt LOCKID 0 to 4095 PASSWORD LOCK 4 digit password can be selected to provide security access to calibration information set up parameters and supervisory functions Password can be a defa
38. GNOSTIC Read Only Shows status of Configuration test diagnostic PASS Pass Test passed no errors FAIL Fail Test failed see Troubleshooting page 97 CALTST CALIBRATION TEST DIAGNOSTIC Read Only Shows status of Calibration test diagnostic PASS Pass Test passed no errors FAIL Fail Test failed see Troubleshooting page 97 42 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Drive Set Up Group Drive Set Up Group Table 20 lists the parameters and selections available for the SET DRVINF group Table 20 Drive Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt VERSON FIRMWARE VERSION Read Only Displays the firmware version currently in use by the actuator s CPU SPEED STROKE SPEED Read Only The speed is the number of seconds it takes for the actuator shaft to move its full range 150 60hz of travel SPEED STROKE SPEED Read Only The speed is the number of seconds it takes for the actuator shaft to move its full range 90 60hz of travel SPEED STROKE SPEED Read Only The speed is the number of seconds it takes for the actuator shaft to move its full range 150 5Ohz of travel SPEED STROKE SPEED Read Only The speed is the number of seconds it takes for the actuator shaft to move its full range 90 5
39. HAR Input Characterization type LINR CUSTOM Custom characterization type EQUL XO VAL User configurable characterizer value 0 0 X1 VAL User configurable characterizer value 5 0 X2 VAL User configurable characterizer value 10 0 X3 VAL User configurable characterizer value 15 0 X4 VAL User configurable characterizer value 20 0 X5 VAL User configurable characterizer value 25 0 X6 VAL User configurable characterizer value 30 0 X7 VAL User configurable characterizer value 35 0 X8 VAL User configurable characterizer value 40 0 X9 VAL User configurable characterizer value 45 0 X10 VAL User configurable characterizer value 50 0 X11 VAL User configurable characterizer value 55 0 X12 VAL User configurable characterizer value 60 0 X13 VAL User configurable characterizer value 65 0 X14 VAL User configurable characterizer value 70 0 X15 VAL User configurable characterizer value 75 0 X16 VAL User configurable characterizer value 80 0 X17 VAL User configurable characterizer value 85 0 X18 VAL User configurable characterizer value 90 0 X19 VAL User configurable characterizer value 95 0 X20 VAL User configurable characterizer value 100 0 Release HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 105 7 02 Appendix A HercuLine 2001 2002 Configuration Record Sheet Set Up Group Parameter Prompt YO VAL User configurable characterizer value Y1 VAL User configurable ch
40. Honeywell HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Doc No 62 86 25 10 Release 1 Last Revision Date 7 02 Industrial Measurement and Control Notices and Trademarks Copyright 2002 by Honeywell Release 1 July 2002 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 5008
41. L switch to manually drive the actuator motor to its low position e Wait 5 seconds then go to step 3 3 Calibrate Span FUNCTION Upper Display APLY 10096 Lower Display MTR HI e Use the Handwheeel or AUTO MANUAL switch to manually drive the actuator motor to its high position e Wait 5 seconds then go to step 4 4 FUNCTION 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 Table 26 You may also exit calibation mode by pressing the DISPLAY or SETUP keys NOTE If you are calibrating the motor to a short stroke range the procedure is the same n 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 56 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Calibration Calibrate Output HercuLine 2001 2002 actuator can be one of three output types 1 Oto 20 mA or 4 to 20 mA output 2 Oto 5 Volts or 1 to 5 Volts with 250 ohm range resistor 3 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 2001 2002 Actuator comes already calibrated from the factory If it becomes necessary to do a calibration in the field adj
42. Maintenance Manual 107 7 02 Appendix A HercuLine 2001 2002 Configuration Record Sheet Set Up Group SET DRVINF CAL NCSOUT Prompt SET MAIN Parameter VERSON Firmware Version SPEED Stroke Speed POWER Power Input Voltage Line Frequency TAG Tag Name MFGDAT Manufacturing Date LREP Date of Last Repair LCAL Date of Last Field Calibration REPTYP Repair Type TEMP Actuator Temperature TEMPHI High Temperature Limit TEMPLO Low Temperature Limit ACST Accumulated Stall Time STARTS Accumulated Motor Starts RLnCNTS Relay Cycle Counts n 1 2 3 or4 REGNy Accumulated Motor Starts for regions of motor travel y 0 through 9 DATSAV Forced maintenance data save MANRST Maintenance Statistic Reset LDCAL Restore Factory Calibration Type LDCFG Restore Factory Default Configuration RESTRT System Restart NCSOUT Non contact sensor circuit output Note 1 Type is set from model number 108 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Read Only Factory Set Factory Set Factory Set Factory Set Factory Set Factory Set Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only DIS NONE NONE DIS DIS Read Only Release 1 7 02 7 02 Index Index A E Actuator Rotation 27 51 Electrical Installation 15 Actuator Set Up 21 Exiting Set Up mode 21 Set up groups 21 Set up procedure 23 F
43. Manual Release 1 7 02 Set Up and Calibration Procedures Setting Auxiliary Switches Table 31 Auxiliary 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 3 Using a flat blade screwdriver on the slots on edge of cams or your fingers rotate the cams until the switches are set See Figure 19 e he 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 Figure 20 for auxiliary switch settings 4 For Switches 3 and 5 e Rotate the actuator shaft using the manual handwheel or the auto manual switch to the desired low scale position e 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 e Repeat for Switch 5 if applicable 5 For Switches 4 and 6 e Rotate the actuator shaft using the manual handw
44. N Shielded and grounded cables are recommended Actuator output is 4 to 20 mA analog signal If a voltage input is required for customer devices a range resistor is needed at the device input See Table 4 page 17 for more information 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 See Table 4 page 17 for more information 18 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Overview Set Up and Calibration Procedures Overview Once you have installed the actuator you can verify set or change certain operating parameters Set up 1s accomplished through use of the local display and keypad interface or through your PDA with HercuLink software see HercuLink manual 62 86 25 11 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 Release 1 7 02 The alphanumeric display and keys on the keypad are the local operat
45. NC OUT OF AUTO CONTACT IS SW6 o no FOR A MAXIMUM CURRENT N c OF 5 AMPS AT 120VAC OR RATED FOR A MAXIMUM 2 5 AMPS AT 240VAC AUXILIARY SWITCHES CURRENT RATING OF 2 5 AMPS AT 120VAC NON INDUCTIVE 51452163 001 Figure 9 HercuLine 2001 2002 connections Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 17 7 02 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 confrom 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 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 15 on page 54 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 15 on page 54 Observing polarity connect the signal input wires to terminals TB3 4 and TB3 5 of the terminal block Output Signal Connections 0 4 20 mA 0 1 5 Vdc Feedback Signal Connections ATTENTIO
46. NOTE below on use of keys 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 When changing the value of the number you can adjust a more significant digit in the upper display by holding in one key A or V and pressing the other A or Y at the same time The adjustment will move one digit to the left Press the key again and you will move one more digit to the left HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 41 Set Up and Calibration Procedures Read Status Set Up Group Read Status Set Up Group Table 19 lists the parameters and selections available for the READ STATUS group Table 19 Read Status Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt FAILSF FAILSAFE Read Only Shows whether actuator in failsafe NO No Actuator not in failsafe YES Yes Actuator in failsafe see Troubleshooting page 97 RAMTST RAM TEST DIAGNOSTIC Read Only Shows status of RAM test diagnostic PASS Pass Test passed no errors FAIL Fail Test failed see see Troubleshooting page 97 SEETST SERIAL EEPROM TEST DIAGNOSTIC Read Only Shows status of serial electrically eraseable PROM test diagnostic PASS Pass Test passed no errors FAIL Fail Test failed see Troubleshooting page 97 CFGTST CONFIGURATION TEST DIA
47. NTINA HONEYWELL S A C BELGRANO 1156 BUENOS AIRES ARGENTINA Tel 54 1 383 9290 ASIA PACIFIC HONEYWELL ASIA PACIFIC Inc Room 3213 3225 Sun Kung Kai Centre N 30 Harbour Road WANCHAI HONG KONG Tel 852 829 82 98 AUSTRALIA HONEYWELL LIMITED 5 Thomas Holt Drive North Ryde Sydney NSW AUSTRALIA 2113 Tel 61 2 353 7000 AUSTRIA HONEYWELL AUSTRIA G m b H Handelskai 388 A1020 VIENNA AUSTRIA Tel 43 1 727 800 BELGIUM HONEYWELL S A 3 Avenue de Bourget B 1140 BRUSSELS BELGIUM Tel 322 728 27 11 BRAZIL HONEYWELL DO BRAZIL AND CIA Rua Jose Alves Da Chunha Lima 172 BUTANTA 05360 050 SAO PAULO SP BRAZIL Tel 55 11 819 3755 BULGARIA HONEYWELL EOOD 14 Iskarsko Chausse POB 79 BG 1592 Sofia BULGARIA Tel 359 791512 794027 792198 CANADA HONEYWELL LIMITED THE HONEYWELL CENTRE 300 Yorkland Blvd NORTH YORK ONTARIO M2J 181 CANADA Tel 800 461 0013 Fax 416 502 5001 CZECH REPUBLIC HONEYWELL Spol s r o Budejovicka 1 140 21 Prague 4 Czech Republic Tel 422 6112 3434 DENMARK HONEYWELL A S Automatikvej 1 DK 2860 Soeborg DENMARK Tel 45 39 55 56 58 FINLAND HONEYWELL OY Ruukintie 8 FIN 02320 ESPOO 32 FINLAND Tel 358 0 3480101 FRANCE HONEYWELL S A B timent le Mercury Parc Technologique de St Aubin Route de l Orme CD 128 91190 SAINT AUBIN FRANCE Tel from France 01 60 19 80 00 From other countries 33 1 60 19 8
48. OMETER FROM AM SWITCH 120 240V a2 it CONTROLLER OUT OF AUTO 50 B Hz CONTACT SUPPLY ewa Y ni H Li J SWITCHES 8W3 54 S5 AND Swi J MB SiG ARE RATED FOR A MAXIMUM y B CURRENT OF 10 AMPS AT 120VAC e E ne OR 5 AMPS AT 240VAC B H er E Swe SW5 Siva SW3 Sib E HO 2 ALIXILIAR Y SWITCHES 24148310800 Figure 8 HercuLine 2000 connections Release 1 7 02 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Installation Electrical Installation Table 4 Terminal Connections HercuLine 2001 2002 with auto manual Connection Terminal Numbers Descriptions and LABEL See Figure 9 IC E IC E TEE Auto Manual Switch Switch contact to indicate setting of actuator AUTO MANUAL Contact 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 8 Shield Customer s contact closure 10 Input SLIDEWIRE USE COPPER CONDUCTORS ONLY EMULATION TB1 OUTPUT INPUT COMMUNICATION INPUT 50 60Hz SUPPLY PROTECTIVE PE EARTH GREEN OR GREEN YELLOW A M SWITCH pc OUT OF AUTO CONTACT NC Y NC A NC Y NC A SWITCHES SW3 SWA SW5 AND SW6 ARE RATED FOR NO ol No v No ol No v A MAXIMUM CURRENT OF 10 AMPS AT 120VAC OR c Nic allo NiC B 5 AMPS AT 240VAC AUTO MANUAL SWITCH RELAY CONTACTS ARE RATED SW6 SWS SW4 SW3 OF Y
49. Ohz of travel POWER INPUT VOLTAGE AND FREQUENCY Read Only Selects the power input voltage and line frequency of the actuator 1206 120Volts 60Hz 1205 120Volts 50Hz 2206 220Volts 60Hz 2205 220Volts 50Hz ROTATE ROTATION Indicates the factory calibrated degrees of rotation 90 Factory calibrated for 90 degrees of rotation 150 Factory calibrated for 150 degrees of rotation TAG TAG NAME Selects the tag name or identifier of the actuator Up to 6 alphanumeric characters See Set Tag Name on next page MFGDAT MANUFACTURING DATE Read Only Displays datecode of manufacture for actuator Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 43 7 02 Set Up and Calibration Procedures Drive Set Up Group Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting 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 REPTYP 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
50. Prompt 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 default NONE 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 default DIS RESTRT SYSTEM RESTART Allows you to force the system to restart DIS Restart disabled ENAB Restart enabled default DIS Note The MANRST function must be set to SYST Temperature units are displayed in degrees C or F and are set by the UNITS parameter See SET DISPLA set up group t 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 seco
51. Sensor Calibration Procedure Step Action 1 2 10 11 12 13 Release 1 7 02 Remove AC power to the actuator 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 Reapply AC power to the actuator Press SET UP key to access the INPUT set up group Press FUNCTION key until the lower display reads Direct Press the A or V keys to set Actuator Rotation direction to CCW 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 Press SET UP key until the display reads CAL POSOUT Press the FUNCTION key until the dispaly reads DIS CALPOS Press the A or V keys until the lower display reads BEGN CALPOS 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 Figure 16 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 Figure 16 Tighten NCS spoiler set
52. Spur Gear Lubrication Procedure Step Action 1 Remove AC power from actuator 2 Remove the six screws and the bottom cover of the actuator case See Figure 29 3 Inspect the final spur gear the idler gear and motor pinion for excessive wear and adequate lubrication See Figure 29 4 If needed use Texaco Starplex 2 EP grease or equivalent and apply lubricant to assure that the gears are adequately protected 5 Install a new gasket and replace side cover Secure to actuator with screws 6 Restore actuator to service 80 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Maintenance Basic Maintenance Bottom cover Gears B Idler spur gear A A es cu Final output I spur gear ead _ Motor pinion gt gear lo Figure 29 Spur Gear Location Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 81 7 02 Maintenance Replacement Procedures 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 Table 35 and refer to Figure 31 for fuse location A WARNING 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 35 Motor D
53. 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 Release 1 7 02 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 Actionato
54. Table 17 Calibration Procedure Table 24 Calibration Procedure Table 25 Calibration Procedure Table 26 Table 18 Table 19 Table 20 Table 21 Table 22 Release 1 7 02 Set Up Procedure Set Up and Calibration Procedures Set Up Procedure Each of the set up groups and their functions are either pre configured at the factory 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 8 Set Up Procedure Using Display and Keypad Step Operation Press 1 Enter Set Up Mode SET UP 2 Select any Set Up SET UP Group 3 Select a Function FUNCTION Parameter 4 Select other FUNCTION function parameters o Result 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 Table 7 You can also use the A or V keys to
55. UTION 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 Release 1 7 02 Contents gt y Mbol BIilalidlo o deeem IV A cadet cedet eee ates tatters tot
56. Z Apt 61 62 R 72921 Bucharest ROMANIA Tel 40 1 211 00 76 21179 RUSSIA HONEYWELL INC 4 th Floor Administrative Builiding of AO Luzhniki Management 24 Luzhniki 119048 Moscow RUSSIA Tel 7 095 796 98 00 01 SLOVAKIA HONEYWELL Ltd Mlynske nivy 73 PO Box 75 820 07 BRATISLAVA 27 SLOVAKIA Tel 421 7 52 47 400 425 SPAIN HONEYWELL S A Factory Josefa Valcarcel 24 28027 MADRID SPAIN Tel 34 91 31 3 61 00 SWEDEN HONEYWELL A B S 127 86 Skarholmen STOCKHOLM SWEDEN Tel 46 8 775 55 00 SWITZERLAND HONEYWELL A G Hertistrasse 2 8304 WALLISELLEN SWITZERLAND Tel 41 1 831 02 71 TURKEY HONEYWELL Otomasyon ve Kontrol Sistemlen San ve Tic A S Honeywell Turkey A S Emirhan Cad No 144 Barbaros Plaza C Blok Kat 18 Dikilitas 80700 Istanbul TURKEY Tel 90 212 258 18 30 UNITED KINGDOM HONEYWELL Unit 1 2 amp 4 Zodiac House Calleva Park Aldermaston Berkshire RG7 8HW UNITED KINGDOM Tel 44 118 906 2600 U S A HONEYWELL INC INDUSTRIAL PROCESS CONTROLS 1100 VIRGINIA DRIVE PA 19034 3260 FT WASHINGTON U S A Tel 1 800 343 0228 VENEZUELA HONEYWELL CA APARTADO 61314 1060 CARACAS VENEZUELA Tel 58 2 239 0211 Honeywell Industrial Measurement and Control Honeywell 11 West Spring Street Freeport IL 61032 62 86 25 10 0702 Printed in USA www honeywell com imc
57. age 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 ey AD 45 _ 45 X Linkage y Start Stop Close o Open Drive Unit E Damper Orne Ane Horizontal Offset rei ARN aln 23199 Figure 4 Constant Torque Linkage Variable Torque Linkage A variable torque linkage 1s 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 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 13 7 02 Installation Mechanical Installation Vertical Vertical Centerli
58. al to deadband Hysteresis Lessthan0 4 offulscale 0 2 to 5 of 90 span programmable Shipped at 0 5 0 2 of 90 span Non contact position sensor 1000 ohm film potentiometer 40 C to 85 C 40 F to 185 F Dual 1000 ohm film potentiometers 500 per 90 at 6 sec 400 per 90 at 6 sec 500 per 90 at 6 sec Voltage Supply 0 25 of span with 10 15 voltage change Stability Temperature Less than 0 030 of span per degree C for 0 C to 50 C Coefficient 5 o o Less than 0 05 of span per degree C for 40 C to 75 C Zero Suppression 90 of span Input Filters Selectable spike and low pass filters NA Solid State Motor Two triac switches for clockwise or anti clockwise motor Control operation Transient voltage protection provided Failsafe operation If input signal exceeds configured input range Selectable and adjustable Direction of Rotation Field programmable Duty Cycle Release 1 7 02 Continuous HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual NA NA NA NA NA NA NA NA NA Specifications Technical and Operating Specifications A HercuLine 2002 HercuLine 2001 Herculine 2000 Programmable Selectable and configurable operating parameters 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 rot
59. aracterizer value Y2 VAL User configurable characterizer value Y3 VAL User configurable characterizer value Y4 VAL User configurable characterizer value Y5 VAL User configurable characterizer value Y6 VAL User configurable characterizer value Y7 VAL User configurable characterizer value Y8 VAL User configurable characterizer value Y9 VAL User configurable characterizer value Y10 VAL User configurable characterizer value Y11 VAL User configurable characterizer value Y12 VAL User configurable characterizer value Y13 VAL User configurable characterizer value Y14 VAL User configurable characterizer value Y15 VAL User configurable characterizer value Y16 VAL User configurable characterizer value Y17 VAL User configurable characterizer value Y18 VAL User configurable characterizer value Y19 VAL User configurable characterizer value Y20 VAL User configurable characterizer value SET RELAY RTYP11 Relay Type NONE R11VAL Relay Value 0 R11 HL Relay High Low LO R11SCALE Relay Scale X1 RTYP12 Relay Type NONE R12VAL Relay Value 0 R12 HL Relay High Low LO R12SCALE Relay Scale X1 RLY1HY Relay Hysteresis 0 RTYP21 Relay Type NONE R21VAL Relay Value 0 R21 HL Relay High Low LO R21SCALE Relay Scale X1 RTYP22 Relay Type NONE R22VAL Relay Value 0 R22HL Relay High Low LO R22SCALE Relay Scale X1 RLY2HY Relay Hysteresis 0 106 HercuLine 2000 Series Actu
60. ation 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 1 row Upper display four characters 2 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 wnen 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 19 for detailed information on display and keypad functions 8 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Specifications Technical and Operating Specifications Specifications Communications Display 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 Operating System Palm OS version 3 5 or greater Communications Serial port with
61. ator Installation Operation and Maintenance Manual Release 1 7 02 Set Up Group Prompt SET CUROUT SET COMM SET DIGINP SET DISPLA SET LOCK READ STATUS Appendix A HercuLine 2001 2002 Configuration Record Sheet Parameter RTYP31 Relay Type R31VAL Relay Value R31 HL Relay High Low R31SCALE Relay Scale RTYP32 Relay Type R32VAL Relay Value R32HL Relay High Low R32SCALE Relay Scale RLY3HY Relay Hysteresis RTYP41 Relay Type R41VAL Relay Value R41 HL Relay High Low R41SCALE Relay Scale RTYP42 Relay Type R42VAL Relay Value RA2HL Relay High Low RA2SCALE Relay Scale RLYAHY Relay Hysteresis CUROUT Output Signal Range COMM Communications Parameters ADDRES Device Address BAUD Baud Rate XmtDLY Response Delay DBLBYT Floating Point Data Format DIGINP Digital Input State Endpos End Position Value DECMAL Decimal Point Location EUNITS Units Display UNITS Display Units LOCKID Password Lock MAENAB Enabled LOCK Lock Out FAILSF Failsafe RAMTST RAM Test Diagnostic NONE LO X1 NONE LO X1 NONE LO X1 NONE LO X1 See Note 1 MODBUS 1 19 2K 20MS FPB Read Only Read Only SEETST Serial EEPROM Test Diagnostic Read Only CFGTST Configuration Test Diagnostic Read Only CALTST Calibration Test Diagnostic Read Only Release 1 HercuLine 2000 Series Actuator Installation Operation and
62. be larger than 357 for a valid calibration 3 Calibrate Span FUNCTION Upper Display XXXX 10096 Lower Display SPAN e Read meter connected to actuator output A or V key e Adjust actuator output to a value equal to 100 output as read from the DVM e NOTE Typically for a 20 mA output the display will show a value of approximately xxxx 4 FUNCTION Calibration for zero and span output values are now stored Output calibration is complete 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 e The sensor output is incorrect e The position sensor in the actuator has been replaced e 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 27 outlines the steps to perform a calibration to the position sensor circuit While the unit is powered a potentially lethal shock hazard exists inside the case A WARNING P P y 58 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Calibration Table 27 NCS Position
63. ble earth ground A WARNING 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 1s brought into the actuator through two access holes located on the side of the actuator case The screw terminals locations and descriptions for all customer connections are identified in the tables and figures that follow Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 15 7 02 Installation Electrical Installation Connection Table 3 Terminal Connections HercuLine 2000 Terminal Numbers and LABEL Descriptions See Figure 8 Hot wire for 120 240VAC mains supply Use only if Auto Manual switch is present Auto Manual Switch Contact Potentiometer 2 Protective Ground Switch contact to indicate setting of actuator AUTO MANUAL switch Switch is closed when actuator is NOT IN AUTO Clockwise End Slider Counterclockwise End Clockwise End Slider Counterclockwise End PROTECTIVE EARTH IGREEN OR GREENYELLOW E re USE COPPER CONDUCTORS ONLY AUTOMANLAL SWITCH QUT OF AUTO CONTACT IS RATED FOR A MAXIMUM CURRENT RATING OF 2 5 AMPS AT 120440 NON INDUCTIVE POTENTIOMETER POTENTI
64. block See Figure 21 Communicaton parameters should be set to the 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 input 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 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Release 1 7 02 Start Up Operation Remote Setpoint Operation Actuator Terminal Block 6 7 9 10 8 A SHIELD COM INE COMMUNICATION DIGITAL INPUT E L Figure 21 Terminal Block Connections for Modbus Communications HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 71 Control Applications Introduction Control Applications Introduction The HercuLine 2000 Series actuators can operate in a variety of control applications Examples are given in this section for the actuator to operate in e A basic flow control application e Proportional flow application using multiple actuators e A split valve configuration Split Range The HercuLine 2001 2002 actuators can be set up to operate within a narrow input range for
65. cterization Q O po eb N i d o i lt O 1 z gt c gt 10 20 30 40 50 60 70 80 90 Xn VAL Actual Input Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 29 7 02 Set Up and Calibration Procedures Input Set Up Group Quick Opening Valve Characteristic Table 11 contains values that approximate the characteristic of a quick opening control valve When the QUIK custom characterization type 1s selected the values in Table 11 are automatically loaded into the 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 Quick Opening Valve Characteristic Quick Opening Valve Characteristic al 20 30 40 50 60 70 80 90 Xn VAL Actual Input ood ES Oo N EN E E O EN EN o O a c 30 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Relays Set Up Group Relays Set Up Group ATTENTION The Relay set up group parameters are acce
66. ctions of a selected configuration set up group Used during field calibration procedure Alternately selects 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 Table 18 page 40 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 A 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 V 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 dir
67. e Specifications AA HercuLine 2002 HercuLine 2001 Herculine 2000 Input Signals Analog Analog e 0 4to20mA 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 120 vac e 0 1 to 5 Vdc 0 1 to 5 Vdc drove close e Oto 10 Vdc 0 to 10 Vdc Digital Series 90 control e Modbus RTU RS485 Digital e Modbus RTU RS485 Input signal output signal and power are isolated from each other Load Requirement 4 20 Current Out 0 to 1000 ohms NA Input Impedance 0 4 to 20 mA 250 ohms 0 1 to 5 Vdc 10 K ohms 0 10 vdc Feedback 0 to 20 mA 4 to 20 mA Dual output 1000 ohms over 0 to 5 Vdc amp 1 to 5 Vdc with 250 ohm resistor 0 to 16 Vdc with 90 degrees 135 ohms with 800 ohm resistor 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 Release 1 7 02 Specifications Technical and Operating Specifications ss HercuLine 2002 HercuLine 2001 Herculine 2000 Slidewire emulation Provides output voltage ratiometric to shaft position and potentiometric to supply voltage 1 Vdc to 20 Vdc without a slidewire Emulates a 100 ohm to 1000 ohm slidewire 10 mA output maximum Operating Temperature 40 C to 75 C 40 F to 170 F Position sensing 0 2 to 5 of 90 span proportion
68. ection 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 xt STALLED Indicates that the actuator has detected a motor stall condition xt ALARM Indicates a programmed alarm condition exists Xt MANUAL Indicates actuator is in manual mode Yt AUTO Indicates actuator is in automatic mode 20 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up Tips Set Up and Calibration Procedures Set Up Tips Table 6 contains tips that will help you view verify and enter the operating parameters more quickly If you can not 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 Function Displaying Groups Displaying Functions Scrolling Changing values quickly Exiting Set Up mode Timing out from Set Up mode Set Up Groups Table 6 Set Up Tips Tip 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 u
69. ents as they are factory set to stop the actuator precisely at 0 and 100 See Setting End of Travel Limit Switches page 63 If optional auxiliary switches were ordered these switches are factory set to 10 and 90 for switches 3 and 4 and to 20 and 80 for switches 5 and 6 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 Z4 to operates in synchronism with switch 2 etc See Figure 20 for auxiliary switch settings SW 3 SW 4 SW 5 SW 6 0 10 20 80 90 100 SW6 COM sw3coM C swscow O Q sw4cowv NO NC e NO Q E NO NC NC NO e Clockwise and counterclockwise rotation is the direction of the output shaft when facing the end of the shaft As shown CW roation of the output shaft activates SW3 at 10 on top pointer scale and CCW rotation activates SW4 at 90 on top pointer scale SW5 is set to activate similar to SW3 on CW rotation at 20 on the top pointer scale CCW rotation activates SW6 at 8096 on the top pointer scale Figure 20 Auxiliary Switch Settings If it becomes necessary to do adjust the auxillary switch cams in the field use the procedure given in Table 31 A WARNING While the unit is powered a potentially lethal shock hazard exists inside the case 66 HercuLine 2000 Series Actuator Installation Operation and Maintenance
70. er Gasket 51452045 001 Bottom Cover Gasket 51500166 503 Power Distribution Pwa Kit 51451694 005 Resistor 1000 Ohm 25w 14 Simeon PowerDitPva Sid EC A 51451856001 Pin Snap Lock 125187 ig susmsQo Top Cover Gast 0 Eg y O 0 20q20q2 gt MM Qty Unit Part Number Description Figure ID 51500457002 Transformer O o o 5Homo205 SptWamer o Machine Screw Pan Hd Cross Rec EE Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 93 7 02 Replacement Upgrade Accessory Kits Upgrade Kits 51500581 503 Auto Manual Switch HercuLine 2000 17 NENNEN AA 5D Qty Unit Part Number Description Figure ID 51500581 504 Auto Manual Switch HercuLine 2001 2002 EH mmo AmMawale O rr susmen Nut Sealing 8 82 ma emm e 00 1 st600887 008 AM SwichWie Assy Lr susmeroi Labe Customerwiing PT sraszoss Top Cover Gasket A O NN 51500657 502 Rvit Z Ncs Kit 19 51500657 001 Ncs Rvit Z Pwa 0 150 09514 Machnl 4 40 X 31 Pnslstl 51452045 002 Top Cover Gasket Upgrade Kits ssamen Auxaryswihesupgradekit 4 sr192367 100 Actuator microswitcholer 4 s1451430 001 Switch mounting plate molding s st1o8aer o05 Flatwasherm OOOO a s1451968 001 Extension bot 120010n 3 558500 Extension bot2205Iong 1 SM688500 Camshaft 6 54934600 Retaining rng
71. ercuLine 2001 model only ooccoocccoccnccccccccnccncnconcncnanonononnnonos 77 COMING COM Sess areata eee taze atte es A sa yack A wate eee 77 CONTAMINA e eee ease tes 17 MaltenanCe sida 19 MOGUC UON ada dd did 79 Basic Malta Ceci AAA AAA E aE 80 Spur Gear LUIS 80 Replacement Procedures ccccscccsecceseceeeceeeceeceecceeecceeeeeeeeeeeueeseeeseeeceuesseeseeesas 82 Replacement Upgrade Accessory Kits ccoocccccccccccnccocncccnnnocnnononcncncnnos 84 Replacement IS ct a Ea a E TR 84 Voorde KiS ean a ei 94 ACTES O I a a S ene Ms DENEN A NCMO Cet En ETUR 96 v HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Contents OUD S NOON essa ir eo 97 Rio e Deli o nad TETUER EON TUNES 97 Tro blesh oting Procedures eid eei ld uec Seat Aaa 98 Appendix A HercuLine 2001 2002 Configuration Record Sheet 105 ge soa eno O AMMEM cae M MEM 109 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual vii 7 02 Contents Tables Table Specilications a I MEE 5 Table 2 Recommended Min Wire SIZ6 oS REISEN MIU II M RIMIS RU AN 15 Table 3 Terminal Connections Hercubme 2000 oia 16 Table 4 Terminal Connections HercuLine 2001 2002 with auto manual eese I Table Keypad Description ied HERR R DIR epe n tes E saend dns danheaen sannca ll stare rashes ena canteae eanschalaaiar nae 20 A 21 Table set Up Groups e EE 22
72. f 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 Figure 28 T775 Controller connections 78 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Maintenance Introduction Maintenance Introduction There is some basic maintenance that 1s recommended for the HercuLine 2000 Series Actuators The electronic PWAs within the actuator require no maintenance or servicing under normal conditions If there is a problem refer to information in this section as well as Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 79 7 02 Maintenance Basic Maintenance Troubleshooting 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 Table 34 to access the spur gear compartment and lubricate the gears 1f necessary A WARNING 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 Table 34
73. fe states Signal failure 1s not a problem since the available failsafe settings allow you to set the actuator position on signal loss 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 Orifice Plate PV Positioner amp Actuator Controller Valve SP 4 to 20 mA Linkage Position mA Figure 22 Flow Diagram Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 73 7 02 Control Applications Master Slave Arrangement Current Output Controller Actuator See Figure 15 for jumper location Jumper W2 Current 120 240 VAC Figure 23 Interconnection Diagram Proportional Flow using Multiple Actuators Refer to flow diagram in Figure 24 and interconnection diagrams in Figure 25 The controller governs flow rate in one burner Only that 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 Orifice Plate PV Positioner amp Actuator Controller SP 4 to 20 mA Linkage Valve Linkage Valve Proportional
74. g Actuator Lower Display Prompt NONE INPUT FILTER TYPE Allows selection of a software digital FILTYP input filter to smooth the input signal SPIK Spike Selects spike filter to remove transients in the input signal when actuator is installed in noisy environments S LP Spike plus Low Pass Selects spike and low pass filtering Allows setting of lag time constant for low pass filter LPAS Low Pass Selects low pass filter Allows setting of lag time constant default NONE NOTE When Input Type R_SP or S 90 is selected Input Filter Type NONE LPFILT 0 to 50 00 LAG TIME CONSTANT Filter Type S LP or LPAS only in seconds 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 default 0 5 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 default CCW eee is a Pei and refers to the direction of Dband 0 2 to 5 0 INPUT DEADBAND Specifies an adjustable gap that is the in percent of difference between the setpoint value and the value at which span the motor energizes Deadband is set in percent of full span default 0 2 FsFTYP FAILSAFE TYPE Selects the motor position you want the actuat
75. haft 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 Travel Output Shaft Speed sec 150 Stroking Time Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 5 7 02 Specifications Technical and Operating Specifications Mains Supply 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 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 Switches Standard Two SPDT end of travel limits rated 10 A at 125 Vac 5 A at 250 Vac 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 Ib in 10 N m Electrical and Performanc
76. he prompts listed in the set up group e Press the A or Y keys to view selections or change range settings Table 9 Input Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt INPUT ACTUATION TYPE This selection specifies the IN TYP signal type and range you are going to use for the actuator l input Be sure that the values configured for the high and low Note If input range alarm setpoint etc are within the measuring range type from model for the selected signal range selection guide IS 4 to 20 mA 0 4 20mA 0 1 0 to 20 mA 5Vdc 0 10Vdc 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 Series 90 0 to 135 ohms Note If input type from model selection guide is Series 90 control 10 0 to 100 INPUT HIGH RANGE VALUE in is displayed NOTE When Input Type R SP or S 90 is selected Input Hi is not configurable default 100 0 0 to 90 0 INPUT LOW RANGE VALUE in is displayed NOTE When Input Type R_SP or S_90 is selected Input Hi is not configurable default 0 0 26 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Input Set Up Group Selections or Parameter Definition PDA HercuLink Prompt Range of Settin
77. heel or the auto manual switch to the desired up scale position e Rotate the 4 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 e Repeat for Switch 6 if applicable 6 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 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 67 7 02 Start Up Operation Introduction Start Up Operation 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 T
78. his 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 e RAM diagnostic RAMTST e Check of the electrically eraseable PROM SEETST e Verification that valid parameter values are in the actuator configuration CFGTST e Verification of valid calibration values CALTST e Test of the local display and LED indicators all display segments and LED indicators light simultaneously The local display shows the status of the diagnostics 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 Table 19 for more information on the power up diagnostics Operations Checklist 68 To make sure that the actuator 1s properly installed and set up for your particular application you should check and verify the following e 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 e Verify operation of end of travel limit switches e Verify operation of auxiliary switches or relay function if installed e Check operation of AUTO MANUAL
79. ion is the direction of the output shaft when facing the end of the shaft As shown full clockwise rotation of the output shaft activates SW1 and CCW rotation activates SW2 Figure 18 End of Travel Limit Switch Settings O 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 8 page 16 and Figure 9 page 17 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 Table 30 While the unit is powered a potentially lethal shock hazard exists inside the case A WARNING is cd po Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 63 7 02 Set Up and Calibration Procedures Setting End of Travel Limit Switches Table 30 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 3 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 Figure 19 e Rotate the actuator shaft
80. k 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 None No reset of maintenance statisitics 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 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 Set Up and Calibration Procedures Regions of Motor Travel Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting PDA users The prompts are organized differently on your PDA s HercuLink
81. nd the other above 12mA Refer to Figure 26 for an interconnection diagram for split valve operation using two actualtors 76 Current Output Controller Actuator 1 Jumper W2 Hot Current Neutral 120 240 4 to 20 mA Ground VAC Note Controller must Actuator 2 be capable of sourcing See Figure the impedance 15 for jumper location Jumper W2 Hot Preferred id Neutral 120 240 Ground VAC Wiring Current Output Controller Actuator 1 n Jumper W2 Hot Current Neutral 120 240 4 to 20 mA Ground VAC Actuator 2 See Figure 15 for jumper location Jumper W2 Voltage Alternate Neutral 120 240 ne Ground VAC Wiring Figure 26 Interconnection Diagrams HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Control Applications 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 1s 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
82. nds 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 Figure 12 regions are numbered 0 through 9 Maintenance statistics are accumulated 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 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 48 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Release 1 7 02 Set Up and Calibration Procedures Regions of Motor Travel Percent of Span 0 20 40 60 80 100 Region of Travel 0 1 2 3 4 5 6 7 8 9 0 30 60 90 Degrees of Rotation Percent of Span 0 20 4 0 60 8 0 100 Regio n of Trave 0 1 2 3 4 5 6 7 8 9 09 30 9 609 150 9 De grees of Rotation Figure 12 Regions of Motor Travel HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 49 Set Up and Calibration Procedures CAL POSOUT Group CAL POSOUT Group The CAL POSOUT group is used to verify tha
83. ne Centerline 45 45 Actuator Linkage 7 Crank Arm Damper Crank Arm 9 a Horizontal Offset aln 23200 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 7 Crank arm with optional ball joint and push rod HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Installation Electrical Installation Electrical Installation General Wiring Recommendations A WARNING 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 ME Despion Earth ground wire to common power supply 18 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 Safety Precautions A WARNING 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 n ATTENTION The ground terminal must be connected to a relia
84. ng Point Big Endian format with byte swapped Floating Point Little Endian format Floating Point Little Endian format with byte swapped Set Up and Calibration Procedures Digital Input Set Up Group Digital Input Set Up Group Table 16 lists the parameters and selections availible for the SET DIGINP group Table 16 Digital Input Set Up Group Parameters Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt Digital Input State Selects the position of the actuator in response to a digital input signal contact closure None No action by the actuator UP Up Actuator motor moves to full scale value DOWN Down Actuator motor moves to zero value USER User selected value Actuator motor moves to a customer selected value default NONE Allows setting of End Position Value 0 100 END POSITION VALUE DIGINP USER only Selects the in percent motor position you want the actuator to go to when digital input signal present contact closure 38 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Display Set Up Group Set Up and Calibration Procedures Display Set Up Group Table 17 lists the parameters and selections availible for the SET DISPLA group Table 17 Display Set Up Group Parameters Actuator Lower Selections or Display Range of Setting Prompt DECMAL default 8888 EUNITS PCNT
85. nm cdrtetibo ceto o eta ea era V MOGUCOM 1 Prou Diele me ES 1 Vifeie zi Kol YN IR e1l o RISE D QS ELLE 1 HercubLink Palm t SoIWaleue e died at Bae opta dieu aut ictu a LU IQ E I do 1 SPECE uuo Ode NEDE NE ED cM e ata a oca art M DR dE 5 Technical and Operating SpecificatiONS ooocccconnccccncoccnnocnncnnnncnnnonnnnonanononnnonanonnnoss 5 oo 10 Al o A 10 A pd E Eee po Doe Uc oS E CIE 11 Installation Considerations coca ii ae dks ene P e a 11 Actuator MOUNTING sata 11 Mechanical Installation unitat oo uiu ru Bde vie bi oc vi oo 13 LINKS SEU crc PIS 13 Electrica 1S Ca HT MN 15 Set Up and Calibration Procedures occooccccncocncococoncocncccnnococanonanoncnnns 19 I 19 Local Bier E aeg jecomece I rm 19 SOPUDSDIDS ente padece LR a er E LE ELE et ETN 21 Set UD GOUD S uus Deoa ded Ge aloes deseas dale lt 21 S6 UD POCO Ut E UIT Em 23 Configuration Prompt Hierarchy ccooccccoccoccnnoconccncnccncnocannononnnnanonnnnnnnnnnnnnnonannnnaninos 25 HOUT SOU Ui OUD seis at ter tie ete ta rad 26 Equal Percentage Valve CharacteriStiC ocoooncococonnncococonocononocononcnnanonononcnnononnnnnnnnnonnns 29 Quick Opening Valve CharacteriStiC ooooccconccncconnnnooonnnnnnncnnononcnconnnonononnnonnnrnnnnnrnnnnnanons 30 Relays Set Up GlOUD edith 31 Relay Examples ur A 33 Current Out Set UP Grous a E 36 Communications oe UND ol te
86. nnnnnnnnnnss 56 Table 26 Output Calibration Procedure iia ionien ia aiaa ia nh a nn nn non nono iaeiaeua 57 Table 27 NCS Position Sensor Calibration Procedure eese nnn nnns 59 Table 28 Potentiometer Position Sensor Calibration Procedure esee nnns 61 Table 29 Load Position Sensor Factory Cali DratiOM aa 62 Table 30 Endsot Iravel Limit Switch Setting Procedures 64 Table ST Auxiliary S Witc i Serine Procedir in A aa 67 Table 52 15 pic al Operate DISPLAYS A A ases 69 Table 33 split Ranse Set Up Procedure A Es 72 Table 34 Spur Gear Lubrication Procedure o OS RENDERE URN TRES EE SU Ie Debes Oe ON MORE SIE R 80 Table 55 Motor Drive Fuse KReplacment Proc oer ierra RO OD NR pP OON INN RE RU DDR Ege o iiaia 82 Table 36 Relay PWA Replacement Procedure sacadas 83 Taben t Replacement O to 89 Table38 Observable Symptoms of Eco eM E E a 97 viii HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Figures Figure 1 HercuLine 2000 Series Actuator Figure 2 HercuLine 2002 Actuator Internal View Figure 3 Outline and Dimensions of HercuLine 2000 Series Actuators Figure 4 Constant Torque Linkage Figure 5 Variable Torque Linkage Figure 6 Standard crank arm Figure 7 Crank arm with optional ball joint and push rod Figure 8 HercuLine 2000 connections Figure 9 HercuLine 2001 2002 connections Figure 10 HercuLine 2000 Display and Keypad Figure 11 Rela
87. nput value x and associated shaft position y NOTE Selecting CUST input characterization causes the following prompt CUSTOM to be displayed CUSTOM Equal percentage Sets the characterization as explained in Equal Percentage Valve Characteristic on page 29 Values are read only Quick opening Sets the characterization as explained in Quick Opening Valve Characteristic on page 30 Values are read only default EQUE User configurable Lets you create your own characterization using the following Xn VAL and Yn VAL prompts 0 to 100 Input Value as a percentage of input range Defaults are in increments of 596 0 to 100 Shaft Position Value as a percentage of position range Defaults are in increments of 5 28 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Input Set Up Group Equal Percentage Valve Characteristic Table 10 contains values that approximate an equal percentage valve characteristic in the actuator When the EQUL custom characterization type is selected the values in Table 10 are automatically loaded into the actuator configuration to produce the characteristic as presented in the graph The Xn VAL 1s the input value as a percentage of range and Yn VAL 1s the characterized output actuator shaft position as a percentage of range Table 10 Equal Percentage Valve Characteristics Equal Percentage Valve Chara
88. ntenance Manual Release 1 7 02 Replacement Upgrade Accessory Kits Replacement Kits E d a ra UT d 1 e E d p A m 3 T j E A 1 k i ze k F L wi z T ut Yl 2 EPH iia RPM Figure 33 Replacement Kit 10 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 85 7 02 Replacement Upgrade Accessory Kits Replacement Kits 86 Figure 34 Replacement Kits 1 2 3 4 5 9 15 16 19 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Replacement Upgrade Accessory Kits Replacement Kits Figure 35 Replacement Kit 13 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 87 7 02 Replacement Upgrade Accessory Kits Replacement Kits Figure 36 Replacement Kits 17 18 88 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Replacement Upgrade Accessory Kits Replacement Kits See Figure 32 through Figure 36 for drawings of replacment kit contents Table 37 Replacement kits 51450802 503 Relay Kit 51450802 001 Relay Pwa 30755139 003 Plug 03 Position 51452045 002 Top Cover Gasket Qty Unit Part Number Description Figure ID sus IT a 1 srasraaro01 Hereuline CPU Bd Assembly CN ESE AT A 1 swa tmePhoComedwiToio 1 suso mo A ra sweiseoy Pin Srap toce 25x871 ri swemsog Top
89. ocal display mode settings When not in auto the manual LED will flash every second MANUAL SOOO 90909 S8 PX x5 AUTO MANUAL DRIVE Figure 13 Auto Manual Switch Table 23 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 Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 51 7 02 Set Up and Calibration Procedures Calibration 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 contact 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 n ATTENTION Input calibraton 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 A WARNING High voltages exist inside the actuator case Do not touch the p
90. operation While the unit is powered a potentially lethal shock hazard exists inside the case A WARNING i caine Do not open the case while the unit is powered Do not access the terminals while the unit is powered 98 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Troubleshooting Troubleshooting Procedures Test for Actuator Operation Cycle power to actuator Does display light up Move handwheel Observe self test on actuator 2 or 3 turns Does motor reposition itself Do all diagnostics pass RAMTST PASS SEETST PASS CALTST PASS CFGTST PASS Yes No Replace display assembly Replace display assembly Figure 37 Test for Actuator Operation Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 99 7 02 Troubleshooting Troubleshooting Procedures Power Up Self Test Diagnostics Cycle power to actuator Does display light up Observe self test Yes No RAMTST PASS Yes No Replace CPU Assembly Check actuator Cycle power to Yes No configuration actuator If CFGTST setup reconfigure fails again replace if necessary CPU assembly Check actuator Cycle power to No calibration actuator If CALTST recalibrate fails again replace if necessary CPU assembly Do all LEDs and display segments ligh up No Replace display assembly
91. or case See Figure 2 Lay extended cover assembly on a flat surface Remove relay cards if present Reapply AC power to the actuator Press SET UP key to access the INPUT set up group Press FUNCTION key until the lower display reads Direct Press the A or V keys to set Actuator Rotation direction to CCW 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 Press SET UP key until the display reads CAL POSOUT Press the FUNCTION key until the dispaly reads DIS CALPOS Press the A or V keys until the lower display reads BEGN CALPOS 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 Tighten set screw with an allen wrench Press DISPLAY key to exit calibration mode Remove AC power to the actuator Reinstall relay cards If present Install a new gasket and replace extended cover Secure to actuator with screws Continue with calibration procedure in Table 29 HercuLine 2000 Series Actuato
92. or interface for control 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 Figure 10 shows the physical features of the display and keypad Table 5 summarizes the various functions you can perform using the keys as well as descriptions of the status indicators STALLED ALARM MANUAL AUTO Upper Display p Four Characters Lower Display Six Characters SET UP FUNCTION MAN AUTO DISPLAY SS Figure 10 HercuLine 2000 Display and Keypad HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 19 Set Up and Calibration Procedures Local Display and Keypad Key or LED Indicator SET UP DISPLAY gt ec e o Table 5 Keypad Description Function Places the actuator in the set up group select mode Sequentially displays set up groups and allows the FUNCTION key to display function parameters within the set up group See Set Up and Calibration Procedures page 19 for descriptions of the various options available in the set up groups Used in conjunction with the SET UP key to select the individual fun
93. or to go to when input signal is out of range failsafe NOTE Failsafe condition occurs when the input exceeds its 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 Last Position Actuator motor remains at last position Up Actuator motor moves to full scale value Down Actuator motor moves to zero value B User selected value Actuator motor moves to a Jeau e EAST customer defined value Allows setting of failsafe input value Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 27 7 02 Set Up and Calibration Procedures Input Set Up Group Actuator Lower Selections or Parameter Definition PDA HercuLink Prompt Display Range of Setting Prompt FSFVAL 0 to 100 FAILSAFE INPUT VALUE Failsafe Type USER only Selects the motor position you want the actuator to go to when input signal is interrupted Range is from 0 to 100 default 0 CHAR LINR INPUT CHARACTERIZATION Selects a characterization type that causes the actuator to characterize a linear input SQRT signal to represent a non linear input CUST Linear Provides linear characterization of the input signal Square Root Provides square root characterization of the input signal Custom Custom characterization Selecting custom allows you to create a twentieth order characterization of default LINR i
94. owered wires inside Death or serious injury can occur Equipment Needed 52 The table below lists the equipment you will need to calibrate the HercuLine 2000 input and output circuits Procedure Equipment Needed Input Calibration e Acalibrated signal source which can provide current 4 to 20 mA or voltage 0 to 10 V with an accuracy of 0 02 or better e Two insulated copper leads for connecting the current source to the actuator Output Calibration e A digital voltmeter with an accuracy of 0 01 or better e A250 ohm resistor 0 01 tolerance HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 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 15 on page 54 for jumper location 3 Connect the copper leads from the signal source to the input terminals of the actuator as shown in Figure 14 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 Herculine Calibrated 2001 2002 Signal Terminal Block 3 source Digital
95. p groups However when any set up group is displayed you can scroll through the set up groups twice as fast using the A or Y key When in 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 A or Y and pressing the other A or Y at the same time e The adjustment will move one digit to the left e 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 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 Table 7 on the next page lists the set up groups that are available by using the SET UP and FUNCTION keys on the keypad Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 21 7 02 Set Up and Calibration Procedures Set Up Groups Set Up Group Title SET INPUT SET RELAYn
96. r Installation Operation and Maintenance Manual 61 Set Up and Calibration Procedures Calibration Potentiometer position sensor Mounting bracket Figure 17 Location of potentiometer position sensor Table 29 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 A or V keys until the display reads POS 3 Perform the Calibrate Motor procedure exactly as in Table 25 Motor calibration must be performed for the factory configured full span range 0 100 4 When motor calibration is complete the calibration is now stored as the factory calibration of the actuator motor 62 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Setting End of Travel Limit Switches Setting End of Travel Limit Switches n ATTENTION Referring to Figure 19 The first two cams starting from the front are for the 0 and 100 limit switches Switch 1 and Switch 2 and should not need any adjustments as they are factory set to stop the drive at 0 and 100 See Figure 18 for limit switch settings END OF TRAVEL LIMIT SWITCH SETTINGS FACTORY SET AT 0 AND 100 0 100 SW1 COM SW2 COM SW 1 Clockwise Rotation Counterclockwise Rotation Clockwise and counterclockwise rotat
97. rive Fuse Replacment Procedure Step Action 1 Remove AC power from actuator Remove the 6 screws and the extended cover of the actuator case See Figure 30 Lay assembly down on a flat surface Remove connectors from CPU and power distribution PWA Remove power distribution PWA OIO AJOJN Locate the two fuses on the power distribution PWA See Figure 31 Carefully remove and replace fuse s with Wickmann T1 type 6A 250V or equivalent not available from Honeywell T 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 a e e eu N terrer didi i 35 08 4 e N gt aans b 5 S Mi E i 7 mu Relay connector 1 S Power CPU Relay connector 2 Relay PWA 1 distribution connections Relay connector 3 PWA Relay connector 4 Relay PWA 2 Figure 30 Power Distribution PWA and Relay PWA Locations 82 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Maintenance Replacement Procedures Fuses for An A mam Circuit Power Distribution PWA O o O Oo AANA iW quA QU Figure 31 Motor Drive Circuit Fuses Relay PWA Replacement If a relay PWA needs to be replaced follow the procedure in Table 36 to access and replace the PWA A WARNING Disconnect power before opening the actuator case A potentially lethal shock hazard exis
98. rs M640A 740A 940A for drop in replacement Optional adaptor plates available for replacing Landis and Staefa SQM53 56 and Barber Coleman series MP495 models HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 11 Installation Actuator Mounting CLEARANCE FOR TOP REMOVAL 289 101 6 11 379 4 0 TIEFE QA EU UU WI JG BHL i ll n 1 600 187 42 E WITH DISPLAY 1 319 179 WITH A 7 047 HANDWHEEL 63 5 WITHOUT 168 2 500 6 614 WITHOUT D6 6 260 15 88 625 I 11 12 CL TmBRRFHBI 45 12 38 68 2 800 ALMA S 800 1 523 18 SS 125 ml EE ANNE BB Y i i E F 79 38 13 630 1 4 20 UNC 3 125 MOUNTING HOLES E 8 PLACES 111 75 4 400 101 6 4 000 206 71 8 138 WITH AUTO MANUAL SWITCH 50 81 WIE 45 degr es 2 000 C NPT CONDUIT HOLE 193 71 600 TH DISPLAY 179 1 041 WITHOUT 3 4 NPT CONDUIT HOLE mm inches Figure 3 Outline and Dimensions of HercuLine 2000 Series Actuators 12 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Relea se 1 7 02 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 link
99. 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 Press DISPLAY key to exit calibration mode Remove AC power to the actuator Reinstall relay cards If present Install a new gasket and replace extended cover Secure to actuator with screws Continue with calibration procedure in Table 29 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 59 Set Up and Calibration Procedures Calibration o i lee oe d J E W set i A screw E y NCSPWA AN Relay PWA card b Ww guides relay a M y 4 PWAs removed J P3 NCS Spoiler shown at full 150 degree travel CCW Figure 16 Location of NCS Assembly 60 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Calibration Table 28 Potentiometer Position Sensor Calibration Procedure Step Action 1 2 10 11 12 13 Release 1 7 02 Remove AC power to the actuator Remove the six screws and the top cover from the actuat
100. scroll through the set up 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 Shows the current value or selection for the function prompt in the selected set up group Lower Display Shows the first function prompt within the selected set up group Example display shows Input group function prompt IN TYP and the selection 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 then proceed to the next step Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 23 7 02 Set Up and Calibration Procedures Set Up Procedure Step Operation Press 5 Change the Value or Selection A o or 6 Enter Value or FUNCTION Selection e or SET UP 7 Exit Set Up mode DISPLAY Result These keys increase or decrease the value or display the next available selection for the selected function prompt See Table 6 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 promp
101. ssible only if relay PWAs are installed in the actuator HercuLine 2001 actuators can be equipped with one PWA for a total of two SPDT relays Using the Relay set up groups you can program the installed relays to operate in response to various operating conditions Table 12 lists the parameters and selections available when the SET RELAY group is selected Table 12 Relay Set Up Group Parameters Selections or Range of Setting Actuator Lower Display Prompt default InPR and X1 X10k default X1 0 0 to 100 0 Rny HL n 1 2 3 or4 y 1or2 RLYnHY n 1 2 3 or4 0 0 to 100 0 in percent n is the relay number y is the relay contact Release 1 7 02 Parameter Definition PDA HercuLink Prompt RELAY TYPE Selects the relay number and the relay activation type See Table 13 Relay Type Descriptions 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
102. t 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 24 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Set Up and Calibration Procedures Configuration Prompt Hierarchy Configuration Prompt Hierarchy Here is an overview of all the Set up groups and their prompts Set Up Group Function Prompts PEAR EUSTON ga var femvar govar A OS ES ee A ee n 1 2 30r4 y 10r2 CUROUT COMM DIGINP DIPPER LOCK abd oo coa era oon la ja MAINT ue ENA TEMPLO AA STARTS RENT ARAN RON RAENT RGN REGIS Tori j Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 25 7 02 Set Up and Calibration Procedures Input Set Up Group Input Set Up Group Table 9 lists the parameters and selections available when the SET INPUT group is selected On the keypad and local display e Press the SET UP key to enter the Input Set Up group e Press the FUNCTION key to scroll through t
103. t 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 Table 22 shows the selections available for the CAL POSOUT group Table 22 CAL POSOUT Group Parameters Actuator Lower Selections or Display Range of Setting Prompt CALPOS Parameter Definition PDA HercuLink Prompt POSITION SENSOR OUTPUT Read Only Displays the output voltage of the position sensor To access the display Press Result SETUP Upper Display CAL until you see Lower Display POSOUT FUNCTION Upper Display DIS Lower Display CALPOS A or V key Upper Display BEGN Lower Display CALPOS FUNCTION Upper Display n nnn sensor output in volts Lower Display POSOUT 50 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 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 13 shows an illustration of the Auto Manual switch and Table 23 describes the switch settings The Auto Manual Drive switch setting overrides all input signals analog signal and remote setpoint and l
104. tion Operation and Maintenance Manual Release 1 7 02 Replacement Upgrade Accessory Kits Replacement Kits SMSHSHN T a SM5 69 00 Capacitor 75M 400480 1 SM6160005 Resistor 10000hm250 ra SH0930612 Machine Screw Pan Head Sioted ra SH0892006 SpltwasherMS ra 81108962 009 SpltLockWasher 4 51108490 305 Machine Screw Pan Head Sted 1 st4st650 001 CapactorHoldown 1 st4s2046 002 Top Cover Gasket 1 1452046 001 Bottom Cover Gasket III III Qty Unit Part Number Description Figure ID ZEN 51452342 501 1000 Ohm Potentiometer Kit 250 Degrees HercuLine NEAN 2001 SMSEMGO0i Postion Sensor SAMO o roo f632HNuN SHOES eewer swooe o etockwa SHOBG6312 MahineScewfanH CrssReo SusmMsQ TopowrGmke _ u A Susmdssi SpuGexKR S 1 st500840 001 SpurGear24p 38 1 1452046 001 Bottom Cover Gasket TET NEN LN nm Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 91 7 02 Replacement Upgrade Accessory Kits Replacement Kits SMMAME ET A A 6 Suemeri00 ActuatorMiroswichRoler SSS Ps 1461498 001 Switch Mounting Pate voina SS 3 enoo Fewer OOOO s srasrase o02 Extension Bolt 2205 Log 1 Sueno E A 6 81452040 011 Retaining Ring Enora s smsa CamMoing Ss s stast497 001 CamRWerMd mg rs smao BowdWmhr
105. tion See Relay Examples for setting range limits Deviation 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 Upper Limit Travel 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 Lower Limit Travel 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 Temperature High 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 units are defined in the UNITS setting of the DISPLA set up group Temperature Low 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 Starts 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
106. ts inside the case if the unit is opened while powered Table 36 Relay PWA Replacement Procedure Step Action 1 Remove AC power from actuator Remove the six screws and the cover of the actuator case See Figure 30 Lay assembly down on a flat surface Disconnect the wire connector from the relay PWA 2 3 4 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 Plug in wire connector to relay PWA Install a new gasket if needed and replace cover Secure to actuator with screws Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 83 7 02 Replacement Upgrade Accessory Kits Replacement Kits 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 To determine which kit you need cross reference Figure 32 through Figure 36 with Table 37 on page 89 Each kit contains replacement parts accessories and instructions for component replacement Figure 32 Replacement Kits 6 7 8 11 12 14 84 HercuLine 2000 Series Actuator Installation Operation and Mai
107. ulated stall time of the actuator motor since it was last reset STARTS ACCUMULATED MOTOR STARTS Displays the accumulated motor starts since it was last reset Multiply displayed value times 10 to get actual value Range is 0 to 999 900 000 RLnCNT 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 Multiply displayed value times 10 to get actual value Range is 0 to 999 900 000 REGNn ACCUMULATED MOTOR STARTS Displays the accumulated motor starts in the 1 10 of motor span since n 0to9 it was last reset See Regions of Motor Travel page 48 Multiply displayed value times 10 to get actual value Range is 0 to 999 900 000 vm TOTAL DEGREES OF MOTOR TRAVEL Displays the n 1 2 30r4 total number of degrees of motor travel since it was last reset Multiply displayed value times 10 to get actual value Range is 0 to 999 900 000 46 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual Release 1 7 02 Release 1 7 02 Actuator Lower Selections or Display Range of Setting Prompt DATSAV DIS ENAB i n MANRST NONE STAL STRT REGNn n 0to9 TEMP TDEG RELn n 1 2 30r4 ALL SYST default NONE HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 47 Set Up and Calibration Procedures Maintenance Set Up Group Parameter Definition PDA HercuLin
108. ult 0 number from O to 4095 LOCK OUT FEATURE Selects lockout security for 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 Full Lockout for calibration and all set up group values Only SET LOCK and READ STATUS groups are accessible default NONE MAENAB Manual Auto Allows the ability to lockout mode changes from the front panel DIS Disabled Disables the front panel auto manual switch functionality ENAB Enabled Enables the front panel auto manual switch default ENAB functionality 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 40 HercuLine 2000
109. ust the output using the procedure in Table 26 Refer to Figure 14 for a 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 n ATTENTION 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 To exit calibation mode press DISPLAY or SETUP keys Table 26 Output Calibration Procedure Step Operation Press Result 1 Enter Calibration SETUP Upper Display CAL Mode until you see Lower Display OUTPUT FUNCTION Upper Display DIS Lower Display CALOUT A or Y key Upper Display BEGN Lower Display CALOUT Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 57 7 02 Set Up and Calibration Procedures Calibration Step Operation Press Result 2 Calibrate Zero 0 FUNCTION Upper Display XXX Lower Display ZERO e Read meter connected to actuator output A or V key e 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 381 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
110. y connectors Figure 12 Regions of Motor Travel Figure 13 Auto Manual Switch Figure 14 Calibration Wiring Connections Figure 15 Jumper Location on CPU PWA Figure 16 Location of NCS Assembly Figure 17 Location of potentiometer position sensor Figure 18 End of Travel Limit Switch Settings Figure 19 Location of End of Travel Limit and Auxiliary Switches Figure 20 Auxiliary Switch Settings Figure 21 Terminal Block Connections for Modbus Communications Figure 22 Flow Diagram Figure 23 Interconnection Diagram Figure 24 Proportional Flow Using Multiple Actuators Figure 25 Multiple Actuator Interconnection Diagrams Figure 26 Interconnection Diagrams Figure 27 Series 90 connections Figure 28 T775 Controller connections Figure 29 Spur Gear Location Figure 30 Power Distribution PWA and Relay PWA Locations Figure 31 Motor Drive Circuit Fuses Figure 32 Replacement Kits 6 7 8 11 12 14 Figure 33 Replacement Kit 10 Figure 34 Replacement Kits 1 2 3 4 5 9 15 16 19 Figure 35 Replacement Kit 13 Figure 36 Replacement Kits 17 18 Figure 37 Test for Actuator Operation Figure 38 Power Up Diagnostics Figure 39 Test Power Distribution PWA Figure 40 Test AUTO MANUAL Switch Figure 41 Test Relay Function Release 1 HercuLine 2000 Series Actuator Installation Operation and Maintenance Manual 7 02 Contents 12 r3 14 14 14 16 17 19 49 51 53 54 60 62 63 65 66 71 73 74 74 75 76 71 78 81 82 83 84

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