Hamilton Sundstrand Company ACT2000 User's Manual
Contents
1. j95 500 002 Nez 4 75 12 70 05 120 7 11 86 VIEW 301 2 5 24 133 1 2 25 57 2 1 58 40 1 s i panum 40 6 e EXT E A A L 1 Figure 3 1 ACT2000 590P Envelope 32 PRECISION ACT2000 E e B 2 76 70 1 4 B 1 1 58 40 1 MAX N 2 62 HL JU ew B B e Sn U HOLE GND uum um y 218 g 218 4 R 50 12 Figure 3 2 ACT2000 200F Envelope 3 3 2000 PRECISION s Note The clevis can be rotated to any orientation to support installation To rotate loosen the four retaining screws and rotate to desired angle Screw pattern can be indexed 45 degrees to provide additional adjustment Torque the four retaining screws to 117 138 in Ibs WARNING Explosion Hazard Do not remove the clevis Remov2. PRECISION ACT2000 Operations Manual ACT2000 All Electric Actuator SD 6008 03 PRECISION This manual provides installation maintenance and operating instructions for the ACT2000 All Electric Actuator Every attempt has been made to provide sufficient information in this manual for the proper operation and preventive maintenance of the actuator It is recommended that the user read this manual in its entirety Operating the ACT2000 All Electric Actuator in accordance with instructions herein ensures long term and reliable operation If additional information is required please contact Marketing Department Precision Engine Controls Corporation 11661 Sorrento Valley Road San Diego California 92121 858 792 3217 e 800 200 4404 fax 858 792 3200 e mail peccntl precisioneng com 2000 PRECISION ENGINE CONTROLS CORPORATION ALL RIGHTS RESERVED 2000 PRECISION PRECISION ACT2000 Table of Contents Table of Contents ii ia i 1 INTRODUCTION aa er man Dr am eu ue 1 1 T1 APPICADON rre ER e e etd tete ul avete tt er ec a eet ite ae 1 1 1 2 Mounting Provisions em ida 1 1 1 3 Main Flousing Assembly uu u u atn adea d E 1 2 1 4 Brushless DG Motor Asserrbly L a cr c c d e ea 1 3 1 5 Motor Control Electronics 2 ette da n Eae voce dr nen 1 3 1 6 Resolver Assembly nina 1 3 1 7 Linear Drive Mechanism pp 1
3. Ensure 120 VDC Primary System Power at Actuator Check laptop PC com port 42 PRECISION ACT2000 Table 4 2 ACT2000 In Service Troubleshooting Chart Symptom Probable Causes Corrective Action FAULT alarm Various Upload Fault File to identify source of fault OVER TEMP alarm Ambient temperature limit Allow actuator to cool and re start exceeded Reduce ambient temperature Electronics or Motor winding temperature out of range Check for jammed extension rod FAULT and OVERTEMP No 120VDC Power alarm DSP Failure Ensure 120 VDC at actuator Contact factory For troubleshooting purposes use Table 4 3 to verify the actuator electrical continuity integrity Disconnect the actuator power and digital harness connectors and use a digital multimeter DMM to check the resistance values between the wires indicated on the table If an open circuit is detected send actuator to Precision Engine Controls Corporation for test and repair WARNING Shock Hazard Remove all power to actuator prior to continuity check Table 4 3 ACT2000 Electrical Hook Up Continuity Troubleshooting Chart Function Actuator Wire Colors Resistance Value DEMAND BRN and WHT BRN 2250 RUN VIO and WHT VIO RESET GRY and WHT GRY POWER RED and WHT RED High Impedance but not open circuit MOTOR CURRENT BLU and WHT BLU High Impedance POSITION YEL and WHT YEL High Impedance F
4. Nominal Voltage 120 VDC Minimum Voltage 80 VDC Maximum Voltage 160 VDC Maximum Current 20A Typical Transient Current 20A lt 60ms 10A 600ms 5A 100ms Typical Continuous Current 1A ON Voltage 12 to 32 VDC 24 VDC Nominal ON Current 6 5 mA Nominal 24 VDC OFF Voltage 3 5 VDC Maximum OFF Current 0 75 mA Maximum OFF Voltage 32 VDC Maximum OFF Leakage Current 150 uA Maximum ON Current 25 mA Maximum ON Voltage Drop 1 5 VDC Maximum 25 mA Current 4 to 20 mA 25 mA Maximum Voltage 5 VDC Maximum Internal Impedance 200 Q Current 4 to 20 mA External Load Resistance 500 Q Maximum 200 VDC User I O to 120 VDC Return less serial interface Operating Ambient 40 C 40 F to 93 C 200 F Operating Fuel 40 C 40 F to 125 C 257 F Storage 40 40 F to 125 C 257 F 10 in sec 500 Ibf 100 Duty Cycle 1000 Ibf 100 Duty Cycle 5 9 in Configuration Dependent 1 Full Stroke CSA Type 3 European IP65 EN 50081 2 and EN50082 2 for DC powered industrial equipment Mil Std 810E Category 4 5 2000 Hz 30 000 Hours 32 000 Minimum Power Harness 4 AWG 14 90 NPT Conduit EP Digital Harness 17 AWG 20 90 NPT Conduit EP CSA Class I Div 1 Group B C D T4 EEx d IIB H2 T4 94 9 EC Potentially Explosive Atmospheres ATEX 98 37 EC Machinery Directive 89 336 EEC Electromagnetic Compatibility Directive EMC 6061 T6 An
5. The ACT2000 accepts two discrete two wire external commands RUN and RESET The commands are 24 VDC ON High and 0 VDC OFF Low Refer to Figure 2 3 for typical connection Refer to Section 6 for specification values CONTROLLER DISCRETE OUTPUT 24Vde jp ACTUATOR DISCRETE INPUT RUN VIO RESET GRY HT VIO WHT GRY RESET RTN CONTROLLER DISCRETE OUTPUT ACTUATOR DISCRETE INPUT RUN VIO E RESET GRY w yy RUN RTN WHT VIO RESET RTN WHT GRY Figure 2 3 Typical Discrete Command Connection 2000 PRECISION Run Command The RUN command is a user provided discrete input to the ACT2000 which allows the actuator to track position demand The 24 VDC signal shall be provided on the VIOLET wire The signal return shall be provided on the WHITE VIOLET wire Reset Command The RESET command is a user provided discrete input to the ACT2000 which causes the actuator to go through the initial homing sequence and reset all internal position indicators RUN and position demand inputs are ignored during the RESET command The 24VDC signal shall be provided on the GRAY wire The signal return shall be provided on the WHITE GRAY wire 2 2 3 Analog Inputs Outputs The ACT2000 receives analog position demand from an external user provided controller and provides analog actuator position and motor current feedback Refer to Figures 2 4 and 2 5 for typical
6. 3 3 page 3 8 Wire exposed beyond the shield should be as short as possible WARNING Property Damage Hazard This actuator is 89 339 EEC EMC Directive compliant CE mark using watertight flexible conduit plastic over steel and Belden 8719 shielded twisted pair audio broadcast and instrumentation cable Use of other conduit or wire invalidates EMC Directive compliance Property Damage Hazard Do Not connect 24VDC power without current limiting 25 mA across digital or analog outputs Serial Wiring The serial inputs are not electrically isolated Isolation must be provided when connecting to a computer PRECISION ACT2000 WARNING Property Damage Hazard Serial inputs are not electrically isolated Failure to properly isolate the user serial interface could result in actuator or A computer damage Use separate conduits for power and signal wiring Close proximity to power lines may cause signal interference Shock Hazard The serial inputs are not electrically isolated If the 120 VDC power input is floating not grounded the serial input connections may have up to 120 VDC present Property Damage Hazard DO NOT connect 24VDC power to any of the serial interface connections A Note Serial connection limited to 50 ft for local interface only with laptop PC 3 4 2 Wire Lists This section will provide ACT2000 wire hook up information Power Harness Electrical Hook Up Table 3 3 sho
7. Command Connection sees 2 3 Figure 2 4 Typical Analog Input Connection pp 24 Figure 2 5 Typical Analog Output Connection eee 2 4 Figure 2 6 Typical Fault Alarm Connection pp 2 5 Figure 2 7 ACT2000 State Machine essen 2 7 Figure 3 1 ACT2000 590P Envelope seen 3 2 Figure 3 2 ACT2000 200F Envelope seems 3 3 Figure 3 3 ACT2000 Wiring Diagram ps 3 8 List of Tables Table 2 1 ACT2000 Setup Parameters 2 12 Table 3 1 Power Harness Recommended Wire 3 5 Table 3 2 Digital Harness Recommended Wire Size pp 3 6 Table 3 3 ACT2000 Power Harness Wire LiSt pp 3 7 Table 3 4 ACT2000 Digital Harness Wire List pp 3 9 Table 3 5 Power Supply Requirement ppp 3 10 Table 4 1 ACT2000 Initial Installation Troubleshooting 4 2 Table 4 2 ACT2000 In Service Troubleshooting 4 3 Table 4 3 ACT2000 Electrical Hook Up Continuity Troubleshooting Chart 4 3 PRECISION ACT2000 1 INTRODUCTION This publication covers operation installation and maintenance instructions for the ACT2000 Actuators manufactured by Precision Engine Controls Corporation 1 1 Application The ACT2000 All Electric Actuator is designed to meet general industrial motion control requirements f
8. WHITE VIOLET BALL SCREW AND GRAY SHAFT WHITE GRAY ORANGE FAULT ALARM FAULT RTN OVERTEMP ALARM OVERTEMP RTN SERIAL TX OUT SERIAL RX IN SERIAL RTN Di WHITE ORANGE BLACK WHITE BLACK WHT ORN BLU WHT ORN YEL RS 232 DRIVER WHT ORN GRN CONTROL INTERFACE DIGITAL ASSY ACTUATOR Figure 2 1 ACT2000 Electronics System Block Diagram 2 2 PRECISION ACT2000 2 2 1 Power The ACT2000 operates on nominal 120 VDC user provided input voltage via the four wire power harness Refer to Figure 2 2 for typical connection Refer to section 6 for specification values Primary power wires e 120 VDC is connected to the RED wire e The 120 VDC return wire is GREEN Redundant power wires e 120 VDC is connected to the WHITE RED wire e 120 VDC return wire is WHITE GREEN ACTUATOR 120V INPUT BATTERY POWER SUPPLY PWR RED 120VDC 2E FUSE w REVERSE VOLTAGE PROTECTION PWR RTN AUX WHT GRIN PWR GRN Figure 2 2 Typical Power Connection WARNING Shock Hazard Both the 120 VDC power and auxiliary wires should be connected If only the primary power wires connected the 120 VDC auxiliary power wires are electrically hot and must be insulated on the ends A Note Ifa 120 VDC power supply is used it must have at least 50 000 uF internal capacitance See Power Supply Requirements Table 3 5 2 2 2 Discrete Commands
9. connection Refer to Section 6 for load specification values CONTROLLER 4 20mA OUTPUT ACTUATOR 4 20mA INPUT CONTROLLER 4 20mA INPUT ACTUATOR 4 20mA OUTPUT POSITION MTR CURRENT POSITION RTN WHT YEL a MTR CURRENT RTN WHT BLU Figure 2 5 Typical Analog Output Connection Position Demand The position demand is a 4 20mA user provided analog input that causes the actuator to a command position The position demand shall be provided on the BROWN wire The position demand return shall be provided on the WHITE BROWN wire The position demand internal impedance is 200 ohms The position demand requires a sourcing current Position Feedback The ACT2000 provides actuator analog position feedback to the user This internally generated feedback signal is proportional to the actual position The actuator position feedback is provided on the YELLOW wire The actuator position feedback return is provided on the WHITE YELLOW wire The expected external impedance is 250 ohms The maximum external impedance is 500 ohms Typically the position feedback will be within 0 1 mA of the position demand 24 PRECISION ACT2000 Motor Current Feedback The ACT2000 provides motor current feedback to the user This internally generated feedback signal is proportional to actuator load 4mA represents no load on the actuator The motor current feedback is provided on the BLUE wire The motor current feedback return is provided on the WHITE B
10. 000 A WARNING 94 9 EC ATEX Compliance Special Conditions for Safe Use Two special factory sealed unions are mounted on the equipment to ensure the electrical connection to the network and to provide the feedback signal to the user The installation of these devices and the final connections to the conduit shall comply with the requirements of the European standards Power Harness Recommended Wiring Under normal operation and load the ACT2000 requires less than one 1 amp input current Under transient operation under load the ACT2000 may require up to 20 amps of current The recommended wiring is a two conductor shielded cable containing twisted pair wires with individual shields Use a wire size large enough to accommodate the installation and provide a maximum one 1 ohm loop resistance See Table 3 1 below for recommended wire sizes Distance to User Power Wire Size Minimum Up to 500 ft AWG 10 stranded Over 500 ft Consult Factory Table 3 1 Power Harness Recommended Wire Size WARNING Shock Hazard Both the 120 VDC power and auxiliary wires should be connected If only the primary power wires are connected the 120 VDC auxiliary power wires are electrically hot and must be insulated on the ends A note Use a separate conduit for the power wiring This will prevent noise pickup and transmission from ancillary equipment which could cause instability in the a
11. 4 1 8 Power and Digital Flaress ttt tn o ea eH Hp a u i raa e 1 4 1 9 Identification Plates u a S 1 5 2 FUNCTIONAL DESCRIPTION AND OPERATION Nt 2 1 2 1 System Description n dada AA dees 2 1 2 2 Electronic DescriptiOn dd da teta 2 1 2 3 Basic Operation and State Description pp 2 6 2 4 Health Monttoririg rette n edi n e et a i ete eme 2 8 2 5 FAULT Alarm MEET 2 9 2 6 OVERTEMP Alarm Haren ra rao e eden ed den 2 10 2 7 Automatic Shutdown sss enne ai Beea aati 2 10 2 8 ACT2000 Set Up Parameters Nt 2 11 ov INSTALLATION nih iieri itt iR Eni Eni EC ea sassa 3 1 ST Ipspection eee te cas al ee am e eie a dedo 3 1 3 2 Environmental Considerations pp 3 1 3 9 Mechanical InstallatiOri n 3 ttp rb ite el e Gu 3 1 23 4 Electrical Installation a yu nr E e etre tel wade 3 4 4 terere aida 4 1 5 DECOMMISSIONING AND DISPOSAL Ne 5 1 6 ACT2000 GENERAL SPECIFICATIONS eine aia 6 1 2 CELOSA a BEA as 7 1 2000 PRECISION List of Figures Figure 1 1 ACT2000 Pin 1 1 Figure 1 2 2000 Flange Mounted 1 1 Figure 1 3 ACT2000 Cut Away View 1 2 Figure 1 4 Typical Identification Plate pe 1 5 Figure 2 2 Typical Power Connection ee 2 3 Figure 2 3 Typical Discrete
12. AULT ALARM ORN and WHT ORN High Impedance OVERTEMP BLK and WHT BLK High Impedance 4 3 2000 PRECISION PRECISION INTENTIONALLY BLANK PRECISION ACT2000 5 DECOMMISSIONING AND DISPOSAL This section contains recommended ACT2000 decommissioning and disposal practices It is for permanent removal or replacement of the installed product with no intentions of rework overhaul or to be used as spares For removal follow proper lockout tagout procedures and verify no live electrical circuits 1 Disconnect power harness to ACT2000 2 Disconnect signal harness to ACT2000 A note Follow local environmental codes in regards to disposal of electronic components specifically all electrolytic capacitors 5 1 2000 PRECISION PRECISION INTENTIONALLY BLANK 5 2 PRECISION ACT2000 6 ACT2000 GENERAL SPECIFICATIONS Power Input RUN and RESET Command Input FAULT and OVERTEMP Output Analog Command Input Position and Motor Current Feedback Analog Maximum Common Mode Voltage Temperature Limits Maximum Velocity Maximum Continuous Force Maximum Peak Force Maximum Stroke Accuracy Environmental Rating EMC Vibration Mean Time Before Unscheduled Removal Life Cycles Electrical Connection North American Certifications European Directive Compliance CE Mark Materials Housings Conduit Union Extension Rod Clevis Rod End Bearing Seals Dimensions Approx Dry Weight
13. E position to thermally expand or contract without damaging the ACT2000 If the actuator firmware program entered the HOME DEAD BAND state from POWER UP RESET the firmware program will immediately define the current actuator position as HOME zero The actuator firmware program will also enter this state from RUN if the position demand is 4 1mA and position feedback is lt 4 2mA A note If RUN command is removed or position demand lt 2 mA the actuator will go to the STOP position Run State The RUN state is the ACT2000 normal operating mode See Figure 2 7 In the RUN state the actuator tracks position demand and will apply up to the maximum force to reach the demand position The actuator firmware program enters this state from the HOLDING MOTOR CURRENT state if the position demand is 2 4 1mA The actuator firmware program will remain in this state as long as the demand is greater than 4 1mA V Note If RUN command is removed or position demand x 2 mA the actuator will go to the STOP position Stop Position The STOP position is a user defined fail safe position The STOP position is a set up parameter stored in the EEPROM The STOP position may be anywhere between HOME zero position and maximum span The STOP position is not a state per se However while in the STOP position the ACT2000 firmware program will track and hold the position defined in the Set Up parameters The actuator will move to the STOP po
14. ION ACT2000 Table 3 4 shows the factory wiring and reference signals for the ACT2000 signal harness A note The serial wiring is segregated from the other wires Wire Color Function AWG Signals WHITE ORANGE YELLOW Serial RX In 20 12V WHITE ORANGE BLUE Serial TX Out 20 12V WHITE ORANGE GREEN Serial Return 20 OV BLACK OVER TEMP Alarm 20 0 24V WHITE BLACK OVER TEMP Alarm Return 20 OV ORANGE FAULT Alarm 20 0 24V WHITE ORANGE FAULT Alarm Return 20 OV VIOLET RUN Command 20 0 24V WHITE VIOLET RUN Command Return 20 OV GRAY RESET Command 20 0 24V WHITE GRAY RESET Command Return 20 OV BROWN Position Demand 20 4 20mA WHITE BROWN Position Demand Return 20 OV YELLOW Position Feedback 20 4 20mA WHITE YELLOW Position Feedback RTN 20 OV BLUE Motor Current 20 4 20mA WHITE BLUE Motor Current RTN 20 OV Table 3 4 ACT2000 Digital Harness Wire List Note The serial Return is connected to the 120 V input return 3 9 2000 3 10 Power Supply Requirements PRECISION A battery power system is recommended Table 3 5 lists the power supply requirements Voltage Max Ripple Max Current Typical Continuous Current Typical Transient Current Output Capacitance 120VDC nominal 80VDC minimum 160VDC maximum 4 VAC RMS or 12VAC p p 20 AMPS lt 1 AMP 20 A 60ms 10 lt 600 ms 5A lt 100 ms 50 000 uF The output capacitance applies for non bat
15. LUE wire The expected external impedance is 250 ohms The maximum external impedance is 500 Ohms 2 2 4 Fault Alarms The discrete alarm outputs are opto isolated electronic switches that are normally closed The user controller provides 24 VDC with current limiting resistor to complete the circuit If a FAULT or OVERTEMP alarm has occurred the switch opens thereby communicating an alarm to the user s controller Refer to Figure 2 6 for typical connection Refer to Section 6 for load specification values CONTROLLER DISCRETE INPUT ACTUATOR DISCRETE OUTPUT EAULT ALARM OVERTEMP ALARM BLK FAULT RTN WHT ORN OVERTEMP RTN WHT BLK FAULT OVERTEMP RTN WHT BLK FAULT ALARM ORN OVERTEMP ALARM BLK Figure 2 6 Typical Fault Alarm Connection The FAULT alarm is provided on the ORANGE wire The FAULT alarm return is provided on the WHITE ORANGE wire The OVERTEMP alarm is provided on the BLACK wire The OVERTEMP alarm return is provided on the WHITE BLACK wire WARNING Property Damage Connection of 24 VDC power across the actuator discrete output will cause electrical failure of the output Series resistance should be added to the 24 VDC output from the controller to limit the current to 25mA max 2 2 5 RS232 Communications RS232 serial communications is achieved with user provided connection to the Serial Rx In Serial Tx Out and Seria
16. ard The ACT2000 will not hold position when communicating with ActWiz software Ensure there is no load on the extension rod when communicating with the actuator Once the ACT2000 has completed the power up operations it will wait for a RUN command The actuator will not move or hold load until a RUN command is received 2 3 2 Run Modes Upon receipt of RUN command the ACT2000 firmware program will transition to one of the run modes listed below A note As a Safety feature the ACT2000 will not move without a RUN command Home Dead Band State The HOME DEAD BAND state is used to find HOME position after a POWER UP RESET See Figure 2 7 The firmware program will transition to HOME DEADBAND upon receipt of RUN command While in the HOME DEAD BAND state the actuator moves at constant velocity homing velocity and direction extend or retract until a mechanical stop is found M note If RUN command is removed the actuator will not function 2000 PRECISION When the mechanical stop is found actuator velocity less 0 05 inches per second the MCE will apply the maximum homing force Once the maximum homing force is applied the firmware program will transition to the HOLDING MOTOR CURRENT state Holding Motor Current State In the HOLDING MOTOR CURRENT state the MCE applies a constant HOLDING FORCE as long as the position demand is gt 2mA and lt 4 1mA See Figure 2 7 This feature allows the HOM
17. as a fault file that can be uploaded to pinpoint a failure cause See ActWiz Software Manual for more details If after following the troubleshooting procedures the user is unable to find the cause of the problem and repair it contact the factory for assistance See Section 8 for retum information 2000 Table 4 1 ACT2000 Initial Installation Troubleshooting Chart PRECISION Symptom Probable Causes Corrective Action Actuator Inoperative FAULT alarm Power Wires not connected No or low 120 VDC power Ensure RED and GREEN wires correctly connected to Actuator Ensure 120 VDC Primary System Power at Actuator Actuator Inoperative NO FAULT alarm No RUN or position command Ensure VIOLET and WHITE VIOLET wires correctly connected to Actuator Ensure 24 VDC and position command at Actuator Actuator moves toward HOME then stops Intermittent RUN command Homing Force Too Low No position demand Ensure consistent 24 VDC RUN and position command Ensure position command at actuator Actuator moves toward HOME intermittently Actuator finds HOME then moves to STOP position Actuator does not track position demand Intermittent RESET command No position demand signal No position demand signal Ensure GRAY and WHITE GRAY wires correctly connected to Actuator Ensure consistent 24 VDC RESET command Ensure BROWN and WHITE BROWN wires correctly connected to Actuator Ensur
18. ce the program is complete with the health check it waits for either the RUN RESET or SET UP command e f the ACT2000 receives a SET UP command from the ActWiz software through the RS232 interface firmware program will transition to the SET UP state PRECISION ACT2000 A f the ACT2000 receives a discrete RUN command the firmware program will transition to the HOME DEAD BAND state e If the ACT2000 receives a discrete RESET command the firmware program will continuously reset The actuator will not function and will remain in the power up reset state WARNING Property Damage Hazard Always remove RUN command during Set Up state If a RUN command is given during program download the actuator will not respond until download is complete Set Up State The ACT2000 communicates with the user in this state See Figure 2 7 Contact Precision Engine Controls for a copy of ActWiz software in order to communicate with the ACT2000 In this state a set up file can be uploaded or downloaded A Fault file can also be uploaded using the ActWiz software Please see ActWiz software manual for more information The ACT2000 can only enter this state via POWER UP RESET The ACT2000 enters this state via a SET UP command received via the RS232 interface The actuator will leave this state after a file has been uploaded or downloaded The ACT2000 will not hold position while in this state WARNING Property Damage Haz
19. clear the fault file The following faults are recorded Driver over current The maximum MCE current output limit is 25 amps If the MCE is outputting its maximum current for ten 10 seconds the MCE signals a FAULT Should MCE maximum current drop below the maximum current the FAULT signal is cleared Tracking error The ACT2000 position should continuously track demand Should the position versus demand vary more than one motor revolution 0 20 inches for more than ten 10 seconds the MCE signals a FAULT Should the position return to within one motor revolution the FAULT signal is cleared Watchdog expired The MCE watchdog timer continuously monitors the firmware program Should the MCE firmware program stop functioning or attempt to access an illegal address the MCE signals a FAULT This FAULT does not clear without RESET command Resolver to Digital Converter RDC failure The MCE contains a resolver to digital converter chip RDC that provides position feedback information to the DSP The RDC chip has on board health monitoring Should the RDC detect an internal tracking error a signal is sent to the MCE Upon receipt the MCE signals a FAULT 2000 De PRECISION This FAULT does not clear without RESET command Unregulated Voltage Low The MCE signals a FAULT if the reference voltage drops below minimum for ten 10 seconds Should the voltage return to acceptable level the FAULT signal is cleare
20. ctuator Signal Harness Recommended Wiring The signal harness contains both analog and digital inputs and outputs The analog inputs and outputs are 4mA to 20mA and are electrically isolated up to 500 VAC from the enclosure 120VDC power digital I O and serial interface The analog interfaces are not isolated from each other 2000 3 6 PRECISION A For proper operation of the actuator the voltage between the control inputs and the negative terminal of the power supply should be below 200 VDC The discrete inputs and outputs are 24 VDC and are electrically isolated up to 500 VAC The recommended wiring is a fourteen conductor shielded cable containing twisted pair wires with individual shields Use a wire size large enough to accommodate the installation and provide a maximum fifty 50 ohm loop resistance See Table 3 2 for recommended wire sizes Distance to User Controller Wire Size Minimum Up to 1000 ft AWG 18 stranded Over 1000 ft Consult Factory Table 3 2 Digital Harness Recommended Wire Size note Use a separate conduit for the signal wiring This will prevent noise pickup and transmission from ancillary equipment which could cause instability in the actuator Shielded Wiring All shielded cable must be a twisted conductor pair with either a foil or braided shield All signal lines should be shielded to prevent picking up stray signals Connect shields per Figure
21. d 14V High Low The MCE signals a FAULT if the internal 14 VDC power supplies exceed operating limits This FAULT does not clear without RESET command Input voltage High Low The MCE signals a FAULT if the 120 VDC supply exceeds 180 VDC or drops below 75 VDC for more than 10 seconds This FAULT clears when the 120 VDC supply voltage returns 2 6 OVERTEMP Alarm The OVERTEMP alarm is a discrete output from the ACT2000 The OVERTEMP circuit is CLOSED in the normal operating condition During normal operation the ACT2000 monitors the electronics and motor winding temperatures If ACT2000 detects the motor or electronics temperature above the maximum allowable the OVERTEMP circuit is opened The user provided controller should detect the open circuit An OVERTEMP Alarm will be indicated if the motor winding temperature is 130 C or higher for ten 10 seconds or the electronics temperature is 110 C or higher for ten 10 seconds Should an OVERTEMP alarm occur the user should shut down the actuator Removing 120 VDC power shuts down the ACT2000 Toggling the RESET command will clear the FAULT alarm but it does NOT clear the fault file S note The ACT2000 outputs an OVERTEMP alarm 5 C before the shut down threshold 2 7 Automatic Shutdown 2 10 The ACT2000 has a self protective shutdown feature e two motor winding temperatures exceed 135 C for one 1 minute the ACT2000 will shut down e f the electr
22. e position demand gt 2 0 mA at Actuator Ensure BROWN and WHITE BROWN wires correctly connected to Actuator Ensure position demand gt 4 1 mA at Actuator Actuator does not hold consistent position oscillates or dithers Varying position demand signal Ensure stable position demand at the actuator No position feedback Position feedback wires not connected No or low 120 VDC power Actuator auto shut down Ensure YELLOW and WHITE YELLOW wires correctly connected Ensure 120VDC at Actuator Upload Fault File check for electronics or motor windings over temperature faults Check for jammed extension rod No motor current feedback Motor current wires not connected No or low 120 VDC power Ensure BLUE and WHITE BLUE wires correctly connected Actuator Operative FAULT alarm active Open circuit Internal FAULT Ensure ORANGE and WHITE ORANGE wires correctly connected to Actuator Upload Fault File to identify source of fault Actuator Operative OVER TEMP alarm active RS232 Interface Inoperative Open circuit Electronics or Motor winding temperature out of range Incorrect wiring No or low 120 VDC power COMI not connected Ensure BLACK and WHITE BLACK wires correctly connected to Actuator Reduce External ambient temperature Check for jammed extension rod Ensure WHITE ORANGE YELLOW WHITE ORANGE BLUE WHITE ORANGE GREEN wires correctly connected to Actuator and laptop PC
23. eat sink digital and driver component assemblies CA The MCE electronics communicate with the user s controller through analog and serial interfaces The MCE controls the brushless DC motor to position the actuator based on position feedback from the resolver A note The digital board analog and discrete interfaces are electrically isolated The MCE serial interface is NOT electrically isolated 1 6 Resolver Assembly A Brushless non contacting resolver is the primary ACT2000 feedback sensor A sinusoidal feedback signal is provided from the resolver to the motor control electronics A sinusoidal signal from the MCE provides the resolver excitation The resolver includes a stator and rotor See Figure 1 3 Resolver Stator The resolver stator is clamped to the main housing between the main bearing retaining nut and resolver retainer The resolver stator angular position relative to the rotor is adjustable Electrical wires from the resolver are reeled in the resolver adapter to allow rotation The resolver wires along with the motor and thermistor leads are routed through a conduit into the electronics housing Resolver Rotor The resolver rotor is mounted by a key to a ball screw shaft As the rotor rotates the stator transformer output signal provides shaft rotation information to the MCE 2000 PRECISION 1 7 Linear Drive Mechanism The Linear Drive Mechanism converts the rotary motion of the Motor Assembly to linea
24. g Force This parameter sets the maximum force the ACT2000 will use to find the HOME position Maximum Holding Force This parameter sets the maximum force at the HOME position while the position demand is lt 4 1mA 2 11 2000 PRECISION Table 2 1 lists the set up parameters and factory default settings Parameter Factory Setting Part Number Per Drawing Actuator Type Stand Alone Command Source Analog Home Retract Span 5 9 inches Stop Position 0 1 inches Interpolation Table Linear Position Loop Constant 20 Current Loop PID Constants Proportional 20 Integral 200 Derivative 0 Velocity Loop PID Constants Proportional 40 Integral 10 000 Derivative 0 Maximum Velocity 6 in s Maximum Force 1000 Ibf Maximum Homing Velocity 0 5 in s Maximum Homing Force 500 Ibf Maximum Holding Force 500 Ibf Table 2 1 Typical ACT2000 Setup Parameters PRECISION ACT2000 3 INSTALLATION The purpose of this section is to aid personnel in the installation placement and environmental considerations to be observed for the ACT2000 and associated equipment 3 1 Inspection The ACT2000 should be inspected immediately after unpacking Check for damage paying particular attention to the external lead wires A note Retain the actuator s original shipping container In the event of future transportation requirements this container will minimize damage duri
25. ing the clevis violates the warranty The extension rod has a 0 375 24 UNF 3B female thread for user provided hardware The user may provide a standard 0 375 24 3B rod end recommended or other appropriate mounting hardware The extension rod has wrench flats to counteract mounting hardware installation torque WARNING Property Damage Hazard Always use the extension rod wrench flats when installing mounting hardware Failure to use the wrench flats may damage or break the internal anti rotation guide 3 3 3 Extension Rod Movement With 120 VDC power removed the ACT2000 extension rod is free to move Approximately 60 to 100 Ibf is required to extend or retract the extension rod A rod guide is provided internally to prevent extension rod rotation WARNING Property Damage Hazard Do not attempt to rotate the extension rod This may damage the internal anti rotation guide and void the warranty 3 4 Electrical Installation The ACT2000 is suitable for use in hazardous locations See nameplate for certifications Care should be taken to ensure compliance with the factory recommendations Wiring must be in accordance will local authorities jurisdiction 3 4 4 Wiring Specifications and Requirements This section describes the recommended power and control harness wiring to the ACT2000 Please consult the factory if there are any questions See Table 3 5 for DC power supply requirements PRECISION ACT2
26. is permanently installed into the aluminum main housing A retaining ring is included for redundant retention The main housing contains rigid mechanical stops to prevent extension rod travel beyond the design specification Extension Shaft Por 0 Rod End Bearing RN Y 7 Qi NY Z NA Motor Control IN s Electronics Rigid Stop u y Anti Rotation Guide ec Linear Drive Main Resolver Assembly Bearings Main Housing Assembly Motor Rotor Brushless DC Motor Stator Motor Assembly Motor End Bearing Motor Cover N NM Mounting Clevis Figure 1 3 ACT2000 Cut Away View PRECISION ACT2000 1 4 Brushless DC Motor Assembly A brushless DC motor powers the ACT2000 linear drive mechanism The DC motor contains a stator and rotor See Figure 1 3 Motor Stator The motor stator is attached to the main housing by a pre loaded wave spring and screws Thermistors are embedded in the stator windings to monitor winding temperatures The motor electrical power and thermistor wires pass from the motor through a conduit into the electronics housing Motor Rotor The motor rotor is locked to the ball screw shaft via a straight key The motor rotor contains powerful magnets that align with the energized stator windings thereby creating torque and shaft rotation 1 5 Motor Control Electronics The motor control electronics MCE are contained within the main housing electronics enclosure The MCE includes harnesses h
27. l Rtn wires e The Serial RX In wire is WHITE ORANGE YELLOW e The Serial Tx Out wire is WHITE ORANGE BLUE e The Serial Rtn wire is WHITE ORANGE GREEN The RS232C type interface is used to communicate with the ACT2000 using ActWiz software 2000 PRELISIUN 2 3 Basic Operation and State Description The basic operation ofthe ACT2000 is described in the following sections The Power Up mode section covers the Power Up Reset and the Set Up states The Run Mode section covers the Home Dead Band Holding Motor Current and the Run states POWER F UPIRESET oT a IS SET UP RESET COMMAND HOME COMMAND POSITION b DEADBAND 4 1 mA AI POSITION FEED BACK lt 4 2 mA MOTOR CURRENT gt MAX HOMING FORCE AND RUN ACTUATOR VELOCITY lt 0 05 IN SEC e POSITION HOLDING DEMAND MOTOR CURRENT Figure 2 7 ACT2000 State Machine 2 3 1 Power Up Modes When 120 VDC is applied to the ACT2000 the on board DC converter supplies power to the driver and digital boards The ACT2000 will operate with voltages ranging from 80 VDC to 160 VDC Power Up Reset State Once the digital signal processor DSP receives required voltage it starts the firmware program and enters the POWER UP RESET state See Figure 2 7 The program checks electronics health clears system registers and retrieves set up parameters from the electrically erasable programmable read only memory EEPROM On
28. m is active A mechanical rigid stop at which the ACT2000 calculates position from HOME is found at start up during Homing sequence The ACT2000 defines HOME when the motor current exceeds the HOMING FORCE and velocity is zero HOME is defined as 4mA position demand When the ACT2000 extends or retracts to find a rigid mechanical stop Maximum distance from HOME SPAN is defined as 20mA position demand A user defined position between HOME and SPAN that the ACT2000 travels to upon loss of RUN or position demand signal A user defined maximum velocity in inches per second A user defined maximum homing force output setting The motor control electronics uses this setting to determine the maximum motor current in the Homing sequence A user defined maximum force while in the Holding Motor Current state 7 1 2000 PRECISION PRECISION INTENTIONALLY BLANK 7 2 PRECISION ACT2000 7 1
29. ng shipment 3 2 Environmental Considerations The ACT2000 will operate satisfactorily with ambient air temperature of 40 40 F to 93 200 F The ACT2000 is designed as an explosion proof assembly The ACT2000 enclosure is Canadian Standards Association CSA Type 3 WARNING Property Damage Solvent water may enter the electronics area during a high pressure wash 3 3 Mechanical Installation This section describes proper ACT2000 installation Care should be exercised to ensure compliance with the factory recommendations 3 3 1 Space Requirements Figure 3 1 shows external dimensions and mounting provisions for the ACT2000 590P Figure 3 2 shows the external dimensions and mounting provisions for the ACT2000 200F The user should ensure additional swing clearance as required 3 3 2 Mounting Considerations The ACT2000 can be directly mounted to a gas turbine engine using brackets provided by the engine manufacturer The ACT2000 can be mounted in any orientation UP DOWN SIDEWAYS The ACT2000 may provide a clevis or other method for installing the motor end High strength bolts 0 375 diameter are recommended to secure the actuator to a user provided mount bracket WARNING A Lifting Hazard Do not attempt to hand lift actuator Use appropriate lifting equipment ACT2000 PRECISION HU
30. odized Aluminum Zinc Plated Steel 17 4 PH CRES 17 4 PH CRES Aluminum Bronze Nitrile RTV and Teflon 6 0 in x 16 0 in Pin Mounted 35 Ibs Max Flange Mounted 50 Ibs Max 6 1 2000 PRECISION PRECISION INTENTIONALLY BLANK 6 2 PRECISION 7 GLOSSARY ACT2000 Term Definition RUN Command A discrete 24 VDC signal that enables the ACT2000 extension rod to move RESET Command A discrete 24 VDC signal that causes the ACT2000 internal program firmware to jump to the beginning Controller A user provided computer that executes commands to the ACT2000 Position Demand Position Demand Feedback Motor Current Feedback FAULT alarm OVERTEMP alarm HOME Homing sequence SPAN STOP position Maximum Velocity Maximum Homing Force Maximum Holding Force and accepts analog and discrete feedback A 4mA to 20mA signal that commands the ACT2000 to move to a certain position The signal is scaled with SPAN A 4mA to 20mA signal that communicates the actual ACT2000 position to the controller A 4mA to 20mA signal that is proportional to the ACT2000 motor current The signal is scaled with Max Force A discrete signal from the ACT2000 that communicates an internal failure The controller will see an open circuit when a FAULT alarm is active A discrete signal from the ACT2000 that communicates an internal over temperature electronics or motor The controller will see an open circuit when OVERTEMP alar
31. onics temperature exceeds 115 C for one 1 minute the ACT2000 will shut down V Note Actuator position feedback and motor current will be set to 0 mA when the actuator shuts down WARNING Property Damage and Injury Hazard If the motor windings exceed 135 C or the electronics exceed 115 C the MCE will shut down power to the motor and electronics thereby allowing the actuator to move with load Touching actuator may result in serious burn injury PRECISION ACT2000 2 8 ACT2000 Set Up Parameters The ACT2000 employs several variables to define its functionality These variables are called set up parameters These parameters are downloaded through the RS232 interface to the ACT2000 using ActWiz software See ActWiz Software Manual for further details The user can define set up any of the following parameters Home Extend or Retract This parameter controls the direction the ACT2000 will move extend or retract to find the mechanical stop HOME Span This parameter sets the maximum stroke length The span is measured from the HOME position Stop Position This parameter sets the signal loss position The signal loss position is measured from the HOME position Maximum Velocity This parameter sets the maximum velocity Maximum Force This parameter sets the maximum force output Maximum Homing Velocity This parameter sets the maximum velocity used to find the HOME position Maximum Homin
32. or high temperature hazardous locations Typical applications include gas turbine guide vane and valve motion control 1 2 Mounting Provisions The ACT2000 can be pin or flange mounted Figure 1 1 shows a pin mounted actuator Figure 1 2 shows a flange mounted actuator Other configurations can be provided Please consult Precision Engine Controls Corporation Figure 1 1 ACT2000 590P Pin Mounted Figure 1 2 ACT2000 200F Flange Mounted The pin mounted ACT2000 configuration includes a stainless steel machined clevis The clevis is fully rotational to allow variable angular indexing as required for installation The extension rod provides a female thread for user supplied end attachments A spherical rod end bearing attachment is preferred The ACT2000 contains a brushless direct current DC motor driven linear actuator with on board digital motor control electronics The primary actuator components are described in the balance of this section 2000 PRECISION 1 3 Main Housing Assembly The main housing assembly contains a main housing motor cover extension rod bearing and associated seals See Figure 1 3 The main housing assembly is the primary structural system component and supports all the bearings motor control electronics motor cover and mountings which forms the explosion proof containment In order to provide main bearing thermal dimensional stability the housing is fitted with a stainless steel liner The liner
33. provided ACT2000 1 5 2000 PRECISION PRECISION INTENTIONALLY BLANK 2000 2 FUNCTIONAL DESCRIPTION AND OPERATION This section describes system functions employed in the ACT2000 Electric Actuator 2 1 System Description The ACT2000 is a closed loop servo system containing motor control electronics MCE and a brushless DC motor driven ball screw actuator The actuator closes its own control loop on an internally generated position feedback Thus the actuator continuously modulates its position and provides precise positioning The ACT2000 requires only 120VDC power 4 20 mA position demand and discrete RUN command to achieve basic operational capability The ACT2000 provides position and motor current feedback via integral 4 20 mA circuits Once 120VDC power and RUN command are supplied the actuator will track position demand 2 2 Electronic Description The ACT2000 electric actuator incorporates digital motor control electronics The electronic system block diagram is shown in Figure 2 1 Contained within the motor control electronics MCE are digital and driver CA The digital and driver component assemblies contain analog to digital converters digital signal processor DSP application specific integrated circuit ASIC and power supplies Digital CA The digital CA interfaces with a user provided control system that is typically a programmable logic controller PLC The digital CA acce
34. pts analog position and discrete RUN and RESET commands from the control system The digital CA provides analog position and motor current feedback to the control system In addition the digital CA provides discrete FAULT and OVERTEMP alarms to the control system The digital CA receives position feedback from the resolver and current feedback from the driver CA The digital CA can provide speed temperature voltage and other relevant information through the serial interface using ActWiz software Contact Precision Engine Controls for ActWiz software A note The digital board analog and discrete interfaces are electrically isolated The RS232C serial interface is NOT electrically isolated Driver CA The driver CA interfaces with the user s power supply typically a 120 VDC battery The driver CA controls current to the brushless DC motor and provides precise voltage and current inputs to the digital CA 2000 120V ACTUATOR POWER 80 160 VDC DEMAND DEMAND RTN 9 POSITION RTN WHITE YELLOW gt E MTR CURRENT lt BLUE E MTR CURRENT RTN WHITEBLUE 5 RUN RUN RTN RESET RESET RTN PRECISION DRIVER ASSY WATERED a POLARITY GREEN PROTECTION POWER BRUSHLESS WHITE GREEN ELECTRONICS DC MOTOR POWER INTERFACE BROWN INPUT gt WHITE BROWN TERMINATION lt EN EEE _ 2 4 20 z RESOLVER OUTPUT L o CONTROL ELECTRONICS OPTICAL VIOLET ISOLATION
35. r actuator motion The core of the mechanical drive system is the linear ball screw drive containing a screw shaft ball bearing fitted nut extension rod and main duplex thrust bearings Screw Shaft The thrust bearings motor rotor motor end bearing and resolver rotor are mounted directly to the screw shaft A ball bearing track is machined into the screw shaft Ball Nut As the screw shaft rotates the ball nut translates in an axial direction depending on shaft rotation Extension and Bearings The extension rod is threaded on the ball nut As the ball nut translates the extension rod moves in and out of the ACT2000 main housing The extension rod support bearing is provided for lateral support Thrust and radial loads are transferred from the extension rod through the ball nut to the main preloaded duplex thrust bearings The thrust bearings transfer the loads to the main housing by the main bearing and shaft retaining nuts A motor end bearing is provided for additional shaft radial stability The resolver rotor motor rotor motor bearing and spacers are stacked on the ball screw shaft and retained by a single nut This arrangement prevents actuator axial loads from passing through the resolver rotor and motor rotor 1 8 Power and Digital Harness A four wire electrical harness with two 2 meter free leads provides the ACT2000 electrical power inputs The four wire harness allows for redundant electrical inputs A
36. seventeen wire electrical harness with ninety 90 inch free leads provides ACT2000 signal interface Contained within this seventeen wire harness are discrete commands analog commands feedback and serial interface wires PRECISION 1 9 Identification Plate PRECISION A product identification plate is attached to the actuator housing assembly Figure 1 4 shows a typical identification plate Engine Controls Corporation SAN DIEGO CA 92121 CAGE NO 22787 MADE IN U S A www precisioneng MODEL NO PAT PEND com SERIAL NO CUSTOMER P N PECC P N L TYPI 120 VDC 800 AVERTISSEME NE PAS OUVRIR SOUS TENSION 2 SE REFERER D UTILISATION N WATTS RISQUE D EFLAGRAN AU MANUEL WIRE LIST COLOR FUNCTION 1 RED PWR 2 WHT RED PWR AUX 3 GRN PWR RTN 4 WHT GRN PWR RTN AUX 5 BRN DEMAND 6 WHT BRN DEMAND RTN 7 BLU MTR CURRENT 8 WHT BLU MTR CURRENT RTN 9 YEL POSITION 10 WHT YEL POSITION RTN 1 vio RUN 12 WHT VIO RUN RTN 13 GRY RESET 14 WHT GRY RESET RTN 15 BLK OVERTEMP ALARM 16 WHT BLK OVERTEMP RTN 17 ORN FAULT ALARM 18 WHT ORN FAULT RTN 19 WHT ORN BLU SERIAL TX OUT 20 WHT ORN YEL SERIAL RX IN 21 WHT ORN GRN SERIAL RTN Figure 1 4 Typical Identification Plate The identification plate lists model designation product part number revision and unit serial number Hazardous area operation certification and electrical wiring interface information is also
37. sition if RUN command is removed during any of the running modes or position demand is x 2 mA signal loss 2 4 Health Monitoring The firmware program continuously monitors system health while the ACT2000 is powered PRECISION ACT2000 If any of the health parameters are out of the normal operating range the MCE outputs a discrete FAULT alarm to the user s controller The actuator firmware also captures the fault data in the EEPROM If the motor or electronics temperature is above the normal operation range the MCE outputs a separate OVERTEMP alarm The actuator firmware also captures the fault data in the EEPROM If any of these faults have occurred the user should shut down the ACT2000 to investigate the failure cause If the ACT2000 is operational a fault file can be uploaded using ActWiz software via the RS232 interface The fault file will provide fault information and possible cause 2 5 FAULT Alarm The FAULT alarm is a discrete output from the ACT2000 The FAULT circuit is CLOSED in the normal operating condition During normal operation the ACT2000 monitors system health If the ACT2000 detects a fault the FAULT circuit OPENS and fault records in the fault file The user provided controller should detect the OPEN circuit Should a FAULT occur the user should shut down to troubleshoot the failure Removing 120 VDC power shuts down the ACT2000 Toggling the RESET command will clear the FAULT alarm but it does NOT
38. tery power systems and assumes full stroke step changes in actuator position at rated load Table 3 5 Power Supply Requirements PRECISION ACT2000 4 TROUBLESHOOTING The information contained in this section is intended to aid maintenance technicians in troubleshooting and isolating causes of malfunctions in the ACT2000 Most electrical fault isolation of the actuator can be accomplished by using an external oscilloscope and digital voltmeter DVM The ACT2000 is comprised of highly reliable components and should not develop service problems under normal operating conditions However over a period of time and service failures may develop Personnel responsible for fault analysis should be thoroughly acquainted with physical and electrical configurations Theory of Operation Section 2 and Installation Section 3 Resolve problems noted during operation or maintenance as soon as possible The causes of many problems can be traced through the information contained in the block diagrams shown in Section 2 WARNING Property Damage Hazard Continuing to operate the actuator in a malfunctioning condition is hazardous to personnel and can cause property damage Table 4 1 lists some common failures that can occur upon initial actuator installation Table 4 2 lists some common failures that can occur after initial installation In addition the ACT2000 has some on board troubleshooting capability The ActWiz software h
39. ws the factory wiring for the ACT2000 power harness Wire Color Function AWG RED Power 14 WHITE RED Power AUX 14 GREEN Power Return 14 WHITE GREEN Power Return AUX 14 Table 3 3 ACT2000 Power Harness Wire List 2000 Power Harness Electrical Hook Up POWER SUPPLY 120VDC 120VDC Return Power Gnd Shield Digital Harness Electrical Hook Up Demand Return Shield Gnd Run Return Shield Gnd Reset Return Shield Gnd Motor Current Motor Current RTN Shield Gnd Position Position RTN Shield Gnd Fault Alarm Fault Alarm Shield Gnd Over Temp Alarm Over Temp Alarm Shield Gnd Shield Gnd Serial RX in Serial TX out Serial RTN Shield Gnd ENGINE CONTROLLER Figure 3 3 ACT2000 Wiring Diagram 3 8 PRECISION ACT2000 PWR RED PWR AUX WHT RED PWR RTN GRN PWR RTN AUX WHT GRN Shield No Connection DEMAND BRN DEMAND RTN WHT BRN Shield No Connection RUN VIO RUN RTN WHT VIO Shield No Connection RESET GRY RESET RTN WHT GRY Shield No Connection MTR CURRENT BLU MTR CURRENT RTN WHT BLU Shield No Connection POSITION YEL POSITION RTN WHT YEL Shield No Connection FAULT ALARM ORN FAULT RTN WHT ORN Shield No Connection OVERTEMP ALARM BLK OVERTEMP RTN WHT BLK Shield No Connection Shield No Connection SERIAL TX OUT WHT ORN BLU SERIAL RX IN WHT ORN YEL SERIAL RTN WHT ORN GRN Shield No Connection ACT2000 PRECIS
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