Page 2 - Notices and Trademarks; Copyright 2008 by Honeywell; CE Conformity; Honeywell Process Solutions
ii HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Notices and Trademarks Copyright 2008 by Honeywell Revision 7 July 2008 Warranty/Remedy Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact...
Page 3 - About This Document; Abstract; Document Title; Contacts; World Wide Web; Honeywell Organization; Telephone; Organization Phone
Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual iii 7/08 About This Document Abstract This manual describes the installation, set up, operation, maintenance, and troubleshooting of the HercuLine 2000 series actuators. References The following list identifi...
Page 4 - Symbol Definitions; Symbol Definition; Failure to comply with these
iv HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Symbol Definitions The following table lists those symbols that may be used in this document to denote certain conditions. Symbol Definition This DANGER symbol indicates an imminently hazardous situat...
Page 5 - Contents; Series 90 Control – HercuLine
Contents Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual v 7/08 Contents Introduction ............................................................................................. 1 Product Description .........................................................
Page 6 - Appendix A - HercuLine
Contents vi HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Lock Set Up Group .....................................................................................................53 Read Status Set Up Group................................................
Page 7 - Tables; Table 3 Terminal Connections: HercuLine
Contents Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual vii 7/08 Tables Table 1 Specifications - General.............................................................................................................................5 Table 2 Recommended Mini...
Page 8 - Figures
Contents viii HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Figures Figure 1 HercuLine ® 2000 Series Actuator 2 Figure 2 HercuLine ® 2002 Actuator Internal View 3 Figure 3 Outline and Dimensions of HercuLine ® 2000 Series Actuators 14 Figure 4 Const...
Page 9 - Introduction; Product Description; Model distinctions
Introduction Product Description Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 1 7/08 Introduction Product Description Honeywell’s HercuLine ® 2000 series actuators are available in four versions: HercuLine ® 2000 , HercuLine ® 2001 , HercuLine ® 2002, a...
Page 10 - Handwheel; Figure 1 HercuLine
Introduction Product Description 2 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Display andkeypad Shaft andposition indicator Handwheel Auto/manualswitch Conduitentry Figure 1 HercuLine ® 2000 Series Actuator
Page 11 - Relay PWAs; Figure 2 HercuLine
Introduction Product Description Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 3 7/08 TB3Connectorfor customerinput andoutputconnectionon CPUPWA DisplayKeypadPWA WiringLabel Non-contactsensor Externalauto-manualswitch TB1customerpowerconnection Relay PWA...
Page 13 - Specifications; Technical and Operating Specifications; Table 1 Specifications - General
Specifications Technical and Operating Specifications Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 5 7/08 Specifications This section provides you with the technical specifications and the model selection guide for the HercuLine ® 2000 Series Actuators....
Page 14 - Electrical and Performance Specifications
Specifications Technical and Operating Specifications 6 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Electrical Mains Supply 100-130 Vac single phase, 50 Hz or 60 Hz 200-240 Vac single phase, 50 Hz or 60 Hz Motor Instant start/stop, non-coasting, n...
Page 16 - HercuLine; Specifications – Local Display and Keypad; Display; Keypad
Specifications Technical and Operating Specifications 8 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 HercuLine ® 2002 HercuLine ® 2001 HercuLine ® 2000/2003 Programmable Functions Selectable and configurable operating parameters: NA • Input range •...
Page 17 - Specifications – Communications; Communications; Required Specifications – PDA (customer provided); PDA
Specifications Technical and Operating Specifications Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 9 7/08 Specifications – Communications Communications Communications Option RS 485 Serial Communication, Modbus RTU Protocol Connection Twisted pair cable...
Page 18 - Model Selection Guide; continued
Specifications Model Selection Guide 10 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Model Selection Guide Instructions Select the desired key number. The arrow to the right marks the selection available.Make the desired selections from Tables I th...
Page 20 - Installation; Installation Overview; The procedures to install the HercuLine; Mechanical Stops
Installation Installation Overview 12 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Installation Installation Overview The procedures to install the HercuLine ® 2000 Series actuator and place it in service require that you: • Select a suitable locat...
Page 21 - Before Starting; Unpacking; Actuator Mounting
Installation Before Starting Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 13 7/08 Before Starting Unpacking If there are visible signs of damage to the shipping container, notify the carrier and Honeywell immediately. If there is no visible damage, comp...
Page 22 - Figure 3 Outline and Dimensions of HercuLine
Installation Actuator Mounting 14 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 CLEARANCE FOR TOP REMOVAL: 101,6 4.0 289 11.379 25.41.00 CLEARANCE FOR TOP REMOVAL: 101,6 4.0 289 11.379 25.41.00 mm inches Figure 3 Outline and Dimensions of HercuLine ...
Page 23 - Mechanical Installation; Figure 4 Constant Torque Linkage; Variable Torque Linkage
Installation Mechanical Installation Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 15 7/08 Mechanical Installation Linkage Set-up Many applications require the use of a linkage assembly and often the final control element does not have a linear torque cu...
Page 24 - Close Open; Figure 5 Variable Torque Linkage; Actuator Crank Arms; Figure 6 Standard crank arm
Installation Mechanical Installation 16 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 VerticalCenterline 5° VerticalCenterline 45° 45° Close Open ActuatorCrank Arm DamperCrank Arm Linkage Horizontal Offset a/n 23200 Figure 5 Variable Torque Linkage ...
Page 25 - Electrical Installation; General Wiring Recommendations; AWG; Safety Precautions; Actuator Connections; ATTENTION
Installation Electrical Installation Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 17 7/08 Electrical Installation General Wiring Recommendations Only qualified personnel should perform wiring. Wiring must conform to national and local electrical codes. ...
Page 26 - Connection; Figure 8 HercuLine
Installation Electrical Installation 18 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 HercuLine ® 2000 Terminal Connections Table 3 Terminal Connections: HercuLine ® 2000 Connection Terminal Numbers and LABEL See Figure 8 Descriptions Hot 1 Hot wire...
Page 27 - Figure 9 HercuLine
Installation Electrical Installation Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 19 7/08 HercuLine ® 2001/2002 with Auto/Manual Terminal Connections Table 4 Terminal Connections: HercuLine ® 2001/2002 with auto/manual Connection Terminal Numbers and LA...
Page 28 - Wiring; Operation
Installation Electrical Installation 20 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 HercuLine ® 2003 Wiring Connections and Operation (Actionator 640D Replacement) Wiring Figure 10 HercuLine ® 2003 connections Operation The 2003 actuator is uni-di...
Page 29 - Power Connections; You need the following tools:; Step; Figure 11 CE wiring part 1
Installation Electrical Installation Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 21 7/08 Power Connections Depending on which power supply selection is ordered for your actuator, wire the power input (MAINS POWER) as described in the previous tables an...
Page 30 - Figure 12 CE Wiring part 2
Installation Electrical Installation 22 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Step Action 8 • AC power connection • Auxiliary switches connection • Relay contact connection Relays 3 and 4 Relays 1 and 2 Aux switches 1 and 2(SW3 and SW4) Aux ...
Page 31 - Output Signal Connections; Slidewire Emulator Connections; Burner Control/Flame Safety
Burner Control/Flame Safety Electrical Installation Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 23 7/08 Output Signal Connections 0/4-20 mA, 0/1-5 Vdc Feedback Signal Connections ATTENTION Shielded and grounded cables are recommended. Actuator output i...
Page 32 - Connections; White; Figure 14 Series 90 connections
Burner Control/Flame Safety Series 90 Control – HercuLine® 2001 model only 24 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Series 90 Control – HercuLine ® 2001 model only Series 90 Controls are commonly used in building environmental systems and fl...
Page 33 - Auto; Figure 15 T775 Controller connections
Burner Control/Flame Safety Series 90 Control – HercuLine® 2001 model only Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 25 7/08 GND toHercuLine2001 (2) W W W R R B B Auto Man I out fromHercuLine2001 + Signal toHercuLine2001 T775 B 3 T775 W 1 T775 R 2 Fi...
Page 34 - Split Range; The HercuLine; Table 5 Split Range Set Up Procedure; Master/Slave Arrangement
Burner Control/Flame Safety Split Range 26 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Split Range The HercuLine ® 2001/2002 actuators can be set up to operate within a narrow input range (for example, 4 to 12mA input) in certain applications. The...
Page 35 - Basic Flow Control
Burner Control/Flame Safety Master/Slave Arrangement Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 27 7/08 Basic Flow Control When the process variable signal is below set point, the controller increases current (4 to 20mA) to the actuator input and open...
Page 36 - Figure 18 Proportional Flow Using Multiple Actuators
Burner Control/Flame Safety Master/Slave Arrangement 28 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Proportional with Bias Ratio Position mA PV SP 4 to 20 mA Controller Positioner & Actuator Linkage Valve Orifice Plate FT MP#1 MP#2 MP#3 FIC Li...
Page 37 - Figure 19 Multiple Actuator Interconnection Diagrams
Burner Control/Flame Safety Master/Slave Arrangement Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 29 7/08 Hot 10260S Series Actuator #1 Neutral Ground 120/240 VAC 250 Ohms1 to 5 VDC + - Current Output Controller 4 to 20 mA Hot 10260S Series Actuator #2 ...
Page 38 - Split Valve Configuration; Figure 20 Interconnection Diagrams
Burner Control/Flame Safety Master/Slave Arrangement 30 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 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 po...
Page 39 - Set Up and Calibration Procedures; Overview; software (see HercuLink; Local Display and Keypad; Figure 21 HercuLine
Set Up and Calibration Procedures Overview Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 31 7/08 Set Up and Calibration Procedures Overview Once you have installed the actuator, you can verify, set or change certain operating parameters. Set up is accomp...
Page 40 - Table 6 Keypad Description
Set Up and Calibration Procedures Local Display and Keypad 32 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Table 6 Keypad Description Key or LED Indicator Function SET UP Places the actuator in the set up group select mode. Sequentially displays th...
Page 41 - Set Up Tips; Table 7 Set Up Tips; Function
Set Up and Calibration Procedures Set Up Tips Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 33 7/08 Set Up Tips Table 7 contains tips that will help you view, verify and enter the operating parameters more quickly. If you cannot change the parameters, ch...
Page 42 - Set Up Groups; Table 8 Set Up Groups
Set Up and Calibration Procedures Set Up Groups 34 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Set Up Groups Pressing the SET UP key on the keypad provides access to the various set up groups and allows you to set up operating parameters, (such as...
Page 43 - SET
Set Up and Calibration Procedures Set Up Groups Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 35 7/08 SET MAINT Display various operating statistics. Reset accumulated operating statistics Table 22 CAL POSOUT Use the display as an indicator, (in this cas...
Page 44 - Set Up Procedure; Table 9 Set Up Procedure Using Display and Keypad
Set Up and Calibration Procedures Set Up Procedure 36 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 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 thro...
Page 45 - or
Set Up and Calibration Procedures Set Up Procedure Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 37 7/08 Step Operation Press Result 5 Change the Value or Selection or These keys increase or decrease the value, or display the next available selection for...
Page 46 - Configuration Prompt Hierarchy
Set Up and Calibration Procedures Configuration Prompt Hierarchy 38 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Configuration Prompt Hierarchy TEMP TEMPHI TEMPLO ACSTAL STARTS RL1CNT RL2CNT RL3CNT RL4CNT REGN0 REGN9 TOTDEG DATSAV PASSWD MANRST LD ...
Page 47 - Input Set Up Group; On the keypad and local display:; Table 10 Input Set Up Group Parameters
Set Up and Calibration Procedures Input Set Up Group Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 39 7/08 Input Set Up Group Table 10 lists the parameters and selections available when the SET INPUT group is selected. On the keypad and local display: • ...
Page 52 - Relays Set Up Group; Table 13 Relay Set Up Group Parameters
Set Up and Calibration Procedures Relays Set Up Group 44 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Relays Set Up Group ATTENTION The Relay set up group parameters are accessible only if relay PWAs are installed in the actuator. HercuLine ® 2001 ...
Page 53 - Table 14 Relay Type Descriptions; When this Relay Type is
Set Up and Calibration Procedures Relays Set Up Group Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 45 7/08 Table 14 Relay Type Descriptions When this Relay Type is selected… (RTYP) The Relay can be set up to indicate … Input Range The upper / lower limi...
Page 54 - Relay Type - Position Range; Set Up Group; The figure below shows the resulting action.
Set Up and Calibration Procedures Relays Set Up Group 46 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Relay connector #1 Relay connector #2 Relay connector #3 Relay connector #4 Figure 22 Relay connectors Relay Examples Relay Type - Position Range ...
Page 55 - Relay Type - Deviation; The resulting action is shown below.
Set Up and Calibration Procedures Relays Set Up Group Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 47 7/08 Relay Type - Deviation Setting up a relay to alarm (energize) when the motor position deviates 10% (+ or -) from the actuator setpoint can be set ...
Page 56 - Relay Type – Upper Limit Travel with Hysteresis
Set Up and Calibration Procedures Relays Set Up Group 48 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Relay Type – Upper Limit Travel with Hysteresis Selecting relay type ULim will cause the relay to energize when the motor position exceeds the upp...
Page 57 - Current Out Set Up Group; Table 15 Current Out Set Up Group Parameters
Set Up and Calibration Procedures Current Out Set Up Group Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 49 7/08 Current Out Set Up Group Table 15 lists the parameters and selections available for the SET CUROUT group. Table 15 Current Out Set Up Group P...
Page 58 - Communications Set Up Group; Table 16 Communications Set Up Group Parameters
Set Up and Calibration Procedures Communications Set Up Group 50 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Communications Set Up Group Table 16 lists the parameters and selections available for the SET COMM group. Table 16 Communications Set Up ...
Page 59 - Digital Input Set Up Group; Table 17 Digital Input Set Up Group Parameters
Set Up and Calibration Procedures Digital Input Set Up Group Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 51 7/08 Digital Input Set Up Group Table 17 lists the parameters and selections availible for the SET DIGINP group. Table 17 Digital Input Set Up G...
Page 60 - Display Set Up Group; Table 18 Display Set Up Group Parameters
Set Up and Calibration Procedures Display Set Up Group 52 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Display Set Up Group Table 18 lists the parameters and selections availible for the SET DISPLAY group. Table 18 Display Set Up Group Parameters A...
Page 61 - Lock Set Up Group; Table 19 Lock Set Up Group Parameters
Set Up and Calibration Procedures Lock Set Up Group Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 53 7/08 Lock Set Up Group Table 19 lists the parameters and selections available for the SET LOCK group. Table 19 Lock Set Up Group Parameters Actuator Lowe...
Page 63 - Read Status Set Up Group; Table 20 Read Status Set Up Group Parameters; — Actuator in failsafe, see; — Test failed, see see; Fail
Set Up and Calibration Procedures Read Status Set Up Group Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 55 7/08 Read Status Set Up Group Table 20 lists the parameters and selections available for the READ STATUS group. Table 20 Read Status Set Up Group ...
Page 64 - Drive Set Up Group; Table 21 Drive Set Up Group Parameters
Set Up and Calibration Procedures Drive Set Up Group 56 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Drive Set Up Group Table 21 lists the parameters and selections available for the SET DRVINF group. Table 21 Drive Set Up Group Parameters Actuator...
Page 66 - Set Tag Name
Set Up and Calibration Procedures Drive Set Up Group 58 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Set Tag Name The actuator tag name can be an alphanumeric name up to six characters. The tag name is set by using the keys on the keypad and the lo...
Page 67 - Maintenance Set Up Group; Table 22 Maintenance Set Up Group Parameters
Set Up and Calibration Procedures Maintenance Set Up Group Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 59 7/08 Maintenance Set Up Group The Maintenance set up group consists of information about actuator operation accumulated through time. This informa...
Page 70 - Regions of Motor Travel; The full span of motor travel can be 90; Figure 23 Regions of Motor Travel
Set Up and Calibration Procedures Regions of Motor Travel 62 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 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 sh...
Page 71 - CAL POSOUT Group; Table 23 CAL POSOUT Group Parameters
Set Up and Calibration Procedures CAL POSOUT Group Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 63 7/08 CAL POSOUT Group The CAL POSOUT group is used to verify that the position sensor is operating and adjusted properly. This group allows the local disp...
Page 72 - Auto - Manual Drive Switch; MANUAL; Switch Setting
Set Up and Calibration Procedures Auto - Manual Drive Switch 64 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Auto - Manual Drive Switch The Auto - Manual switch is located on the side of the actuator case below the handwheel. The switch allows manu...
Page 73 - Calibration; Calibration of the HercuLine; Equipment Needed; Procedure
Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 65 7/08 Calibration Calibration of the HercuLine ® 2000 Series Actuator may consist of calibrating the motor circuit that positions the actuator with 0/4-20mA inp...
Page 74 - Calibration Set up
Set Up and Calibration Procedures Calibration 66 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 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...
Page 75 - FB; Figure 26 Calibration Wiring Connections (slidewire emulation)
Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 67 7/08 Actuator Input 5 4 - + Output 2 1 3 - + + - CalibratedSignalSource DigitalVoltmeter + - FB Terminal Block Power Supply1-18 VDC + - Internal 250 ohm resist...
Page 76 - Jumper W2; Figure 27 Jumper Location on CPU PWA
Set Up and Calibration Procedures Calibration 68 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Jumper W2 Figure 27 Jumper Location on CPU PWA Calibrate Input The HercuLine ® 2001/2002 actuator accepts a variety of signal inputs. 1. 0 to 20 mA, or 4 ...
Page 77 - Table 25 Input Calibration Procedure
Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 69 7/08 Table 25 Input Calibration Procedure Step Operation Press Result 1 Enter Calibration Mode SETUP until you see Upper Display = CAL Lower Display = INPUT FU...
Page 78 - Calibrate Motor
Set Up and Calibration Procedures Calibration 70 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Calibrate Motor Use the procedure in Table 26 to calibrate the actuator motor for 0% and 100% input signal ATTENTION For a motor calibration to be saved, ...
Page 79 - Calibrate Output; Table 27 Output Calibration Procedure
Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 71 7/08 Calibrate Output HercuLine ® 2001/2002 actuator can be one of three output types: 1. 0 to 20 mA, or 4 to 20 mA output 2. 0 to 5 Volts, or 1 to 5 Volts wit...
Page 80 - Slidewire Emulation
Set Up and Calibration Procedures Calibration 72 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Step Operation Press Result 2 Calibrate Zero (0%) FUNCTION Upper Display = xxx Lower Display = ZERO • Read meter connected to actuator output. or key • Ad...
Page 81 - Table 28 Slidewire Emulation Calibration Procedure; The sensor output is incorrect,
Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 73 7/08 Table 28 Slidewire Emulation Calibration Procedure Step Operation Press Result 1 Enter Calibration Mode SETUP until you see Upper Display = CAL Lower Disp...
Page 82 - Table 29 NCS Position Sensor Calibration Procedure
Set Up and Calibration Procedures Calibration 74 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 While the unit is powered, a potentially lethal shock hazard exists inside the case. Table 29 NCS Position Sensor Calibration Procedure Step Action 1 Remo...
Page 83 - NCS PW A; Figure 28 Location of NCS Assembly
Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 75 7/08 NCS Spoiler (shown at full150 degree travel CCW) NCS PW A NCS setscrew Relay PW A cardguides (relayPW As removed) Figure 28 Location of NCS Assembly
Page 84 - Table 30 Potentiometer Position Sensor Calibration Procedure
Set Up and Calibration Procedures Calibration 76 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Table 30 Potentiometer Position Sensor Calibration Procedure Step Action 1 Remove AC power to the actuator. 2 Remove the six screws and the top cover from...
Page 85 - Potentiometer position sensor; Figure 29 Location of potentiometer position sensor
Set Up and Calibration Procedures Calibration Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 77 7/08 Potentiometer position sensor Mounting bracket Figure 29 Location of potentiometer position sensor Table 31 Load Position Sensor Factory Calibration Step ...
Page 86 - Figure 30 End of Travel Limit Switch Settings; REFERENCE
Set Up and Calibration Procedures Setting End-of-Travel Limit Switches 78 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Setting End-of-Travel Limit Switches ATTENTION Referring to Figure 31. The first two cams (starting from the front) are for the 0...
Page 87 - Table 32 End-of-Travel Limit Switch Setting Procedure
Set Up and Calibration Procedures Setting End-of-Travel Limit Switches Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 79 7/08 Table 32 End-of-Travel Limit Switch Setting Procedure Step Action 1 Remove AC power to the actuator. 2 Remove the six screws and ...
Page 88 - Figure 31 Location of End-of-Travel Limit and Auxiliary Switches
Set Up and Calibration Procedures Setting End-of-Travel Limit Switches 80 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 ATTENTION Make sure you do not to set the switches too close to the hard stop. Relay #1Relay #2Relay #3Relay #4 Aux switch #1 Aux...
Page 89 - Setting Auxiliary Switches; Figure 32 Auxiliary Switch Settings
Set Up and Calibration Procedures Setting Auxiliary Switches Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 81 7/08 Setting Auxiliary Switches ATTENTION Referring to Figure 31. The first two cams (starting from the front) are for the 0% and 100% end of tr...
Page 90 - Table 33 Auxiliary Switch Setting Procedure
Set Up and Calibration Procedures Setting Auxiliary Switches 82 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Table 33 Auxiliary Switch Setting Procedure Step Action 1 Remove AC power to the actuator. 2 Remove the six screws and the cover from the a...
Page 91 - Verification of valid calibration values (CALTST); Operations Checklist
Start-Up/Operation Introduction Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 83 7/08 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 a...
Page 92 - Operating Displays; Table 34 Typical Operating Displays; Motor Stall
Start-Up/Operation Operating Displays 84 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Operating Displays Pressing the DISPLAY key cycles the display through a number of operating parameters. Table 34 shows a number of sample displays that can be sh...
Page 93 - Position Sensor Operation; On HercuLine; POSOUT; Remote Setpoint Operation
Start-Up/Operation Position Sensor Operation Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 85 7/08 Position Sensor Operation On HercuLine ® 2000 and HercuLine ® 2001 the potentiometer position sensor is a sealed film pot that is directly coupled to the o...
Page 94 - Figure 33 Terminal Block Connections for Modbus Communications
Start-Up/Operation Remote Setpoint Operation 86 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 9 8 6 7 C O M M U N IC AT IO N S H IE L D 1 0 IN P C O M D IG IT A L IN P U T - + A ctu a to rT e rm in alB lo ck Figure 33 Terminal Block Connections for ...
Page 95 - Maintenance; 000 Series Actuators. The; Basic Maintenance; Position Sensor
Maintenance Introduction Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 87 7/08 Maintenance Introduction There is some basic maintenance that is recommended for the HercuLine ® 2000 Series Actuators. The electronic PWAs within the actuator require no main...
Page 96 - Figure 34 Spur Gear Location
Maintenance Basic Maintenance 88 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Bottom cover Gears Motor piniongear Final outputspur gear Idler spurgear Figure 34 Spur Gear Location
Page 97 - Replacement Procedures; Fuse Replacement; Figure 35 Power Distribution PWA and Relay PWA Locations
Maintenance Replacement Procedures Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 89 7/08 Replacement Procedures Fuse Replacement The motor drive circuit contains two fuses. They are located on the power distribution PWA. If it becomes necessary to replac...
Page 98 - Figure 36 Motor Drive Circuit Fuses
Maintenance Replacement Procedures 90 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Power Distribution PW A Fuses forMotor Drive Circuit Figure 36 Motor Drive Circuit Fuses Relay PWA Replacement If a relay PWA needs to be replaced, follow the proced...
Page 99 - Replacement Kits; 000 Series Actuators and optional equipment.
Replacement/Upgrade/Accessory Kits Replacement Kits Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 91 7/08 Replacement/Upgrade/Accessory Kits Replacement Kits This section provides you with a complete list of all the spare parts that may be needed for the...
Page 100 - Figure 38 Replacement Kit 10
Replacement/Upgrade/Accessory Kits Replacement Kits 92 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 10 Figure 38 Replacement Kit 10
Page 102 - Figure 40 Replacement Kit 13
Replacement/Upgrade/Accessory Kits Replacement Kits 94 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 13 Figure 40 Replacement Kit 13
Page 104 - Table 38 Replacement kits
Replacement/Upgrade/Accessory Kits Replacement Kits 96 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 See Figure 37 through Figure 41 for drawings of replacement kit contents. Table 38 Replacement kits Qty/Unit Part Number Description Figure ID # 514...
Page 108 - Part Number
Replacement/Upgrade/Accessory Kits Replacement Kits 100 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Qty/Unit Part Number Description Figure ID # 51452443-504 Display and Keypad Kit 13 1 Display Gasket 1 Overlay, Display 1 Lens, Display 1 Gasket,Ad...
Page 110 - Upgrade Kits
Replacement/Upgrade/Accessory Kits Upgrade Kits 102 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Qty/Unit Part Number Description Figure ID # 51500581-504 Auto/Manual Switch (upgrade for SA2001 & SA2002) 18 1 Auto/Manual Label 1 Nut, Sealing 3/...
Page 112 - Accessory Kits
Replacement/Upgrade/Accessory Kits Accessory Kits 104 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Qty/Unit Part Number Description 51451656-511 1000 ohms 150 degrees upgrade kit 2 Machine screw-pan hd-cross rec 1 Knob 1 Bracket molding 1 Pot 1K do...
Page 113 - Troubleshooting; Table 39 Observable Symptoms of Failure; Symptom
Troubleshooting Introduction Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 105 7/08 Troubleshooting Introduction Troubleshooting procedures can be followed when inaccurate or faulty actuator operation is detected. In this section, troubleshooting procedu...
Page 114 - Troubleshooting Procedures; DC Milliammeter – mA DC; Safety precautions
Troubleshooting Troubleshooting Procedures 106 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Troubleshooting Procedures Overview Follow the procedure or flow chart to test for and determine actuator component operation. When using the flow charts fo...
Page 115 - Test for Actuator Operation
Troubleshooting Troubleshooting Procedures Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 107 7/08 Test for Actuator Operation Do all diagnostics pass? RAMTST PASS SEETST PASS CALTST PASS CFGTST PASS Replace display assembly Does motor reposition itself? ...
Page 116 - Power Up Self Test Diagnostics
Troubleshooting Troubleshooting Procedures 108 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Power Up Self Test Diagnostics Replace display assembly. Cycle power toactuator. If CALTSTfails again, replace CPU assembly. Cycle power toactuator. If CFGT...
Page 117 - Test Power Distribution PWA; Figure 44 Test Power Distribution PWA; Connector
Troubleshooting Troubleshooting Procedures Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 109 7/08 Test Power Distribution PWA Replace CPUassembly. Is correct voltage present at test points? See below. Remove top cover of actuator. Are fuses good? Replace...
Page 118 - Test AUTO - MANUAL DRIVE Switch; Figure 45 Test AUTO - MANUAL Switch
Troubleshooting Troubleshooting Procedures 110 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Test AUTO - MANUAL DRIVE Switch Possible trouble spotsa. Auto/Manual switchb. Power Supply PWA. (See D) c. Limit switchesd. Motore. R/C networksf. etc.,Othe...
Page 119 - Test Relay Function; Relay Associated
Troubleshooting Troubleshooting Procedures Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 111 7/08 Test Relay Function Set suspect Relaytype to MAN. Replace Relay PWA orWire harness from RelayPWA to terminal block. See Relay replacementin Maintenance, Sec...
Page 124 - Index
Index 116 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual Revision 7 7/08 Index A Actuator Rotation, 40, 64 Actuator Set Up, 33 Set up groups, 34 Set up procedure, 36 Actuator Statistics Accumulated motor starts, 59 Motor starts, 59 Relay cycle counts, 59 Reset, 60 T...
Page 125 - POSITION SENSOR OUTPUT
Index Revision 7 HercuLine™ 2000 Series Actuator - Installation, Operation and Maintenance Manual 117 7/08 Inputs, 39 Installation, 12 Installation Considerations, 13 Isolation, 6 K Keypad, 8, 31 Description, 32 L LEDs on Local Display, 32 Limit Switches, 78 Setting, 78 Linkage Kits, 96 Linkage Set-...
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