Linear Actuators - Altra Industrial Motion Literature Portal
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1. so please be sure to read them thoroughly before proceeding with unit installation P 6150 WL Mounting Warner Linear actuators are quickly and easily mounted by slipping pins through the holes at each end of the unit and into brackets on the machine frame and load to be moved Proper diameter solid pins provide maximum holding capability Use of a retaining ring or cotter pin on each end will prevent the solid pin from falling out of the mounting bracket It is best to avoid roll pins and spring pins Mounting pins must be parallel to each other as shown in Figure 1 Pins which are not parallel can cause excess vibration or binding M Track 1 1 4 inch 250 S track 3 8 inch 375 All Others 1 2 inch 500 Figure 1 Loads should act along the axis of the actuator Off center loads may cause binding and lead to premature unit failure See Figure 2 Wrong Actuator Axis Figure 2 Warner Linear e 800 825 6544 Ensure that mounting pins are supported at both ends Cantilevered mounting is unacceptable Failure to provide proper support will shorten unit life Cantilever Yoke Mount Figure 3 Do not attempt to mount Warner Linear actuators by the cover tube The tube is not designed to support the forces required for tube mounting The actuator mounting supports must be capable of withstanding the load and torque developed when the unit extends or retracts Restraining torque v2. Linear Actuators Installation Instructions P 6150 WL Warner Warner Linear An Altra Industrial Motion Company Contents Mounting Guidelines 3 Electrical Installation 4 ciale 5 7 EA Z O A 8 AA E e Cee E DER oe ee 8 RZ IR Cerise tole elena E tea tb da 10 roubleshooting see cc 11 Wa a a ii Back Page NOID Failure to follow these instruc tions may result in product damage equip ment damage and serious or fatal injury to personnel 2 Warner Linear e 800 825 6544 Introduction Warner Electric has many years of experience in providing linear actuators for a variety of applications on a wide range of mobile applications such as combines school buses industrial sweepers as well as in factory applications such as lift tables die handling racks diverters and vent positioning The Warner Electric linear actuator you have purchased is a well designed quality unit which will provide consistent maintenance free service throughout its life Warner Linear actuators are ideally suited for intermittent duty cycle applications requiring lifting positioning sorting opening or adjusting on both in plant or mobile applications This manual provides information needed to install all Warner Linear actuators Please follow the instructions provided in this manual carefully to ensure safe reliable operation Mounting Guidelines on page 4 are of key importance
3. Linear warrants that it will repair or replace whichever it deems advisable any product manufactured and sold by it which proves to be defective in material or workmanship within a period of one 1 year from the date of original purchase for consumer commercial or industrial use This warranty extends only to the original purchaser and is not transferable or assignable without Warner Linear s prior consent Warranty service can be obtained in the U S A by returning any defective product transportation charges prepaid to the appropriate Warner Electric LLC factory Additional warranty information may be obtained by writing the Customer Satisfaction Department Warner Linear 5693 Revlon Drive Belvidere IL 61008 or by calling 815 547 1106 A purchase receipt or other proof of original purchase will be required before warranty service is rendered If found defective under the terms of this warranty repair or replacement will be made without charge together with a refund for transportation costs If found not to be defective you will be notified and with your consent the item will be repaired or replaced and returned to you at your expense This warranty covers normal use and does not cover damage or defect which results from alteration accident neglect or improper installation operation or maintenance Some states do not allow limitation on how long an implied warranty lasts so the above limitation may not apply to you Warner Line
4. actuator in one of the two switch rails provided on the K2E actuator tube with a 6 set screw General Specifications Supply Voltage Up to 200 VDC maximum Switching Current 1 2 Amps maximum Contact Rating 10 Watts maximum Lead Wires 24 AWG Operating Temperature 40 to 105 deg C to 200 VDC maximum 10 Warner Linear e 800 825 6544 Black Hot to retract Red Hot to extend SWITCH SPDT MOMENTARY ON OFF ON HOT COMMON ACTUATOR RED EXTEND ACTUATOR GREEN GROUND ACTUATOR BLACK RETRACT ACTUATOR WHITE ACTUATOR CONDUIT R CAP P 6150 WL Troubleshooting Unit will not extend or retract power concerns Possible Problem Reccomended Action A Inspection Method Use voltmeter to confirm that power is reaching the motor lead wires B Open Blown Fuse Confirm that the fuse installed is sized properly for the application Current draw information for each motor is included with the data for each model of actuator C Switch Failure No Power to the unit If power reaches the switch but not the actuator the switch has failed and must be replaced D Switch Wiring Confirm that the wiring at the switch is accurate per the wiring diagram provid ed with each model of actuator Re wire as needed E Wiring Failure Inspect for cut or broken wires between the power source and the switch and between the switch and the actuator Replace wires as needed Inspection Motor Failure Use ohmmeter
5. alues are also provided with the details on each unit M Track 1 Torque created 20 in Ibs All others Torque created 100 in lbs Figure 4 m z a Scan to watch E Proper Steps and Best Practices for Mounting of Warner Linearing Actuators Video we httos p widencdn net k3etry m l P 6150 WL 3 Electrical Installation One connector is provided mounted to the actuator the mating connector is included in the actuator box M Track with limit switches Use wire gauge 16 AWG Actuator 18 AWG Packard Delphi Connectors Male Connector 8911773 Male Terminal 6294511 2 required Female Connector 8911772 Female Terminal 12040508 2 required re ei ee eM ee eM Me ee X THERMAL RELIEF LAA A A A A A A A A A A A A A ee ee ee _ J BLACK POWER SUPPLY WDC 4 Warner Linear e 800 825 6544 M Track with potentiometer feedback Use wire gauge 16 AWG Packard Delphi Connectors Male Connector 8911773 Male Terminal 6294511 2 required Female Connector 8911772 Female Terminal 12040508 2 required c a THERMAL RELIEF EA AAA ee A A _ A _ A A A A ee _ ee o BLACK VDC POWER SUPPLY VDC 26AWG 10K 26 AWG Feedback Potentiometer 26 ANG 0OHM POT HOOK UP FDBK PURPLE EXT WHITE RET YELLOW P 6150 WL S Track Mechanical The end of travel limit switches are factory set for selected stroke length and are not a
6. ar s obligation under this warranty is limited to the repair or replacement of the defective product and in no event shall Warner Linear be liable for consequential indirect or incidental damages of any kind incurred by reason of the manufacture sale or use of any defective product Warner Linear neither assumes nor authorizes any other person to give any other warranty or to assume any other obligation or liability on its behalf WITH RESPECT TO CONSUMER USE OF THE PRODUCT ANY IMPLIED WARRANTIES WHICH THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL CONSUMER PURCHASE WITH RESPECT TO COMMERCIAL AND INDUSTRIAL USES OF THE PRODUCT THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR OTHERWISE INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Changes in Dimensions and Specifications All dimensions and specifications shown in Warner Linear catalogs are subject to change without notice Weights do not include weight of boxing for shipment Certified prints will be furnished without charge on request to Warner Linear Warner Linear www warner
7. d when these positions are reached the control will remove power to the actuator until input power is cycled Then when power is reapplied it can move in either direction e Positional Accuracy under no load conditions from the initial stop position setting is within 0 10 This will improve with loaded applications since there will be less coast e Repeatability of hitting the same stop position every time is within 010 6 Warner Linear e 800 825 6544 Outputs e Stop 1 Retract and Stop 2 Extend Outputs 12 24VDC 1 amp maximum Active High or Low factory set to Active High e Positional Feedback Signal conditioned potentiometer feedback available in 0 5 or 0 10 or 1 5 or 2 10 VDC 0 10 or 0 20 or 2 10 or 4 20 mA The signal conditioned feature adjusts the output so Stop 1 full Retract is always O or min value of the output setting chosen even if the potentiometer value is not zero Therefore Stop 2 full Extend is also conditioned to be the maximum output of the setting chosen This conditioning is done once either at the factory or when either Stop 1 or Stop 2 is changed Then the value is saved in EEPROM for the life of the actuator e Live Power Keeps outputs and feedback information on when switched power off This power needs to be from the same source as the actuator main power just taken before the switched Note If Positions 1 or 4 are changed the analog out
8. djustable Extension Tube anti rotation is built into the body of the actuator S Track Electrical 12 or 24 volt DC power Feedback will be voltage or current depending upon which unit configuration has been ordered S Track Actuator Integral Metri Pack 150 Series 8 PIN Connector Use wire gauge 16 AWG Packard Delphi Connectors Mating Part 12047937 Body 12066304 TPA 12048074 Terminal 8 pcs 12089678 Seal 8 pcs 12059168 Plug if less than 8 connections are made Port A Motor power in 12 or 24 VDC Port B Extend end limit output Port C Live power in 12 or 24 VDC Port D Motor power in 12 VDC Port E Retract end limit output Port F Stroke position output 0 10 VDC 4 20 mA ect Port G Live power in 12 24 VDC ground Port H Signal ground out Customer Supplied Switch EXAMPLE Input Momentary DPDT Power Switch with 12 24VDC Center Off oe 12VDC 15 Amp 4 24VDC 7 5Amp t Metri Pack Pin A 12 24VDC Input Power Fuse recommended I Connector O EE FREE ATA SUNS up AA O ge E E q o jun fem ja o e eee Ne SR ARA ul RA e TA mem Pin D 12 24VDC Input Power e pe E AA Con Pugsinto im Extend Pin A amp PinD connector LI q i uo um Retract Pin A amp Pin D S Track O fe Ra fac A RR O ROO ne cee a SADO th Ta PROSA I Actuator ing Pin B Extend Limit Output 12 24VDC O 1 Amp j Extend Lamp Relay _ _ 1 Amp Fuse i WEET I I I or Iso
9. ion Set Red LED will turn off amp program returns to normal operation e Press key 2 amp 4 Erase all 4 stop positions and goes back to factory default maximum stroke OR To change only one stop position press one of the keys 1 to 4 again in the new desired location P 6150 WL 7 K2VL K2 and K2X DC Electrical Wiring One connector is provided mounted to the actuator the mating connector is included in the actuator box Packard Delphi Connectors Warner Linear part number Male connector 2973781 055 0101 01 Male Terminal 2 req 2962573 2 Required 055 0107 01 Female connector 2984883 055 01010 02 Female terminal 2962987 2 Required 055 0107 02 r e _ X THERMAL RELIEF LAA _ A A A A _ A A A A A Jl RED BLACK SUPPLY Z VDC Note Wiring diagrams for limit switch and potentiometer feedback are included in the manual for those products 8 Warner Linear e 800 825 6544 K2 K2X EP The external Limit Switch design allows the customer to set the end of travel stop position for both the extend and retract of the extension tube The design includes a magnet within the extension tube and one limit switch at each end of the cover tube As the magnet crosses in front of the switch the switch will change states from open to close The switch limits the retraction Use screwdriver here to pop It should only be moved when co
10. lated PLC Input recommended i Pin C 12 24VDO Live Power Input OL ESSES SR ee WS re ARTE SRI A IE TO SA I mt FINE Retract Limit Output 12 24VDC 1 Amp Extend Lamp Relay 1_ y ti tor Isolated PLC Input a I ma Lea a dotes SEER SS I Lite Display Meter or 1 4 i or Isolated PLC Input i Pin G Live Power Ground Input a l Mean aa sn i q CG I O E CO a a I e a a A E a m m E fe eee ee ee ee ee ee ee ee Pin H Signal Ground Warner Linear e 800 825 6544 Note All dotted lines are customer supplied i l I Me a es SS A ia a P 6150 WL 5 S Track Adjustable End Limit Control Operation Features 12 24VDC 15 7 5Amps maximum 4 Adjustable Stop Positions using Membrane Keypad e Shipped from factory to stop at maximum retract and extend positions using internal switches on potentiometer strip e Customer can adjust Retract amp Extend stops using membrane keypad These values will be stored in permanent EEPROM memory for the life of the actuator e Adjusted stop positions can also be erased at any time to go back to factory default e Retract is Stop 1 and Extend is Stop 2 Stop 3 and Stop 4 can be set anywhere inside these two values e When Stop 1 Retract and Stop 2 Extend positions are reached the actuator will automatically stop and not allow movement in that direction Power will have to be reversed in the opposite direction to move actuator e f Stop 3 and Stop 4 positions are use
11. linear com j Altra 6593 Revlon Drive Belvidere IL 61008 815 547 1106 www altramotion com Fax 815 547 7206 Application Assistance 800 825 9050 An Altra Industrial Motion Company P 6051 WL 11 15 Printed in USA
12. put will reset to provide full range of output for the new positions For example if Full Retract is set at 1 inch then O volt output will be at 1 inch Molded 8 pin Sealed Connector for Customer Connections P 6150 WL S Track Programming Stop Positions Warner Linear Erase All Program Mode Stops Power LED LED ES Program e Green LED indicates there is Power to the control e Red LED indicates when in Program Mode e Press keys 1 amp 3 together to enter Program Mode e Red LED stays LIT for 90 seconds waiting for another key command until Actuator is commanded to extend or retract immediately leaves programming mode One of the keys listed below is pressed Red LED will turn off and control will return to normal operation No key is pressed after 90 seconds Red LED will turn off and control will return to normal operation Warner Linear e 800 825 6544 e Press key 1 or New Retract end limit stop position Signal conditioned output will change this position to OV output Red LED will turn off amp program returns to normal operation e Press key 2 or New Extend end limit stop position Signal conditioned output will change this position to 5V output Red LED will turn off amp program returns to normal operation e Press key 3 or 3rd Stop position Set Red LED will turn off amp program returns to normal operation e Press key 4 or 4th Stop posit
13. run the unit under no load Observe unit behavior and make adjustments as necessary Unit will not extend retract or stops in mid stroke Possible Problem Reccomended Action When a unit is overloaded in a sufficient amount the clutch will slip This will generate a ratcheting noise within the unit Overloading Clutch Load has exceeded the capacity of the unit Reduce the load to fall within Slipping unit specifications or replace the actuator with a unit with sufficient capacity to move the load If the unit has seen many slip occurrences the clutch may be worn out Insufficient current is reaching the unit to provide full load capability Use Insufficient Current the load current draw charts provided for each unit to confirm current requirements and adjust power source accordingly Motor hums but does not move the load AC actuators Possible Problem Reccomended Action Inspect to confirm that the load applied does not exceed the rating for the actuator Reduce load as needed or replace actuator with a unit with sufficient capacity for the load applied Unit stops at mid stroke or exceeds stroke length Units with limit switches Possible Problem Reccomended Action The limit switches have been improperly set Review the limit switch adjustment process and correct so that the unit travel is set properly 12 Warner Linear e 800 825 6544 P 6150 WL NOTES Warner Linear e 800 825 6544 P 6150 WL 13 Warranty Warner
14. teresis is 100 gauss which requires the switches to be at least 1 inch apart so nuisance trips do not occur A pull up resistor is required from the output to the supply power to ensure only 20mA maximum is drawn from the sensor Therefore for a 5 VDC supply a 1K ohm 1 4watt resistor is recommended and for anything above a 5VDC supply a 5K ohm 1 4watt resistor should be used There should also be protection on the power and ground to ensure the switch sees no more than 24VDC General Specifications Supply Power 4 5 to 24 VDC O 8mA max Output Current sinking NPN maximum of 20mA continuous Lead Wires 26 AWG Operating Temperature 40 to 125 C Protection Reverse polarity protected Housing Rugged thermoplastic Typical Hall effect switch wiring example Blue wire Switch Ouput NPN 20mA max Red wire Supply Power Hall effect wires 1K 5K ohm Black wire Supply Ground Note Dotted line supplied by cutomer Warner Linear e 800 825 6544 Output Signal OV at Switch E Supply Power 4 5 to 24VDC P 6150 WL 9 Reed Switch Operation K2AC and K2XAC Normally open switches 23 1 2 inch long cable provided Green to ground General Description White to Neutral The reed switch is a hermetically sealed magnetically operated sensor When the switch comes in range of the magnet internal to the Warner Linear actuator the normally open contacts will close The switch can be set in place on the
15. to check resistance of the coll If the actuator has been run at a duty cycle greater than 25 or the unit has been overloaded the thermal overload in the motor may have opened to protect the motor Thermal Overload Open Allow sufficient time for the motor to cool which will allow the overload to reset Confirm the application to ensure that the unit is not overloaded and that it is not running at greater than 25 duty cycle Power may be reaching the motor but with insufficient current to provide full load Moving capacity Use an amp meter to confirm that sufficient current is reaching the actuator Use the load current charts in the catalog to confirm current requirements based on the unit loading Insufficient Current Warner Linear e 800 325 6544 P 6150 WL 11 Troubleshooting Unit will not extend or retract mechanical issues Power is reaching the motor but the unit will not move the load Possible Problem Reccomended Action Inspect to confirm that the load applied does not exceed the rating for the Unit Overloaded actuator Reduce load as needed or replace actuator with a unit with sufficient capacity for the load applied As noted on page 3 mounting pins must be parallel and mounting must avoid side loading Out of parallel pins or sideloading may cause unit binding that will reduce unit capacity Unit Binding If the above checks do not reveal the source of the problem remove the unit from its mounting and
16. ver out of locking grove actuator rod is fully extended 1 16 Allen Wrench The switch limits the extension It should only be moved when actuator rod is fully retracted To access the limit switches use a thin flat head screw driver to remove the end cap from the side cover Slide the cover off of the unit to expose the limit switches e par MS SPO RIE DIR di Aia Paz MEO Rata lo LAS SA When the actuator leaves the manufacturing plant the switches are set at the maximum stroke for that unit Care should be taken so that the switch is not moved past the point where the extension tube can travel If this happens the actuator will continue to drive causing excess wear on the clutch assembly Wiring for the EP limit switch design is the same as for internal limit switches m ne Scan to watch How to Adjust the Limit Switches for a K2 or e K2X Actuator with External or EP Limit Swtiches m a httos p widencdn net imzc9v P 6150 WL Hall Effect Switch Wiring General Description The hall effect switch is a non contact NPN output solid state device When the switch comes in range of the magnet internal to the Warner Linear actuator the output is pulled low and should read 0 VDC and can sink up to 20mA maximum On the K2E actuators the switches can be adjusted in the outer rail by removing the black switch rail cover and loosening the 6 set screw holding the switch in place The typical switch hys
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